INTRODUCTION

TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct product information and service procedures.

If you have any questions or comments, at if you

found any errors regarding the contents of this
manual, please contact using Service Manual
Revision Request Form at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162

ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
The Operators Manual
The Parts Catalog

The Engine Manual

Parts Catalog of the Engine
Hitachi Training Material

MANUAL COMPOSITION
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.

Information included in the Technical Manual

(Troubleshooting):
technical information needed for operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assemble/disassemble 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 : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual

W: Workshop Manual

IN-01

INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.

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

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

NOTE:
Indicates supplementary technical information or
know-how.

UNITS USED
SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.

Quantity
Length
Volume

Weight
Force
Torque

To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm

Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft

A table for conversion from SI units to other system

units is shown below for reference purposees.

Quantity

Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375

Pressure
Power
Temperature
Velocity
Flow rate

IN-02

To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev

Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev

Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0

SECTION AND GROUP

CONTENTS

TECHNICAL MANUAL
(Troubleshooting)

SECTION 4 OPERATIONAL
PERFORMANCE TEST
Group
Group
Group
Group
Group
Group

1 Introduction
2 Standard
3 Engine Test
4 Wheel Loader Test
5 Component Test
6 Adjustment

SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group

1 Diagnosing Procedure
2 Dr-ZX
3 e-Wheel
4 Component Layout
5 Troubleshooting A
6 Troubleshooting B
7 Troubleshooting C
8 Electrical System Inspection

TECHNICAL MANUAL (Operational Principle)

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.

COPYRIGHT (C) 2006

Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved

SECTION 1 GENERAL
SECTION 3 COMPONENT OPERATION
Group 1 Specification
Group 1 Pump Device
Group 2 Component Layout
Group 2 Control Valve
Group 3 Component Specifications Group 3 Hydraulic Fan Motor
SECTION 2 SYSTEM
Group 4 Steering Pilot Valve
Group 1 Control System
Group 5 Steering Valve
Group 2 ECM System
Group 6 Pilot Valve
Group 3 Hydraulic System
Group 7 Charging Block
Group 8 Ride Control Valve
Group 4 Electrical System
Group 9 Drive Unit
Group 10 Axle
Group 11 Brake Valve
Group 12 Others

WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling
and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic
Oil Tank
SECTION 2 BASE MACHINE (UPPER
STRUCTURE)
Group 1 Cab
Group 2 Counterweight
Group 3 Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Pilot Valve
Group 7 Ride Control Valve
Group 8 Pilot Shutoff Valve
Group 9 Hydraulic Fan Motor

SECTION 3 BASE MACHINE (TRAVEL

SYSTEM)
Group 1 Tire
Group 2 Drive Unit
Group 3 Axle
Group 4 Propeller Shaft
Group 5 Brake Valve
Group 6 Charging Block
Group 7 Steering Pilot Valve
Group 8 Steering Valve
Group 9 Steering Cylinder
Group 10 Parking Brake Solenoid Valve
Group 11 Emergency Steering Pump Unit
(Optional)
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE

SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or
in operator`s manual, be alert to the potential for
personal injury.
Follow recommended precautions and safe operating practices.

001-E01A-0001

SA-688

UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating
the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation
which, if not avoided, may result in minor or
moderate injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listed on CAUTION safety signs.
Some safety signs dont use any of the designated signal words above after the safety alert
symbol are occasionally used on this machine.

To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided,
could result in damage to the machine.

NOTE indicates an additional explanation for

an element of information.
002-E01A-1223

SA-1

SA-1223

SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the

machine and all safety messages in operator`s

manual.
Safety signs should be installed, maintained and
replaced when necessary.
If a safety sign or operator`s manual is damaged
or missing, order a replacement from your authorized dealer in the same way you order other
replacement parts (be sure to state machine
model and serial number when ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine.
Keep your machine in proper working condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect machine life.
Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety,
function, and/or service life. In addition, personal
accident, machine trouble, and/or damage to
material caused by unauthorized modifications
will void Hitachi Warranty Policy.
Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do
so may deteriorate the safety, function, and/or
service life of the machine. In addition, personal
accident, machine trouble, and/or damage to
material caused by using unauthorized attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your authorized dealer before operating or performing
maintenance work on the machine.

SA-003

003-E01B-0003

PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

To ensure that a fire-extinguisher can be always

used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department
posted near your telephone.
004-E01A-0437

SA-2

SA-437

SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.

SA-438

Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.

Operating equipment safely requires the full attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438

PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

006-E01A-0434

SA-434

NSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal injury.
In the walk-around inspection be sure to cover all
points described in the PRE-START INSPECTION chapter in the operators manual.

007-E01A-0435
SA-435

SA-3

SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any

controls such as a pedal is operated while with
dirt and/or oil on the soles of the operators work
boots the operators foot may slip off the pedal,
possibly resulting in a personal accident.
Do not leave parts and/or tools lying around the
operators seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decorations on the windowpanes as they may focus
sunlight, possibly starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
Keep all flammable objects and/or explosives
away from the machine.
After using the ashtray, always cover it to extinguish the match and/or tobacco.
Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000

SA-4

SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.

008-E01A-0439

SA-439

ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again.
Adjust the rear view mirror position so that the
best rear visibility is obtained from the operators
seat. If the mirror is broken, immediately replace it
with a new one.
009-E01A-0462

ENSURE SAFETY BEFORE RISING FROM

OR LEAVING OPERATORS SEAT
Before rising from the operators seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
Before leaving the machine, be sure to first lower
the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.
Before leaving the machine, close all windows,
doors, and access covers and lock them up.

SA-5

SA-462

SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.
Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent condition.

SA-237

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.
Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or
operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate hand signals before starting the machine.
Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.

SA-398

011-E01A-0398

HANDLE STARTING AIDS SAFELY

Starting fluid:

Starting fluid is highly flammable.

Keep all sparks and flame away when using it.
Keep starting fluid well away from batteries and
cables.

Remove container from machine if engine does

not need starting fluid.

To prevent accidental discharge when storing a

pressurized container, keep the cap on the container, and store it in a cool, well-protected location.
Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3

SA-6

SA-293

SAFETY
OPERATE
SEAT

ONLY

FROM

OPERATOR'S

Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious injury or death.
Start the engine only when seated in the operator's seat.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
Before starting the engine, confirm the safety
around the machine and sound the horn to alert
bystanders.

SA-431

012-E01B-0431

JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to

follow the instructions shown in the OPERATING

THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts.
Jump starting is a two-person operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032
S013-E01A-0032 SA-032

SA-7

SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
Investigate the configuration and ground conditions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
Make a work plan. Use machines appropriate to
the work and job site.
Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
When working on an incline or on a road shoulder,
employ a signal person as required.
Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
When the footing is weak, reinforce the ground
before starting work.
When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing becomes loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.

015-E01B-0447

SA-8

SA-447

SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure

SA-521

PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines,
provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal persons directions.

018-E01A-0481
SA-481

SA-9

SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as being struck by foreign objects and being thrown off
the machine.
Only the operator should be on the machine.
Keep riders off.
Riders also obstruct the operators view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0427

SA-427

DRIVE SAFELY

Beware of the possibility of slipping and/or turning

over the machine when driving on a slope.
When driving on level ground, hold the bucket at
mark (A) 400 to 500 mm above the ground as illustrated.
Avoid driving over any obstacles.
Drive the machine slowly when driving on rough
terrain.
Avoid quick direction changes. Failure to do so
may cause the machine to turn over.
If the engine stops while driving, the steering
function becomes inoperative. Immediately stop
the machine by applying the bake to prevent
personal accident.

SA-448

019-E07A-0448

DRIVE MACHINE SAFELY (WORK SITE)

Before driving the machine, always confirm that the
steering wheel/F-N-R lever direction corresponds to
the direction you wish to drive.
Be sure to detour around any obstructions.

Driving on a slope may cause the machine to slip or

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

SA-449

SA-450

Driving across the face of a slope or steering on a

slope may cause the machine to skid or overturn. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
safe operation.
019-E05B-0515
SA-451

SA-10

SAFETY
DRIVE SAFELY WITH BUCKET LOADED
If the machine is incorrectly operated while driving
with the bucket loaded, turning over of the machine
may result. Be sure to follow all the instructions indicated below.
When driving the machine on a job site with the
bucket loaded, hold the bucket as low as possible
to keep the machine balanced and to have good
visibility.
Do not exceed the rated load capacity. Always
operate the machine within the rated load capacity.
Avoid fast starts, stops, and quick turns. Failure to
do so may result in personal injury and/or death.
Avoid rapid drive direction changes which could
possibly cause personal injury and/or death.

SA-400

051-E02A-0400

DRIVE ON SNOW SAFELY

Beware of the possibility of slipping or turning over
the machine when driving on frozen snow surfaces.
The machine may slip more easily than expected
on frozen snow surfaces even if the inclination is
small. Reduce speed when driving. Avoid fast
starts, stops and quick turns.
Road shoulder and/or set-up utilities covered with
snow are difficult to locate. Be sure where they
are before removing snow.
Be sure to use tire chains when driving on snow.
Avoid applying the brake for quick stops on snow.
If a quick stop is required, lower the bucket to the
ground.

SA-452

052-E02A-0452

TRAVEL ON PUBLIC ROADS SAFELY

This machine is not allowed to drive on public loads
with the bucket loaded.
Be sure to empty the bucket.
Hold the bucket at mark (A) 400 to 500 mm above
the road surface as illustrated.

053-E02A-0453

SA-453

SA-11

SAFETY
AVOID INJURY FROM ROLLAWAY ACCIDENTS
Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park machine.
Do not park the machine on a grade.
Lower the bucket to the ground.
Place the F-N-R lever in neutral, and put the park
brake switch in the ON (parking brake) position.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the lock lever to LOCK position.
Block both tires and lower the bucket to the
ground.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.

SA-457

020-E02A-0516

SA-458

SA-12

SAFETY
AVOID ACCIDENTS FROM BACKING UP
AND TURNING
Make sure no one is working under or close to the
machine before backing up or turning the machine
to avoid personal injury and/or death by being run
over or entangled in the machine.
Keep all personnel away from the machine by
sounding the horn and/or using hand signals. Use
extra care to be sure no one is in from the articulation area before turning the machine.
Keep windows, mirrors, and lights in good condition.
Reduce travel speed when dust, heavy rain, fog,
etc., reduce the visibility.
In case good visibility is not obtained, use a signal
person to guide you.

SA-383

021-E02A-0517

SA-312

SA-13

SAFETY
AVOID POSITIONING
ANYONE

BUCKET

OVER

Never allow the bucket to pass over co-workers

and/or the dump truck operators cab. Falling soil
from the bucket or contact with bucket may cause
serious personal accidents and/or damage to the
machine.
Avoid carrying the bucket over the co-workers to
ensure safe operation.

023-E02A-0518

SA-518

AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER
THAN YOU CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS PERSONAL INJURY OR
DEATH. IF TIPPING OVER OF THE MACHINE IS
PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING
THROWN OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT

The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging loads.

Be careful when working on frozen ground.

Temperature increases will cause the ground to
become soft and make ground travel unstable.

SA-14

SA-463

SAFETY
NEVER UNDERCUT A HIGH BANK
The edges could collapse or a land slide could occur
causing serious injury or death.

026-E01A-0519

SA-519

DIG WITH CAUTION

Before digging, check the location of cables, gas lines,
and water lines.

027-E01A-0396

SA-396

PERFORM TRUCK LOADING SAFELY

Do not operate the machine involuntarily. Unexpected machine movement may cause personal injury and/or death.
Do not lower the bucket with the loader control
lever in the FLOAT position. The bucket may free
fall, possibly causing personal injury and/or death.
Always select a level surface for truck loading.

028-E01A-397

SA-397

SA-15

SAFETY
AVOID POWER LINES
Serious injury or death can result from contact with
electric lines.
Never move any part of the machine or load closer to
any electric line than 3 m (10 ft) plus twice the line
insulator length.
29-E01A-0455
SA-455

PRECAUTIONS FOR OPERATION

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

PRECAUTIONS FOR LIGHTENING

The machine is vulnerable to lighting strikes.
In the event of an electrical storm, immediately
stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the machine only after repairing them.

OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it, resulting in serious injury or death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the position of the bucket support located on the
chassis at the front.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it
is safely and securely situated on supporting
blocks or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0132

SA-16

SA-132

SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.

031-E01A-0432

SA-432

PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Place the F-N-R lever in neutral, and put the park
brake switch in the ON (parking brake) position.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Lower the lock lever to the LOCK position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E07B-0456

SA-17

SA-456

SAFETY
STORE ATTACHMENTS SAFELY
Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.

504-E01A-0034

SA-034

TRANSPORT SAFELY
Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
Observe the related regulations and rules for safe
transportation.
Select an appropriate truck or trailer for the machine to be transported.
Be sure to use a signal person.
Always follow the following precautions for loading or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight.
3. Use the low speed gear.
4. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading
again.
5. After loading, install the lock bar to securely hold
the articulation mechanism.
6. Wedge the front and rear of tires. Securely hold
the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the
TRANSPORTING section.

035-E07A-0454

SA-18

Less than 15

SA-454

SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when
near open flame or sparks.
Always stop the engine before refueling the machine.
Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are

flammable.
Store flammable fluids well away from fire hazards.
Do not incinerate or puncture pressurized containers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.

SA-018

034-E01A-0496

SA-019

SA-19

SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting
work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for
5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
7. Remove the key from the switch.
8. Attach a Do Not Operate tag on the control
lever.
9. Lower the lock lever to the LOCK position.
10. Lock bar connects the front and rear frames.
11. Allow the engine to cool.

SA-028

If a maintenance procedure must be performed

with the engine running, do not leave machine

unattended.
Never work under a machine raised by the lift
arm.
Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the MAINTENANCE chapter of
operator`s manual.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (-) before making adjustments to electrical systems or before
performing welding on the machine.

SA-312

SA-134

500-E02C-0520

SA-527

SA-20

SAFETY
Sufficiently illuminate the work site. Use a maintenance work light when working under or inside
the machine.
Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, attach a Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.

501-E01A-0287

SS2045102

SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without securing the machine first.
Always lower the attachment to the ground before
you work on the machine.
If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a machine that is supported solely by a jack.
519-E01A-0527

SA-527

STAY CLEAR OF MOVING PARTS

Entanglement in moving parts can cause serious
injury.
To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.

502-E01A-0026

SA-026

SA-21

SAFETY
SUPPORT MAINTENANCE PROPERLY
Explosive separation of a tire and rim parts can
cause serious injury or death.
Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
Always maintain the correct tire pressure. DO
NOT inflate tire above the recommended pressure.
When inflating tires, use a chip-on chuck and extension hose long enough to allow you to stand to
one side and not in front of or over the tire assembly. Use a safety cage it available.
Inspect tires and wheels daily. Do not operate with
low pressure, cuts bubbles, damaged rims, or
missing lug bolts and nuts.
Never cut or weld on an inflated tire or rim assembly. Heat from welding could cause an increase in pressure and may result in tire explosion.

SA-249

521-E02A-0249

PREVENT PARTS FROM FLYING

Travel reduction gears are under pressure.
As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury.
GEAR OIL is hot. Wait for GEAR OIL to cool, then
gradually loosen AIR RELEASE PLUG to release
pressure.
503-E03A-0344

SA-344

SA-22

SAFETY
PREVENT BURNS
Hot spraying fluids:

After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap.
The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.

SA-039

Hot fluids and surfaces:

Engine oil, gear oil and hydraulic oil also become

hot during operation.
The engine, hoses, lines and other parts become
hot as well.

Wait for the oil and components to cool before

starting any maintenance or inspection work.
SA-225
505-E01B-0498

REPLACE
CALLY

RUBBER

HOSES

PERIODI-

Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.

Periodically replace the rubber hoses. (See the

page of Periodic replacement of parts in the operators manual.)

Failure to periodically replace rubber hoses may

cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious
injury or death.
S506-E01A-0019

SA-23

SA-019

SAFETY
AVOID HIGH-PRESSURE FLUIDS

Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing serious injury, blindness or death.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or goggles for eye protection.
If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.

SA-031

507-E03A-0499

SA-292

SA-044

SA-24

SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to
fires.
Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
Check before each shift or after eight(8) to ten(10)
hours operation for missing or damaged terminal
caps.
DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately.
Check Key Switch:
If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm
that the engine stops.

If any abnormalities are found, be sure to repair

them before operating the machine.
508-E02B-0019

Check Heat Shields:

Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be repaired or replaced before operating the machine.
508-E02A-0393

SA-25

SA-019

SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the following way:
Stop the engine by turning the key switch to the
OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.

518-E01A-0393

SA-393

BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016

SA-016

PRECAUTIONS
GRINDING

FOR

WELDING

AND

Welding may generate gas and/or small fires.

Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
After finishing welding and grinding, recheck that
there are no abnormalities such as the area surrounding the welded area still smoldering.
523-E01A-0818

SA-26

SA-818

SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area. Install temporary fireresistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS

Do not weld or flame cut pipes or tubes that contain flammable fluids.

Clean them thoroughly with nonflammable solvent

before welding or flame cutting them.

510-E01B-0030

REMOVE PAINT BEFORE WELDING OR

HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
heating.
511-E01A-0029

SA-27

SA-029

SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
Depending on the wok site conditions, the risk of
inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Do not
use compressed air.
When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
Keep bystanders out of the work site during operation.
Asbestos might be present in imitation parts. Use
only genuine Hitachi Parts.

SA-029

PREVENT BATTERY EXPLOSIONS

Battery gas can explode.
Keep sparks, lighted matches, and flame away
from the top of battery.

Never check battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 C (60 F) first.
Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion
of the battery may result.
Loose terminals may produce sparks. Securely
tighten all terminals.

SA-032

Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
Be sure to wear eye protection when checking
electrolyte specific gravity.
512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM

SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the instructions described on the container for proper use when handling the refrigerant.
Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
Never touch the refrigerant.
513-E01A-0405

SA-28

SA-405

SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what the risks are and how to do the job
safely. Then follow procedures and use recommended equipment.
See your authorized dealer for MSDSs (available
only in English) on chemical products used with
your machine.

SA-309

515-E01A-0309

DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do
not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain,
or into any water source.
Air conditioning refrigerants escaping into the air
can
damage the Earths atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center, or from your authorized dealer.

516-E01A-0226

SA-29

SA-226

SAFETY
BEFORE RETURNING THE MACHINE TO
THE CUSTOMER
After maintenance or repair work is complete,
confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced.

S517-E01A-0435
SA-435

SA-30

SECTION 4

OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction

Group 4 Wheel Loader Test

Operational Performance Tests ................... T4-1-1

Travel Speed.................................................T4-4-1

Preparation for Performance Tests .............. T4-1-2

Service Brake Function Check .....................T4-4-2

Service Brake Wear Amount ........................T4-4-3

Group 2 Standard

Parking Brake Function Check.....................T4-4-4

Bucket and Bell Crank Stopper

Operational Performance
Standard Table ........................................... T4-2-1

Clearances ..................................................T4-4-6

Main Pump P-Q Curve............................... T4-2-11

Hydraulic Cylinder Cycle Time .....................T4-4-8

Sensor Activating Range............................ T4-2-13

Cylinder Drift Check................................... T4-4-10

Bucket Levelness .......................................T4-4-11

Group 3 Engine Test

Control Lever Operating Force.................. T4-4-12

Engine Speed............................................... T4-3-1

Control Lever Stroke.................................. T4-4-13

Engine Compression Pressure .................... T4-3-3

Valve Clearance Adjustment ........................ T4-3-4
Lubricant Consumption ................................ T4-3-7

4GBT-4-1

Group 5 Component Test

Primary Pilot Pressure ................................. T4-5-1
Secondary Pilot Pressure ............................ T4-5-3
Solenoid Valve Set Pressure ....................... T4-5-4
Main Pump Delivery Pressure ..................... T4-5-6
Main Relief Valve Set Pressure ................... T4-5-8
Steering Relief Pressure ............................ T4-5-12
Overload Relief Valve Set Pressure .......... T4-5-14
Main Pump Flow Rate................................ T4-5-16
Regulator Adjustment................................. T4-5-20
Service Brake Pressure (Front and Rear) . T4-5-22
Parking Brake Pressure ............................. T4-5-24
Brake Accumulated Pressure .................... T4-5-26
Brake Warning Set Pressure (Decrease) .. T4-5-28
Brake Warning Set Pressure (Increase) .... T4-5-30
Transmission Clutch Pressure ................... T4-5-32
Torque Converter Pressure
(Inlet and Outlet)..................................... T4-5-34

Group 6 Adjustment
Transmission Learning................................. T4-6-1
Lift Arm Angle Sensor
Learning (Optional)................................... T4-6-6
Drive Belt Tension Adjustment ..................... T4-6-8

4GBT-4-2

OPERATIONAL PERFORMANCE TEST / Introduction

OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quantitatively check all system and functions on the machine.
Purpose of Performance Tests
1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machines performance to the desired
standard.
3. To economically operate the machine under optimal conditions.

The machine performance does not always deteriorate as the working hours increase. However, the
machine performance is normally considered to reduce in proportion to the increase of the operation
hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machines working hours.
Definition of Performance Standard
1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.

Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
Performance Standard is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.

T4-1-1

OPERATIONAL PERFORMANCE TEST / Introduction

PREPARATION
TESTS

FOR

PERFORMANCE

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
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
operate steering.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
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
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

T105-06-01-003

OPERATIONAL PERFORMANCE TEST / Standard

OPERATIONAL PERFORMANCE
STANDARD TABLE
ZW220
Acceletor Pedal
: Full Stroke
Driving Mode Switch
: H Mode
Work Mode Switch : N Mode
Hydraulic Oil Temperature : 505 C (12241 F)

The standard performance values are listed in the

table below. Refer to the Group T4-3 or later for
performance test procedures.
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
PERFORMANCE TEST DESIGNATION
ENGINE SPEED (FAN SPEED min/max) min-1
Slow Idle Speed (without load)
Fast Idle Speed (without load)
Fast Idle Speed (with engine stalled)
Fast Idle Speed (with engine stalled and
relieved)
ENGINE COMPRESSION PRESSURE
2

MPa (kgf/cm , psi)

VALVE CLEARANCE (IN, EX)

mm
LUBRICANT CONSUMPTION
(Rated output)
mL/h
DRIVE BELT BEND
mm
RADIATOR CAP OPENING PRESSURE
2

kPa (kgf/cm , psi)

Performance
Standard
84025
2240/233025
2010/192050
1780/177050
3.04 (31.0, 442)
0.4
45 or less
6 to 8
49 (0.5, 7)

T4-2-1

NOTE: 1 mm=0.03937 in
Reference
Remarks
Page
T4-3-1
Value indicated on Dr. ZX

Engine speed: 200min-1

T4-3-3

With the engine cold

Hour meter: 2000 hours or
less

T4-3-4
T4-3-7
T4-6-8
-

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION
TRAVEL SPEED
km/h
First Gear (Forward/Reverse)
Second Gear (Forward/Reverse)
Third Gear (Forward/Reverse)
Fourth (Forward)
SERVICE BRAKE CAPACITY
m
SERVICE BRAKE WEAR
mm
Brake Disc
Brake Ring (t=15)
Brake Ring (t=5)
PARKING BRAKE CAPACITY
mm/5 min
PARKING BRAKE WEAR
mm
Brake Disc
Brake Ring
BUCKET STOPPER CLEARANCE
mm
BELL CRANK STOPPER CLEARANCE
mm

FRONT PIN WEAR

mm
(to new pin outer diameter)
FRONT BUSHING WEAR
mm
(to new pin outer diameter)
CLEARANCE BETWEEN FRONT PIN
AND BUSHING
mm
BUCKET BUMP
mm
HYDRAULIC CYLINDER CYCLE TIME sec
Lift Arm Raise
Lift Arm Lower (Float)
Bucket Roll-Out
Steering (engine: neutral)
Steering (engine: full)
DIG FUNCTION DRIFT CHECK mm/15 min
Lift Arm Cylinder
Bucket Cylinder
Bucket Bottom

Performance
Standard
7.0/7.10.7
12.0/12.61.2
23.0/23.82.3
36.53.6
5.0 or less

Remarks

Reference
Page
T4-4-1

Value indicated on Dr. ZX

T4-4-2
T4-4-3

6.2
15.0
5.0
0

Allowable Limit: 5.3

Allowable Limit: 13.5
Allowable Limit: 4.3

2.2
2.4
0

Allowable Limit: 1.9

Allowable Limit: 2.2

T4-4-4
-

T4-4-6
T4-4-6

2
-

Allowable Limit: -1.0

Allowable Limit: -1.5

0.3
14

T4-4-11
T4-4-8

5.30.3
2.90.3
1.20.3
2.80.3
2.50.3
T4-4-10
45 or less
15 or less
150 or less

T4-2-2

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION

Performance Standard

CONTROL LEVER OPERATING FORCE

N (kgf, lbf)

Lift Arm Raise (STD/MF)

Lift Arm Raise Detent (STD/MF)
Lift Arm Raise Detent Release (STD/MF)
Lift Arm Lower (STD/MF)
Lift Arm Lower Float (STD/MF)
Lift Arm Lower Float Release (STD/MF)
Bucket Lever Tilt (STD/MF)
Bucket Lever Tilt Detent (STD/MF)
Bucket Lever Tilt Detent Release (STD/MF)
Bucket Lever Dump (STD/MF)
Steering Wheel (Right/Left)

11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20(2.0, 4.5) or less
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
12 (1.2, 2.7)/
22 (2.2, 5) or less
18 (1.8, 4)/
33 (3.3, 7.4) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
17(1.7, 3.8)/
28 (2.9, 6.3) or less
17 (1.7, 3.8)/
17 (1.7, 3.8) or less

Forward/Reverse Lever

11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)/
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)

Accelerator Pedal

25.03.5
(3. 60.4, 5.60.8)

Brake Pedal Right

318+65-45
(32.4+6.6-4.6, 71.6+14.6-10.1)

Inching Pedal Left

288+80-30 (29.4+8.2-3.1,
64.8+18-6.8)

NOTE: STD: Standard Lever (Two-Lever)

MF: Multi-Function Lever (Joystick Lever)

T4-2-3

Remarks

Reference
Page
T4-4-12

OPERATIONAL PERFORMANCE TEST / Standard

Performance
Standard

PERFORMANCE TEST DESIGNATION

CONTROL LEVER STROKE
mm
Lift Arm Raise Position (STD/MF)
Lift Arm Raise Detent Position (STD/MF)
Lift Arm Lower Position (STD/MF)
Lift Arm Lower Float Position (STD/MF)
Bucket Lever Tilt Position (STD/MF)
Bucket Lever Tilt Detent Position (STD/MF)
Bucket Lever Dump Position (STD/MF)
Steering Wheel Rotation
(Right Max. to Left Max.)
Forward/Reverse Lever (F/R)
Accelerator Pedal Depressing Angle
(without play)
Brake Pedal (Right) Depressing Angle
(without play)
Inching Pedal (Left) Depressing Angle
(without play)
Steering Wheel Play
Brake Pedal Play
ELECTROLYTE DENSITY
(Specification at 20 C)
2
TIRE INFLATION
kPa (kgf/cm , psi)

Remarks

Reference
Page
T4-4-13

345/6310
545/8010
345/6310
545/8010
345/6310
545/8010
545/8010
3.5 to 4.0
505/505
18.01.5
18.41.0
17.41.0
5 to 15
12 to 20
1.26
325 (3.32, 47.3)

NOTE: STD: Standard Lever (Two-Lever)

MF: Multi-Function Lever (Joystick Lever)

T4-2-4

Allowable Limit: 1.16

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION
PRIMARY PILOT PRESSURE
2

MPa (kgf/cm , psi)

SECONDARY PILOT PRESSURE

2

MPa (kgf/cm , psi)

Performance
Standard
4.0+1.0-0.5
+10
(41 -5, 580+142-71)
3.7+0.5-0.3
+5
(38 -3, 538+73-64)

Remarks

Reference
Page
T4-5-1
T4-5-3

SOLENOID VALVE SET PRESSURE

2

MPa (kgf/cm , psi)

Solenoid Valve Unit Set Pressure

MAIN PUMP DELIVERY PRESSURE
2

MPa (kgf/cm , psi)

Value indicated on Dr.

ZX0.2 (2, 28)
2.0+1.0-0.5
+10
(20 -5, 100+142-71)

Value indicated on Dr.

ZX
In neutral, Value indicated on Dr. ZX

T4-5-4
T4-5-6
T4-5-8

MAIN RELIEF VALVE PRESSURE

2

MPa (kgf/cm , psi)

Lift Arm (Relief operation)

Bucket (Relief operation)
OVERLOAD RELIEF PRESSURE
2

MPa (kgf/cm , psi)

Lift Arm Raise

Bucket Roll-In
Bucket Roll-Out
MAIN PUMP FLOW RATE
STEERING RELIEF PRESSURE

(L/min)
2

MPa (kgf/cm , psi)

SERVICE BRAKE PRESSURE

2
(Forward/Reverse)
MPa (kgf/cm , psi)
PARKING BRAKE PRESSURE
2

MPa (kgf/cm , psi)

27.4+2.0-0.5
(280+20-5, 3983+284-71)
27.4+2.0-0.5
(280+20-5, 3983+284-71)
(Reference values at
50 L/min)
34.3+1.0-0
(350+10-0, 4987+142-0)
30.4+1.0-0
(310+10-0, 4420+142-0)
30.4+1.0-0
(310+10-0, 4420+142-0)
+2.0
27.4 -0.5
(280+20-5, 3983+291-73)
4.180.85
(42.78.7, 608124)
10.8 to 15.0
(110 to 153,
1570 to 2181)

BRAKE ACCUMULATOR PRESSURE

Value indicated on Dr.

ZX
Value indicated on Dr.
ZX
T4-5-14

Value indicated on Dr.

ZX
at Brake Pedal (Right)

T4-5-16
T4-5-12
T4-5-22
T4-5-24

T4-5-26

MPa (kgf/cm , psi)

Service Brake
Parking Brake
BRAKE WARNING PRESSURE
2
(Pressure-Decreasing)
MPa (kgf/cm , psi)
BRAKE WARNING PRESSURE
2
(Pressure-Increasing)
MPa (kgf/cm , psi)
TRANSMISSION CLUTCH PRESSURE
2

MPa (kgf/cm , psi)

TORQUE CONVERTER PRESSURE

2
(Inlet/Outlet)
MPa (kgf/cm , psi)

14.71.0
(15010, 2137145)
14.70.5
(1505, 213773)
80.5
(825, 116373)
100.5
(1025, 145473)
1.6 to 1.8
(16 to 18, 233 to 262)
1.1 to 1.3 (11 to 13,
160 to 189)/ 0.43 to
0.73 (4.3 to 7.4, 63 to
106)

T4-2-5

T4-5-28
T4-5-30
T4-5-32
T4-5-34

OPERATIONAL PERFORMANCE TEST / Standard

ZW250
The standard performance values are listed in the
table below. Refer to the Group T4-3 or later for
performance test procedures.

Acceletor Pedal
: Full Stroke
Driving Mode Switch
: H Mode
Work Mode Switch : N Mode
Hydraulic Oil Temperature : 505 C (12241 F)

The following switch positions shall be selected and

the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:

PERFORMANCE TEST DESIGNATION

ENGINE SPEED (FAN SPEED min/max) min-1
Slow Idle Speed (without load)
Fast Idle Speed (without load)
Fast Idle Speed (with engine stalled)
Fast Idle Speed (with engine stalled and
relieved)
ENGINE COMPRESSION PRESSURE
2

MPa (kgf/cm , psi)

VALVE CLEARANCE (IN, EX)

mm
LUBRICANT CONSUMPTION
(Rated output)
mL/h
DRIVE BELT BEND
mm
RADIATOR CAP OPENING PRESSURE
2

kPa (kgf/cm , psi)

Performance
Standard
84025
2310/230025
2060/198050
1800/179050
3.04 (31.0, 442)
0.4
45 or less
6 to 8
49 (0.5, 7)

T4-2-6

NOTE: 1 mm=0.03937 in
Reference
Remarks
Page
T4-3-1
Value indicated on Dr. ZX

Engine speed: 200min-1

T4-3-3

With the engine cold

Hour meter: 2000 hours or
less

T4-3-4
T4-3-7
T4-6-8
-

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION
TRAVEL SPEED
km/h
First Gear (Forward/Reverse)
Second Gear (Forward/Reverse)
Third Gear (Forward/Reverse)
Fourth (Forward)
SERVICE BRAKE CAPACITY
m
SERVICE BRAKE WEAR
mm
Brake Disc
Brake Ring (t=15)
Brake Ring (t=5)
PARKING BRAKE CAPACITY
mm/5 min
PARKING BRAKE WEAR
mm
Brake Disc
Brake Ring
BUCKET STOPPER CLEARANCE
mm
BELL CRANK STOPPER CLEARANCE
mm

FRONT PIN WEAR

mm
(to new pin outer diameter)
FRONT BUSHING WEAR
mm
(to new pin outer diameter)
CLEARANCE BETWEEN FRONT PIN
AND BUSHING
mm
BUCKET BUMP
mm
HYDRAULIC CYLINDER CYCLE TIME sec
Lift Arm Raise
Lift Arm Lower (Float)
Bucket Roll-Out
Steering (engine: neutral)
Steering (engine: full)
DIG FUNCTION DRIFT CHECK mm/15 min
Lift Arm Cylinder
Bucket Cylinder
Bucket Bottom

Performance
Standard
7.0/7.00.7
12.0/12.51.2
23.0/23.72.3
36.03.6
5.0 or less

Remarks

Reference
Page
T4-4-1

Value indicated on Dr. ZX

T4-4-2
T4-4-3

6.2
15.0
5.0
0

Allowable Limit: 5.3

Allowable Limit: 13.5
Allowable Limit: 4.3

2.2
2.4
0

Allowable Limit: 1.9

Allowable Limit: 2.2

T4-4-4
-

T4-4-6
T4-4-6

2
-

Allowable Limit: -1.0

Allowable Limit: -1.5

0.3
14

T4-4-11
T4-4-8

5.30.3
2.90.3
1.10.3
2.80.3
2.50.3
T4-4-10
45 or less
15 or less
150 or less

T4-2-7

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION

Performance Standard

CONTROL LEVER OPERATING FORCE

N (kgf, lbf)

Lift Arm Raise (STD/MF)

Lift Arm Raise to Detent (STD/MF)
Lift Arm Raise Detent Release (STD/MF)
Lift Arm Lower (STD/MF)
Lift Arm Lower to Float (STD/MF)
Lift Arm Lower Float Release (STD/MF)
Bucket Lever Tilt (STD/MF)
Bucket Lever Tilt to Detent (STD/MF)
Bucket Lever Tilt Detent Release (STD/MF)
Bucket Lever Dump (STD/MF)
Steering Wheel (Right/Left)

11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20(2.0, 4.5) or less
11 (1.1, 2.5)/
19 (1.9, 4.3) or less
17 (1.7, 3.8)/
30 (3.1, 6.8) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
12 (1.2, 2.7)/
22 (2.2, 5) or less
18 (1.8, 4)/
33 (3.3, 7.4) or less
40 (4.1, 9)/
20 (2.0, 4.5) or less
17(1.7, 3.8)/
28 (2.9, 6.3) or less
17 (1.7, 3.8)/
17 (1.7, 3.8) or less

Forward/Reverse Lever

11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)/
11.8+1-2
(1.2+0.1-0.2, 2.7+0.2-0.5)

Accelerator Pedal

25.03.5
(3. 60.4, 5.60.8)

Brake Pedal Right

318+65-45
(32.4+6.6-4.6, 71.6+14.6-10.1)

Inching Pedal Left

288+80-30 (29.4+8.2-3.1,
64.8+18-6.8)

NOTE: STD: Standard Lever (Two-Lever)

MF: Multi-Function Lever (Joystick Lever)

T4-2-8

Remarks

Reference
Page
T4-4-12

OPERATIONAL PERFORMANCE TEST / Standard

Performance
Standard

PERFORMANCE TEST DESIGNATION

CONTROL LEVER STROKE
mm
Lift Arm Raise Position (STD/MF)
Lift Arm Raise Detent Position (STD/MF)
Lift Arm Lower Position (STD/MF)
Lift Arm Lower Float Position (STD/MF)
Bucket Lever Tilt Position (STD/MF)
Bucket Lever Tilt Detent Position (STD/MF)
Bucket Lever Dump Position (STD/MF)
Steering Wheel Rotation
(Right Max. to Left Max.)
Forward/Reverse Lever (F/R)
Accelerator Pedal Depressing Angle
(without play)
Brake Pedal (Right) Depressing Angle
(without play)
Inching Pedal (Left) Depressing Angle
(without play)
Steering Wheel Play
Brake Pedal Play
ELECTROLYTE DENSITY
(Specification at 20 C)
2
TIRE INFLATION
kPa (kgf/cm , psi)

Remarks

Reference
Page
T4-4-13

345/6310
545/8010
345/6310
545/8010
345/6310
545/8010
545/8010
3.5 to 4.0
505/505
18.01.5
18.41.0
17.41.0
5 to 15
12 to 20
1.26
375 (3.75, 47.3)

NOTE: STD: Standard Lever (Two-Lever)

MF: Multi-Function Lever (Joystick Lever)

T4-2-9

Allowable Limit: 1.16

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION
PRIMARY PILOT PRESSURE
2

MPa (kgf/cm , psi)

SECONDARY PILOT PRESSURE

2

MPa (kgf/cm , psi)

Performance
Standard
4.0+1.0-0.5
+10
(41 -5, 580+142-71)
3.7+0.5-0.3
+5
(38 -3, 538+73-64)

Remarks

Reference
Page
T4-5-1
T4-5-3

SOLENOID VALVE SET PRESSURE

2

MPa (kgf/cm , psi)

Solenoid Valve Unit Set Pressure

MAIN PUMP DELIVERY PRESSURE
2

MPa (kgf/cm , psi)

Value indicated on Dr.

ZX0.2 (2, 28)
2.0+1.0-0.5
+10
(20 -5, 100+142-71)

Value indicated on Dr.

ZX
In neutral, Value indicated on Dr. ZX

T4-5-4
T4-5-6
T4-5-8

MAIN RELIEF VALVE PRESSURE

2

MPa (kgf/cm , psi)

Lift Arm (Relief operation)

Bucket (Relief operation)
OVERLOAD RELIEF PRESSURE
2

MPa (kgf/cm , psi)

Lift Arm Raise

Bucket Roll-In
Bucket Roll-Out
MAIN PUMP FLOW RATE
STEERING RELIEF PRESSURE

(L/min)
2

MPa (kgf/cm , psi)

SERVICE BRAKE PRESSURE

2
(Forward/Reverse)
MPa (kgf/cm , psi)
PARKING BRAKE PRESSURE
2

MPa (kgf/cm , psi)

29.4+2.0-0.5
(300+20-5, 4274+284-71)
29.4+2.0-0.5
(300+20-5, 4274+284-71)
(Reference values at
50 L/min)
36.8+1.0-0
(375+10-0, 5350+142-0)
32.5+1.0-0
(332+10-0, 4725+142-0)
32.5+1.0-0
(332+10-0, 4725+142-0)
+2.0
29.4 -0.5
(300+20-5, 4274+291-73)
4.180.85
(42.78.7, 608124)
10.8 to 15.0
(110 to 153,
1570 to 2181)

BRAKE ACCUMULATOR PRESSURE

Value indicated on Dr.

ZX
Value indicated on Dr.
ZX
T4-5-14

Value indicated on Dr.

ZX
at Brake Pedal (Right)

T4-5-16
T4-5-12
T4-5-22
T4-5-24

T4-5-26

MPa (kgf/cm , psi)

Service Brake
Parking Brake
BRAKE WARNING PRESSURE
2
(Pressure-Decreasing)
MPa (kgf/cm , psi)
BRAKE WARNING PRESSURE
2
(Pressure-Increasing)
MPa (kgf/cm , psi)
TRANSMISSION CLUTCH PRESSURE
2

MPa (kgf/cm , psi)

TORQUE CONVERTER PRESSURE

2
(Inlet/Outlet)
MPa (kgf/cm , psi)

14.71.0
(15010, 2137145)
14.70.5
(1505, 213773)
80.5
(825, 116373)
100.5
(1025, 145473)
1.6 to 1.8
(16 to 18, 233 to 262)
1.1 to 1.3 (11 to 13,
160 to 189)/ 0.43 to
0.73 (4.3 to 7.4, 63 to
106)

T4-2-10

T4-5-28
T4-5-30
T4-5-32
T4-5-34

OPERATIONAL PERFORMANCE TEST / Standard

MAIN PUMP P-Q CURVE
P-Q Control (Torque Control)
(REFERENCE: Measured at Test Stand)

Rated Pump Speed:

ZW220: 2170 min-1 (rpm)
ZW250: 2240 min-1 (rpm)
Hydraulic Oil Temperature: 505 C (12241 F)

L/min

B
C

Flow
Rate

Delivery Pressure

MPa (kgf/cm2)

ZW220

A
B
C
D

T4GB-04-02-001

ZW250

Delivery Pressure
MPa (kgf/cm2, psi)

Flow Rate
L/min (gpm)

Delivery Pressure
MPa (kgf/cm2, psi)

Flow Rate
L/min (gpm)

4.9 (50, 712)

19.6 (200, 2849)
24.5 (250, 3562)
27.4 (280, 3983)

2713 (720.8)
2703 (710.8)
2406 (631.6)
2106 (551.6)

4.9 (50, 712)

19.6 (200, 2849)
24.5 (250, 3562)
29.4 (300, 4274)

2913 (770.8)
2903 (770.8)
2756 (731.6)
2256 (591.6)

T4-2-11

OPERATIONAL PERFORMANCE TEST / Standard

P-Q Control by Pump Control Pilot Pressure
Signal
(REFERENCE: Measured at Test Stand)

Rated Pump Speed:

ZW220: 2170 min-1 (rpm)
ZW250: 2240 min-1 (rpm)
Hydraulic Oil Temperature: 505 C (12241 F)

L/min

Flow
Rate

Pump Control Pressure

MPa (kgf/cm2)

T4GB-04-02-002

Pi1Pi2

ZW220

A
B
C

ZW250

Pump Control Pressure

(Pi1Pi2)
MPa (kgf/cm2, psi)

Flow Rate
L/min (gpm)

Pump Control Pressure

(Pi1Pi2)
MPa (kgf/cm2, psi)

Flow Rate
L/min (gpm)

0.39+0.01-0 (4+0.1-0, 57+1.5-0)

1.470.05 (150.5, 2147)
1.67+0.01-0 (17+0.1-0, 243+1.5-0)

2713 (1720.8)
802 (210.5)
363 (100.8)

0.49+0.01-0 (5+0.1-0, 71+1.5-0)

1.470.05 (150.5, 2147)
1.67+0.01-0 (17+0.1-0, 243+1.5-0)

2913 (770.8)
1002 (260.5)
553 (150.8)

T4-2-12

OPERATIONAL PERFORMANCE TEST / Standard

SENSOR ACTIVATING RANGE
1. Checking Method
Hydraulic Oil Temperature: 50 5 C (12241 F)
Unless specified:
Engine
Speed
Fast Idle

Work Mode
Switch
N

Monitor each sensor by using Dr. ZX.

2. Sensor Activating Range

ZW220
Item
Pump Delivery Pressure
Implement Pressure
Parking Brake Pressure
Service Brake Pressure

Specification
MPa (kgf/cm2, psi)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Relieved
26.7 to 30.0 (272 to 306, 3882 to 4361)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Implement Lever: Relieved
26.7 to 30.0 (272 to 306, 3882 to 4361)
Parking Brake Switch: ON
0 to 0.1 (0 to 1, 0 to 15)
Parking Brake Switch: OFF
10.5 to 15.7 (107 to 160, 1526 to 2282)
Brake Pedal: Neutral
0 to 0.1 (0 to 1, 0 to 15)
Brake Pedal: Fully De- 3.3 to 5.0 (34 to 51, 480 to 727)
pressed
Operation

ZW250
Item
Pump Delivery Pressure
Implement Pressure
Parking Brake Pressure
Service Brake Pressure

Specification
MPa (kgf/cm2, psi)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Relieved
28.7 to 32.0 (293 to 327, 4172 to 4652)
Neutral
1.2 to 2.6 (12 to 27, 174 to 378)
Implement Lever: Relieved
28.7 to 32.0 (293 to 327, 4172 to 4652)
Parking Brake Switch: ON
0 to 0.1 (0 to 1, 0 to 15)
Parking Brake Switch: OFF
10.5 to 15.7 (107 to 160, 1526 to 2282)
Brake Pedal: Neutral
0 to 0.1 (0 to 1, 0 to 15)
Brake Pedal: Fully De- 3.3 to 5.0 (34 to 51, 480 to 727)
pressed
Operation

T4-2-13

OPERATIONAL PERFORMANCE TEST / Standard

(Blank)

T4-2-14

OPERATIONAL PERFORMANCE TEST / Engine Test

ENGINE SPEED
Summary
1. Measure the engine speed by using the monitor
unit or Dr. ZX.
2. Measure the engine speeds in each mode.
NOTE: 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 monitor which is started on the service
mode or Engine Actual Speed on the MC screen
by Dr.ZX.
2. Warm up the machine until coolant temperature
reaches 50 C (122 F) or more, hydraulic oil
temperature is 505 C (12241 F) and Transmission oil temperature is 855 C (18541 F).

M4GB-01-039

Measurement:
1. Measure the items as followings: slow idle with
no load), fast idle (with no load), fast idle (when
engine stalls) and fast idle (when engine stalls
and is relieved).
2. When measuring, set the switch and test condition as shown in the table below in response to
the engine speed to be measured.
Forward/Reverse Lever Accelerator Pedal Travel Mode Switch
Slow Idle
N
No depression
M
(with no load)
Fast Idle
Forward third/fourth gear Full depression
M
(with no load)
Fast Idle
N
Full depression
M
(when engine stalls)
Fast Idle
(when engine stalls Forward third/fourth gear Full depression
M
and is relieved)

T4-3-1

Work Mode Switch

N
N
N
N

OPERATIONAL PERFORMANCE TEST / Engine Test

Slow Idle
(with no load)
Fast Idle
(with no load)
Fast Idle
(when engine
stalls)
Fast Idle
(when engine stalls
and is relieved)

Clutch Cut Position

Switch

Brake Pedal

Parking Brake
Switch

ON

Full depression

ON

OFF

Full depression

OFF

Transporting position
No control lever operation

OFF

Full depression

OFF

Transporting position
Bucket is raised and
relieved.

Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.

T4-3-2

Control Lever (Bucket)

Transporting position
No control lever operation
Transporting position
No control lever operation

OPERATIONAL PERFORMANCE TEST / Engine Test

ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove all the glow plugs from each cylinder.
20 Nm (2.0 kgfm, 14.8 lbfft)
IMPORTANT: If disconnecting the connector of
injector, fuel cannot be jetted.
Therefore, ECM judges that the fuel
system is faulty and the fault code
is displayed. After measurement,
delete the displayed fault code.
5. Disconnect the connector of injector which is installed to the lower head cover.
6. Install the negative terminal of battery.
7. Turn the starter. Exhaust foreign subjects from
the cylinder.
8. Install a pressure gauge and an adaptor (Isuzu
EN-46722) to the glow plug mounting part. (Sufficiently install them in order to prevent air leakage.)

Injector

Lower Head Cover

Connector

T1V7-04-03-002

Measurement:
1. Turn the starter and measure compression pressure of each cylinder.
2. Repeat the measurement three times and calculate the mean values.
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to the engine shop manual.

T4-3-3

T1V1-04-03-005

OPERATIONAL PERFORMANCE TEST / Engine Test

VALVE CLEARANCE ADJUSTMENT
Terminal Nut

Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Remove the head cover.
2. Remove the terminal nut which secures the harness to the injector.
2 Nm (0.2 kgfm, 1.5 lbfft)
3. Remove the harness assembly from the injector.
4. Remove the leak off pipe.

Harness

12 Nm (1.2 kgfm, 8.9 lbfft)

5. Rotate the crank pulley. Align the top dead center
(TDC) mark on crank pulley with the top mark
located on timing gear case.

Injector
T1V1-04-03-008

NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate,
remove all glow plugs and release
compression pressure.
6. Check if piston No.1 (or piston No.4) is now positioned at the TDC in the compression stroke.
Leak Off Pipe

NOTE: Move push rods for the intake and exhaust

valves on the No.1 cylinder up and down
by hand. If any clearances on the both
ends of the push rods are found, piston
No.1 is positioned at TDC in the compression stroke. (If the exhaust valve of cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression
stroke.

T1V1-04-03-007

Top Mark

Crank Pulley

7. Start measurement from the cylinder (No.1 or

No.6) positioned at TDC in the compression
stroke.

TDC Mark

T4-3-4

T1V7-04-03-001

OPERATIONAL PERFORMANCE TEST / Engine Test

Measurement:
1. Insert a thickness gauge into the clearance between rocker arm and bridge cap end and measure the valve clearance.

Adjusting Screw

NOTE: The cylinders are aligned from No.1 to

No.6 in that order, as viewed from the fan
side. Injection Order: 1-5-3-6-2-4
2. When measurement is started from No.1 cylinder,
perform the same measurement to all valves indicated with the mark in the table below.
(When measurement is started from No.6 cylinder, perform the measurement in the valves
shown with mark .)

Cylinder No.
Valve locations
When the measurement is
started from No.1 cylinder
When the measurement is
started from No.6 cylinder

No.1
I
E
{

No.2
I
E
{

No.3
I
E
{

3. Rotate the crankshaft 360. Align the TDC mark

with the pointer. Continue measurement of other
valves in the same way.

Bridge Cap
T4GB-04-03-003

No.4
I
E
{

No.5
I
E

No.6
I
E

Rocker Arm

Evaluation:
Refer to Operational Performance Standard in Group
T4-2.

T4GB-04-03-004

T4-3-5

OPERATIONAL PERFORMANCE TEST / Engine Test

Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.

Adjusting
Screw

Rocker Arm

IMPORTANT: Touch the bridge to the end of valve

heads (2 used) horizontally and adjust the valve clearance carefully.
1. Loosen the lock nuts (12 used) and adjusting
screws (12 used), which secure the bridge and
rocker arm.
2. Insert a thickness gauge into the clearance between rocker arm and bridge cap.
3. Tighten the adjusting screw of rocker arm until
condition for the thickness gauge is proper.
4. Tighten the lock nut of rocker arm.
: 22 Nm (2.2 kgfm, 16.2 lbfft)
5. Tighten the adjusting screw of bridge until the
bridge comes in contact with the valve head.
6. Tighten the lock nut of bridge.
: 22 Nm (2.2 kgfm, 16.2 lbfft)
7. Check the valve clearance after the lock nuts are
tightened.

T1V1-04-03-002

Lock Nut

Bridge

Bridge Cap

T1V1-04-03-003

Valve Head

T4-3-6

Bridge

OPERATIONAL PERFORMANCE TEST / Engine Test

LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in
Step 1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing volume C.
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the following equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.

T4-3-7

OPERATIONAL PERFORMANCE TEST / Engine Test

(Blank)

T4-3-8

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

TRAVEL SPEED
6. Convert the measurement value to be expressed
in km/h.
Measurement value (seconds) = S (sec)
Converted value (hourly speed) = A (km/h)

Summary:
1. The overall performance of the travel drive system
(torque converter through transmission) is judged
by measuring the time necessary for traveling 50
m (164 ft).

A=
Preparation:
1. Adjust air pressure of the tires evenly in advance.
Air pressure:
ZW220: 325 kPa (3.32 kgf/cm2, 47 psi)
ZW250: 375 kPa (3.83 kgf/cm2, 55 psi)
2. On a firm level and uniform supporting surface,
prepare a 50 m (164 ft) straight travel course, and
70 m (230 ft) forward and backward runways. (For
measurement at Speed 4, a forward runway of
300 m (984 ft) is needed.)
3. Empty the bucket, and hold the lift arm afloat 0.4
to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground.
4. Keep the hydraulic oil temperature at 505 C
(12241 F). Warm the axle oil satisfactorily by
repeating travel and brake operations.
Make a warm up operation so that the indicators
of the engine water temperature monitor and the
torque converter oil temperature monitor rise
above the horizontal positions.

50 600
S 1000

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.

0.4 to 0.5 m
(14 to 18)

Ending Point

Travel Course
Runway
Starting Point
T4GB-04-04-001

Measurement
CAUTION: Avoid measurement at reverse for
fear of dangers involved.
1. Make measurement for each mode (Speeds 1 to
4).
2. Select the switches as follows.
Parking Brake
Accelerator
Shift Switch
Switch
Pedal
Speed 1
Speed 1
OFF
Full depression
Speed 2
Speed 2
OFF
Full depression
Speed 3
Speed 3
OFF
Full depression
Speed 4
Speed 4
OFF
Full depression
3. Put the forward-reverse lever at the F (Forward)
position. From the runway, travel by depression
the accelerator pedal to the stroke end.
4. Measure the travel speed (sec) of each travel
mode.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.

T4-4-1

Travel Mode
Switch
H
H
H
H

Work Mode
Switch
N
N
N
N

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

SERVICE BRAKE FUNCTION CHECK
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Summary:
1. The overall performance of the service brake is
judged.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance test.
Preparation:
1. Adjust air pressure of the tires evenly in advance.
Air pressure:
ZW220: 325 kPa (3.32 kgf/cm2, 47 psi)
ZW250: 375 kPa (3.83 kgf/cm2, 55 psi)
2. On a paved dry road, prepare a 100 m (328 ft)
straight travel course (a 50 m (164 ft) of runway
and a 50 m (164 ft) of measurement road), and
set the brake starting point.
3. Empty the bucket, and hold the lift arm afloat 0.4
to 0.5 m (1 ft 4 in to 1 ft 8 in) above the ground.
4. Keep the hydraulic oil temperature at 505 C
(12241 F). Warm the axle oil satisfactorily by
repeating travel and brake operations.
Make a warm up operation so that the indicators
of the engine water temperature monitor and the
torque converter oil temperature monitor rise
above the horizontal positions.

Remedy:
Refer to the Trouble Shooting in Section T5.

0.4 to 0.5 m
(14 to 18)
Stopping Distance
Stopping Point
Brake Starting
Point
T4GB-04-04-002

Measurement
CAUTION: Avoid measurement at reverse for
fear of dangers involved. (Forward-reverse
lever: F)
1. Make measurement for high-speed mode.
2. Select the switches as follows.
Shift Switch

Parking Brake Switch

Speed 4

OFF

Accelerator
Pedal
Full depression

3. Put the forward-reverse lever at the F (Forward)

position. From the runway, travel at 20 km/h (12
mph) by depression the accelerator pedal to the
stroke end.
4. Depression the brake at the brake starting point,
and completely stop the vehicle. (Right Service
Brake Pedal)
5. Measure the distance from the brake starting
point to the point where the front tire is contacting.
6. Make measurement three times, and determine
the measurement value by obtaining their mean
values.

T4-4-2

Travel Mode
Switch

Work Mode
Switch

Clutch Cut Position

Switch

OFF

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

SERVICE BRAKE WEAR AMOUNT
1

Summary:
The extent of wear of the brake disc at the service
brake of the axle is judged by the wear gauge.
Preparation:
1. Clean the inspection plug (1) of the axle, and
loosen it.
2. In the case of the rear axle, the inspection plug (1)
is located below the center line of the differential,
so loosen the inspection plug (1) after draining the
axle oil.

T4GB-04-04-004

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

Inspection Port

T4GB-04-04-005

Evaluation:
1. In case the wear gauge (2) has entered between
the brake rings (3 and 4), and the model scale of
the wear gauge (2) and the housing face (5) have
coincided, the wear amount of the brake disc (6)
is not reached the maximum allowable limit of use.
In case the wear gauge (2) has not entered between the brake rings (3 and 4), and the model
scale is sticking above the housing face (5), the
brake disc (6) is worn in excess of the maximum
allowable limit of use.
2. In the method above, in case the maximum allowable limit of use has not reached, or in case
the service brake portion has been assembled,
refer to the Performance Standard Table in Group
T4-2.
Distance between Housing Face (5) and Brake
Disc (6)
Model
Dimensions (L) mm
ZW220

52

ZW250

54

T4-4-3

3
4
T4GB-04-04-006

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

PARKING BRAKE FUNCTION CHECK
Summary:
1. The function of the parking brake on a determined
slope is measured.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance test.
Preparation:
1. Make measurement on a plane slope of 11.31
(20 %).
2. Empty the bucket, and hold the lift arm afloat 0.4
to 0.5 m (14 to 18) above the ground.
3. Keep the hydraulic oil temperature at 505 C
(12241 F).
4. Warm the axle oil satisfactorily by repeating travel
and brake operations.
Make a warm up operation so that the indicators
of the engine water temperature monitor and the
torque converter oil temperature monitor rise
above the horizontal positions.

0.4 to 0.5 m
(14 to 18)
11.31 (20%)
T4GB-04-04-003

Measurement:
1. Travel up the slope, and put the parking brake
switch at the P position.
2. Stop the engine.
3. After the body has stopped, put a mark (white
line) on the tire and the ground surface respectively.
4. After Five minutes have passed, measure the
amount of movement of the white line of the tire
from that of the ground surface.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-4-4

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

(Blank)

T4-4-5

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

BUCKET AND BELL CRANK STOPPER
CLEARANCE
Summary;
Wear and deformation conditions of the bucket
stopper (dump end and crowd end) and the clearance between the bell crank stopper and the cross
tube are measured.
Preparation:
Stop the vehicle on a plane road surface, and operate the parking brake.

Bucket Dump
Stopper
Bell Crank Stopper

Measurement:
1. Bucket dump stopper
1-1. Raise the lift arm to the highest lifting position,
and stop the engine.
1-2. At stop of the engine, dump calmly until the
buket contacts the dump stopper. At this time,
measure the Strokes (A and B) of the bucket
cylinder and the lift arm and the dump angle (C)
of the bucket. In addition, measure the clearance between the bell crank stopper and the
cross tube.
1-3. At the same time, make measurement of the
contact conditions of the bucket dump stoppers
(left and right).
2. Bucket crowd stopper
1-1. Raise the lift arm until the lift arm cylinder stroke
(E) becomes the length of the standard dimension.
1-2. Set the engine at idling speed, and make
crowding operation until the bucket calmly contacts the bucket crowd stopper.
1-3. At this time, measure the strokes (D and E) of
the bucket cylinder and the lift arm cylinder and
the crowd angle (F) of the bucket. In addition,
measure the height (G) from the ground to the
bucket lowest portion.
1-4. Also measure the contact conditions of the
bucket crowd stoppers (left and right).

T4GB-04-04-008

Bucket Crowd
Stopper

T4GB-04-04-010

T4-4-6

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

Evaluation:
1. Bucket Dumper Stopper
1-1. Cylinder Stroke Strokes A and B
Bucket Cylinder
Lift Arm Cylinder
Model
A (mm)
B (mm)
ZW220
3621.5
11202
ZW250
3731.5
11802

2. Bucket Crowd Stopper

2-1. Cylinder Strokes D and E
Bucket Cylinder
Model
D (mm)
ZW220
690
ZW250
719

1-2. Bucket Dump Angle C

Model
C ()
ZW220
502
ZW250
502

2-2. Bucket Crowd Angle (F)

Model
F ()
ZW220
50
ZW250
50

1-3. Clearance between Bell Crank Stopper and

Cross Tube
Clearance between Bell Crank
Model
Stopper and Cross Tube
(mm)
Standard
2.0
ZW220
Limit
Standard
2.0
ZW250

2-3. Height from Ground to Bucket Lowest Portion

(G)
Model
G (mm)
ZW220
450
ZW250
425

Limit

1-4. Clearance between Bucket Dump Stopper and

Lift Arm
Clearance at Longitudinal and
Unsymmetrical Lateral Clearance
Model
Contact
of a Stopper
(mm)
(mm)
Standard
0
0
ZW220
Limit
0.5
1.0
Standard
0
0
ZW250
Limit
0.5
1.0

2-4. Clearance between Bucket Dump Stopper and

Lift Arm
Clearance at Longitudinal and
Unsymmetrical Lateral Clearance
Model
Contact
of a Stopper
(mm)
(mm)
Standard
0
0
ZW220
Limit
0.5
1.0
Standard
0
0
ZW250
Limit
0.5
1.0
Clearance at Unsymmetrical Contact
Clearance Limit
Left

Clearance at Unsymmetrical Contact

Right

Longitudinal and Lateral Clearance of a Stopper

Clearance Limit

Left

Lift Arm Cylinder

E (mm)
360
371

Clearance Limit

Right

Left

Right
T4GB-04-04-009

Longitudinal and Lateral Clearance of a Stopper

Clearance Limit
Left

Right

T4GB-04-04-009

T4-4-7

NOTE: Standard dimensions indicate those of a

new tire at the designated air pressure.

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

HYDRAULIC CYLINDER CYCLE TIME

Lift Arm Cylinder:

Summary:
1. The overall performance of the cylinders drive
system (main pump through each cylinder) is
judged by measuring the operating time of the
cylinders for the lift arm, bucket, and steeering.
2. The bucket is made empty in advance.

(for Lifting)

Preparation:
1. Measurement is made for the following positions.
1-1. Measurement of Lift Arm Cylinder (for Liftig)
Fully crowd the bucket, and lower the lift arm.
1-2. Measurement of Lift Arm Cylinder (for Lowering)
Lower the lift arm until the bucket bottom face
touches the ground horizontally.
1-3. Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
1-4. Measurement of Steering Cylinder
Empty the bucket, and take the travel forward
position.

T4GB-04-04-016

(for Lowering)

2. Keep the hydraulic oil temperature at 505 C

(12241 F).
CAUTION: Select ground filled with sand or
something so that the bucket contacts the
ground with buffer.

T487-04-03-005

Bucket Cylinder:

T487-04-03-006

Travel Position

0.4 to 0.5 m
(14 to 18)
M4GB-04-001

T4-4-8

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

Measurement:
1. Select the pedal, switches, and forward-reverse
lever as follows.
Parking Brake
Accelerator Pedal
Switch
Lift Arm
Full Stroke
ON
(for Lifting)
(Engine Maximum Speed)
Lift Arm
Neutral
ON
(for Lowering)
(Engine Minimum Speed)
Full Stroke
Bucket
ON
(Engine Maximum Speed)
Neutral
Steering
OFF
(Engine Minimum Speed)
Full Stroke
Steering
OFF
(Engine Maximum Speed)
2. Make measurement operation as follows.
(including the buffer range)
2-1. Measurement of Lift Arm Cylinder (for Lifting)
Operate the lift arm lever to the stroke end, and
measure the time of movement of the lift arm
from the lowest position to the highest position.
2-2. Measurement of Lift Arm Cylinder (for Lowering)
Lower the bucket to the ground in the horizontal
position, and lift the lift arm to the highest position.
Keep the lift arm lever at the afloat position, and
measure the time of movement of the bucket
reaching the ground.
2-3. Measurement of Bucket Cylinder
Operate the bucket lever to the stroke end, and
measure the time of movement of the bucket
from the full crowd position to the full dump position.
2-4. Measurement of Steering Cylinder
Operate the steering wheel to the stroke end,
and measure the time of movement of the
steering wheel from the right to the left end, and
from the left to the right end.
CAUTION: Before measurement, confimr
that there are no human beings or obstacles
in the steering range.
3. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Trouble Shooting in Section T5.

T4-4-9

Forward-reverse
Lever

Work Mode
Switch

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

CYLINDER DRIFT CHECK
Summary:
1. Internal leakage of the lift arm, bucket cylinders,
and control valves when the buket is loaded with
load equivalent to the standard load is judged by
the settlement (shrinkage) of the cylinder rod.
2. Measurement is made in the standard front condition (standard bucket).
3. In case measurement is made immediately after
the cylinder replacement, conduct air venting of
the cylinder before measurement by operating the
cylinders slowly to the stroke ends several times.
Preparation:
1. Load the bucket with weight or sand equivalent to
the standard load
ZW220: 5580 kg (12302 lb)
ZW250: 6120 kg (13492 lb)
2. In the front position, extend the lift arm to the
maximum reach, and hold the bucket at an agle of
about 5 declined forward from full crowding.

Bucket Cylinder

CAUTION: Never allow any personnel to be

under the bucket.
1. Keep the hydraulic oil temperature at 505 C
(12241 F).
Measurement of
Settlement

Lift Arm
Cylinder

Measurement:
1. Stop the engine.
2. After 15 minutes have passed, measure the
shrinkage of the lift arm cylinder, shrinkage of the
bucket cylinder, and the settlement of the bucket
bottom respectively.
3. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4GB-04-04-014

B
A
T4GB-04-04-015

Remedy:
Refer to the Trouble Shooting in Section T5.

T4-4-10

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

BUCKET LEVELNESS
Summary:
Left and right inclinations of the bucket are checked
in order to prevent uneven wear of the cutting edge
of the bucket.
Preparation:
1. Place the unloaded base machine on a horizontal
bed on rhe ground. (In case a bed is not available,
place it on a horizontal flat concrete on the ground.
Deal with the measurement values as guide
lines.)
2. Adjust the tire air pressure to the designated
value.
3. Have the bucket bottom contact the ground horizontally.
Cutting Edge

Measurement:
1. Have the bucket bottom float slightly above the
bed.
2. Measure the vertical distance from the bed and
the bottom face of the cutting edge on the left and
right ends, and confirm the difference.
3. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
CAUTION: Never put hands, feet, and measuring instruments under the bucket.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-4-11

T4GB-04-04-011

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

CONTROL LEVER OPERATING FORCE
Summary
1. Operating conditions of the levers, pedals, and
steering wheel are confirmed, and their operating
force are measured.
2. Maximum operating force of the levers, pedals,
and steering wheel are measured.
3. Measurement of each of the operating levers is
made at the center of the grip.
Measurement of each of the pedals is made at
150 mm (6 in) from the pedal support.
Travel Position
Preparation:
1. In the front position, empty the bucket in advance.
2. Keep the hydraulic oil temperature at 505 C
(12241 F).
Measurement
1. Make measurement for each of the operating
levers, pedals, and steering wheel.
2. Select the pedal, switches, and forward-reverse
lever as follows.
Parking
Forward-reverse
Accelerator Pedal
Brake Switch
Lever
Neutral
(Engine Minimum
ON
N
Speed)

0.4 to 0.5 m
(14 to 18)
M4GB-04-001

CAUTION: Before measurement, confimr

that there are no human beings or obstacles
in the steering range.
3. Apply a spring balance scale (tension type) to
each of the lift arm, bucket, and froward-reverse
lever, and measure their maximum operating efforts by operating them to the stroke end.
4. In the case of the pedals, apply a spring balance
scale (compression type) or a load cell to them,
and measure their operating efforts when they are
stepped slightly.
5. For the steering wheel, apply a spring balance
scale (tension type) to the knob, and measure the
maximum operating effort when it is moved.
6. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-4-12

T4GB-04-04-013

Knob

M4GB-01-004

Brake Pedal

Accelerator Pedal

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

CONTROL LEVER STROKE
Summary:
1. Plays and operating conditions of operating levers,
pedals, and steering wheel are confirmed, and
their strokes are measured.
2. Measurement of each of the operating levers is
made at the tip of the grip.
Measurement of each of the pedals is made at the
top of the pedal.
3. In the case of existence of play at neutral, make
measurement by dividing it on both sides evenly.
Preparation:
1. Keep the hydraulic oil temperature at 505 C
(12240 F).

Measurement:
1. Measurement of Operating Lever
1-1. Have the bucket bottom contact the ground.
1-2. Stop the engine.
1-3. Measure the stroke from the neutral position to
the stroke end of each of the lift arm, bucket,
and forward-reverse operating levers at the top
center of the grip.
2. Measurement of Pedal
2-1. Have the bucket contact the ground.
2-2. Stop the engine.
2-3. Measure the stroke from the neutral position to
the stroke end of the pedal at the top of the
pedal.
3. Measurement of Steering Wheel
3-1. Start the engine. (Low idling)
3-2. Have the bucket float slightly above the ground.
3-3. Measure the number of times of rotation required for reaching the left stroke end from the
right, and vice versa of the steering wheel.
4. make measurement corresponding to a straight
line.
5. Make measurement three times, and determine
the measurement value by obtaining their mean
values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-4-13

OPERATIONAL PERFORMANCE TEST / Wheel Loader Test

(Blank)

T4-4-14

OPERATIONAL PERFORMANCE TEST / Component Test

PRIMARY PILOT PRESSURE
(Including Brake Circuit)
CAUTION: If air is mixed in the brake system,
the brake function is reduced, and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
Refer to Troubleshooting B in Group T5-6.
IMPORTANT: Primary pilot pressure circuit shuts
off a circuit connecting to pilot relief
valve if pressure in the accumulator
is insufficient, and delivers primary
pilot pressure to accumulator circuit.
At this time, primary pilot pressure
reaches 15 MPa (153 kgf/cm2, 2180
psi) or high, so use a pressure
gauge capable of measuring 15 MPa
(153 kgf/cm2, 2180 psi) or higher.

Hose
(3/4-16UNF)

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the hose end from the pilot filter inlet or
outlet port. Install adapter (13/16-16UNF), nipple,
pressure gauge and coupling.
: 22 mm, 24 mm, 27 mm

Pilot Filter

T4GB-04-05-001

4. Start the engine. Check for any oil leaks at the

pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Measure pilot pressure without load by using a
pressure gauge.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
NOTE: When pressure in the service brake accumulator is reduced during measurement
of primary pilot pressure, the measured
valve is increased to 15 MPa (153 kgf/cm2,
2180 psi) for several seconds.

T4-5-1

T1F3-04-05-001

OPERATIONAL PERFORMANCE TEST / Component Test

Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure in charging block
as necessary.

1. Remove plug (1) from the relief valve.

: 30 mm
2. Remove shim (2) from the relief valve.
3. Install the estimated number of shim (2).
4. Install shim (2) to the relief valve.
Tighten plug (1).
: 98.09.8 Nm
(96095 kgfm, 71071 lbfft)

Charging Block

M4GB-07-100

5. Check the set-relief pressure.

Charging Block

NOTE: Standard Change in Pressure (Reference)

Set the thickness of shims at less than 1.5 mm.
Shim Thickness

Change in Pressure

(mm)

kPa

(kgf/cm2)

(psi)

0.2

61.8

(0.63)

(9)

0.4

124.6

(1.27)

(18)

0.8

249.2

(2.54)

(36)

1
X

T4GB-04-05-002

Section X-X

T4GB-04-05-003

T4-5-2

OPERATIONAL PERFORMANCE TEST / Component Test

SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Measure pressure at the location between pilot
valve and main valve.
Remove the pilot hose to be measured. Install
the hose (9/16-18UNF length: approx. 400 mm)
to the signal control valve side. Install a tee and a
pressure gauge between the hoses.
: 17 mm, 19 mm, 22 mm

Pilot Valve

4. Start the engine. Check for any oil leaks at the

pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Measure pilot pressure by using a pressure
gauge with the corresponding control lever operated full stroke.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.

T4-5-3

Pilot Hose

Signal Control
Valve
Pressure Gauge

Tee

T4GB-04-05-004

OPERATIONAL PERFORMANCE TEST / Component Test

SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure by using both Dr.
ZX and the pressure gauge.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the line from port X in the charging block.
Install a tee, a hose and adapter (ST 6461). Install pressure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
Install Dr. ZX and select the monitoring function.
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).

Charging Block

Solenoid
Valve

Measurement:
1. Set engine speed at fast idle.
2. Measure without depressing the accelerator
pedal.
Measure with the accelerator pedal fully depressed.
3. Read the values on both Dr. ZX and the pressure
gauge.
4. Repeat the measurement three times and calculate the average values.

Port X

T4GB-04-05-005

Pressure Gauge

Evaluation:
Refer to the performance Standard Table in Group
T4-2.

To Port X

T4GB-04-05-006

Hose

T4-5-4

Tee

Adapter

OPERATIONAL PERFORMANCE TEST / Component Test

Solenoid Valve Set Pressure Adjustment Procedure
IMPORTANT: O-ring on the threads may come off
the sealing surface and oil leak may
occur. Do not loosen and tighten the
adjusting screw excessively.
Do not loosen the adjusting screw
more than 1.2 turns. Do not tighten
the adjusting screw more than 2
turns.
1. Loosen lock nut (1). Turn adjusting screw (2) and
adjust set pressure of the solenoid valve.
2. Retighten lock nut (1).
: 18 mm
: 19.6 Nm (2 kgfm, 14 lbfft)
: 6 mm

T4GB-04-05-007

Charging Block

3. Check the set pressure of the solenoid valve.

NOTE: Standard Change in Pressure (Reference)
Adjusting Screw
1/4
1/2
3/4
1
Turns
kPa
39.2
80.4
120
160
Change in
(kgf/cm2) (0.4) (0.82) (1.22) (1.63)
Pressure
(psi)
(6)
(12)
(17)
(23)

T4GB-04-05-002

Pressure
Increase

Pressure
Decrease

W107-02-05-129

T4-5-5

OPERATIONAL PERFORMANCE TEST / Component Test

MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be measured by using Dr. ZX.
Summary:
Measure the main pump delivery pressure in order to
check performance of the main pump.

Pressure
Gauge

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm
(If Dr. ZX is used, install Dr. ZX and select the
controller function diagnosing.)
4. Start the engine. Check for any leaks at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Measure pressure without load (with the control
levers in neutral).
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting in Section T5.

T4-5-6

Pressure
Check Port

T4GB-04-05-008

Adapter

OPERATIONAL PERFORMANCE TEST / Component Test

(Blank)

T4-5-7

OPERATIONAL PERFORMANCE TEST / Component Test

MAIN RELIEF PRESSURE
The main relief pressure can also be measured by
using Dr. ZX.
Summary:
Measure the main relief valve set pressure at the
main pump delivery port in order to check performance of the main relief valve.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm
(If Dr. ZX is used, install Dr. ZX and select the
controller function diagnosing.)
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Slowly operate the lift arm or bucket control levers to the stroke end (extend or retract) and relieve each function.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-5-8

Pressure
Gauge

Pressure
Check Port

T4GB-04-05-008

Adapter

OPERATIONAL PERFORMANCE TEST / Component Test

Main Relief Valve Pressure Adjustment Procedure

ZW220
1. Secure lock nut (1). Remove nut (3).
: 17 mm
2. Secure adjusting screw (2). Loosen lock nut (1).
: 17 mm
3. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
4. Secure adjusting screw (2). Tighten lock nut (1).
: 19.5 Nm (2 kgfm, 14 lbfft)
5. Secure lock nut (1). Tighten nut (3).
6. Check the relief set pressure.

T4GB-04-05-009

NOTE: Standard Change in Pressure (Reference)

Adjusting Screw
1/4
1/2
3/4
1
Turns
MPa
2.79
5.59
8.36
11.2
Change in
(kgf/cm2) (28.5)
(57)
(85.2)
(114)
Pressure
(psi)
(406) (813) (1215) (1628)

T4GB-04-05-010

Pressure
Increase

Pressure
Decrease

T105-06-05-002

T4-5-9

OPERATIONAL PERFORMANCE TEST / Component Test

ZW250
1. Loosen lock nut (1).
: 17 mm
2. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
: 6 mm
3. Tighten lock nut (1).
: 29.4 Nm (3 kgfm, 22 lbfft)
4. Check the relief set pressure.

2
T4GB-04-05-011

NOTE: Standard Change in Pressure (Reference)

Adjusting Screw
1/4
1/2
3/4
1
Turns
Change in
Pressure

MPa
(kgf/cm2)
(psi)

4.5
(46)
(654)

8.9
(91)
(1294)

13.4
(137)
(1948)

17.8
(182)
(2588)

Pressure
Increase

Pressure
Decrease

W107-02-05-129

T4-5-10

OPERATIONAL PERFORMANCE TEST / Component Test

(Blank)

T4-5-11

OPERATIONAL PERFORMANCE TEST / Component Test

STEERING RELIEF PRESSURE
The steering relief pressure can also be measured by
using Dr. ZX.
Pressure Gauge

Summary:
Measure the steering relief valve set pressure at the
main pump delivery port in order to check performance of the steering relief valve.
Preparation:
1. Stop the engine.
2. Pusht the air bleed valve on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm
(If Dr.ZX is used, install Dr.ZX and select the controller function diagnosing.)
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the accelerator pedal fully.
2. Install the articulation lock bar. Slowly operate the
steering handle and relieve the steering.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-5-12

Pressure
Check Port

Adapter

T4GB-04-05-008

OPERATIONAL PERFORMANCE TEST / Component Test

Steering Relief Valve Pressure Adjustment Procedure
1. Secure lock nut (1). Remove nut (3).
: 24 mm
2. Secure adjusting screw (2). Loosen lock nut (1).
: 24 mm
3. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
4. Secure adjusting screw (2). Tighten lock nut (1).
: 37 Nm(3.8 kgfm, 27 lbfft)
5. Secure lock nut (1). Tighten nut (3).
: 37 Nm(3.8 kgfm, 27 lbfft)
6. Check the relief set pressure.

Steering Relief
Valve

T4GB-04-05-012

NOTE: Standard Change in Pressure (Reference)

Adjusting Screw
1/4
1/2
3/4
1
Turns
Change in
Pressure

MPa
(kgf/cm2)
(psi)

3.8
(39)
(552)

7.5
(77)
(1050)

11.3
(155)
(1643)

15.0
(153)
(2181)

2
T4GB-04-05-013

Pressure
Increase

Pressure
Decrease

T105-06-05-002

T4-5-13

OPERATIONAL PERFORMANCE TEST / Component Test

OVERLOAD
PRESSURE

RELIEF

VALVE

SET

Summary:
1. The circuit pressure must be increased by
applying an external force while blocking the
return circuit from the control valve. This
measuring method is hazardous and the results
obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload
pressure in the main circuit by increasing the main
relief set-pressure more than the overload valve
set-pressure is not a proper method. In addition, in
case a main relief valve designed to leak a small
quantity of oil before reliving is used, its
pre-leaking start pressure must be increased
more than the overload relief valve set-pressure.
However, the pre-leaking start pressure is not
always increased more than the overload relief
valve set-pressure as the adjustable upper limit of
the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.

4. Install Dr. ZX and select the monitoring function.

Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Set engine speed at fast idle. Depress the
accelerator pedal fully.
2. Slowly operate the control levers (lift arm or
bucket) corresponding to the overload relief valve
to be measured to the stroke ends (extend and
retract) and relieve each function.
3. Read the pressures on the pressure gauge at this
time.
4. Repeat the measurement three times and
calculate the average values.
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.
Refer to the Performance Standard Table in Group
T4-2.
Pressure
Gauge

3. If the overload relief valve performance must be

checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
by using Dr. ZX.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install an adapter, a hose and a pressure
gauge.
: 6 mm

T4-5-14

Pressure
Check Port

Adapter

T4GB-04-05-008

OPERATIONAL PERFORMANCE TEST / Component Test

Overload Relief
Procedure

Valve

Pressure

Adjusting

NOTE: In principle, adjust the overload relief valve

pressure on a test stand.
Adjust the pressure setting of the overload relief valve
with adjusting screw (2) after loosening lock nut (1).
1

1. Loosen lock nut (1).

: 17 mm
2. Turn adjusting screw (2) and adjust the pressure.
: 6 mm
3. Tighten lock nut (1).
: 17 mm
: 29.5 Nm (3.0 kgfm, 22 lbfft)

2
W107-02-05-128

4. Check the set pressure.

NOTE: Standard Change in Pressure (Reference)

Adjusting Screw
1/4
1/2
3/4
1
Turns
MPa
5.2
10.6
15.9
21.1
Change in
(kgf/cm2) (54)
(108)
(162)
(216)
Pressure
(psi)
(770) (1540) (2300) (3070)

Pressure
Increase

Pressure
Decrease

W107-02-05-129

T4-5-15

OPERATIONAL PERFORMANCE TEST / Component Test

MAIN PUMP FLOW RATE
P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring
the pump flow rate by using a hydraulic tester
installed at the main pump delivery port to be
measured. Use Dr. ZX and a pressure gauge at the
same time.
IMPORTANT: This measurement procedure is a
simple method. The measured data
will be lower by approx. 5 % than the
accurately measured value. In order
to measure accurately, disconnect
the return circuit from the control
valve and connect it to the hydraulic
oil tank.
Preparation:
1. Stop the engine. Push the air bleed valve and
release any remaining pressure. Install a vacuum
pump to the oil filler port.
NOTE: Operate the vacuum pump while
connecting the pump flow rate test line.
2. Remove the delivery hose from the main pump.
Install pipe (1) to split flange (8) in the removed
hose with the bolt.
: 41 mm
: 10 mm
3. Connect pipe (1) to hydraulic tester (4) with test
hose (2) and adapter (3). Install adapter (5), joint
(6) and flange (7).
: 41 mm
: 10 mm
4. Connect flange (7) to the delivery hose with split
flange (8) and bolt (9).
: 10 mm

5. Install a pressure gauge to the main pump. (Refer

to the page on Main Pump Relief Pressure.)
: 6 mm
6. Remove hose (11) from the regulator. Install plug
(G1/4) to the hole on hose (11).
: 17 mm
7. Remove the vacuum pump. Loosen plug (10) on
top of the pump casing. Bleed air from the pump
casing until oil only comes out of the plug
clearance.
8. Fully open the loading valve of hydraulic tester.
9. Start the engine. Check for any oil leaks at the
pressure gauge connection. Install Dr. ZX and
select the monitor display function of MC.
Measurement:
1. Maintain the hydraulic oil temperature at 505 C
(12241 F).
2. Measure the maximum flow rate.
3. Set engine speed at fast idle. Depress the
accelerator pedal fully.
4. Adjust the main relief valve set pressure in the
control valve to each pressure point specified
along the main pump P-Q curve. (Refer to T4-2.)
Slowly close the loading valve of the hydraulic
tester while relieving the pressure in the bucket
crowd circuit. Measure the flow rates and engine
speeds at the pressure points specified in the P-Q
curve.
5. Repeat the measurement three times and
calculate the average values.

T4-5-16

OPERATIONAL PERFORMANCE TEST / Component Test

Evaluation:
1. Convert the measured flow rates to those at the
specified pump speed by using the following
formulas:

2. Standard Flow Rate

Refer to the Performance Standard Table in Group
T4-2.

Qc = (Ns Q) Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
Ns : Specified Engine Speed: ZW220: 2170 min-1
ZW250: 2240 min-1
Ne : Measured Engine Speed:
Value by Dr. ZX
1

Delivery Hose
(To Control Valve)

T1F3-04-05-010

10

11

T4GB-04-05-014

1 - Pipe
2 - Test Hose
3 - Adapter (PF1 UNF1-7/8)

456-

Hydraulic Tester
Adapter (PF1UNF1-7/8)
Joint

789-

T4-5-17

Flange
Split Flange
Bolt (4 Used)

10 - Plug
11 - Hose

OPERATIONAL PERFORMANCE TEST / Component Test

Pilot Characteristics
Summary:
Main pump performance is checked by measuring
the pump flow rate by using a hydraulic tester
installed at the main pump delivery port to be
measured. Use Dr. ZX and a pressure gauge at the
same time.
IMPORTANT: This measurement procedure is a
simple method. The measured data
will be lower by approx. 5 % than the
accurately measured value. In order
to measure accurately, disconnect
the return circuit from the control
valve and connect it to the hydraulic
oil tank.
Preparation:
1. Refer to steps 1 to 4 on page T4-5-16. Install a
hydraulic tester to the main pump.
2. Remove the hose from regulator port Pi1 of the
pump. Install a plug to the removed hose.
: 19 mm
3. Install adapters (13) (3 used) to pressure reducing
valve (14). Remove the hose from port P of the
orbit roll. Insert tee (10), adapter (11) and hose
(12) between orbit roll and charging block.
Install hose (12) to port P1 on reducing valve (14).
: 19 mm
4. Install tee (15) to port P2 on pressure reducing
valve (14). Install pressure gauge (16) and hose
(12) to tee (15). Install hose (12) to regulator port
Pi1.
: 19 mm
5. Install hose (12) and adapter (13) to port T on
pressure reducing valve (14). Remove plug L
from the return pipe. Install hose (12).
: 19 mm
6. Connect regulator port Pi2 to the hydraulic oil tank.
As for the emergency steering, install tee (17),
adapter (18) and hose (19) to port E in the
emergency steering block. Install hose (19) to
regulator port Pi2.

7. Remove the vacuum pump. Loosen the plug on

top of the pump casing. Bleed air from the pump
casing until oil only comes out of the plug
clearance.
8. Fully open the loading valve of the hydraulic
tester.
9. Start the engine. Check for any oil leaks at the
pipe connection.
Measurement:
1. Maintain the hydraulic oil temperature at 505 C
(12241 F)
2. The pump flow rate in response to the external
command pilot pressure is measured.
3. Set engine speed at fast idle. Depress the
accelerator pedal fully
4. Adjust the pressure reducing valve set pressure
to each pressure point specified along the main
pump P-Q curve. (Pilot Characteristics) (Refer to
T4-2.) Measure the flow rates and engine speeds
at the pressure points specified in the P-Q curve.
5. Repeat the measurement three times and
calculate the average values.
Evaluation:
1. Convert the measured flow rates to those at the
specified pump speed by using the following
formulas:
Qc = (Ns Q) / Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
Ns : Specified Engine Speed : ZW220: 2170 min-1
ZW250: 2240 min-1
Ne : Measured Engine Speed
Value by Dr. ZX
2. Standard Flow Rate
Refer to the Performance Standard Table in
Group T4-2.

T4-5-18

OPERATIONAL PERFORMANCE TEST / Component Test

1

Delivery Hose
(To Control Valve)

T1F3-04-05-010

Port Pi2

Port Pi1
Pilot Steering Valve

Port P
Pilot Steering
Valve Port P Hose

T4GB-04-05-025

Charging Block

T4GB-04-05-026

Pressure Reducing
Valve Port Position

Emergency
Steering
Check Block

Return Pipe

17
L

P1

P2

19

13

To Regulator
Port Pi2

12

16

13

To Hydraulic
Oil Tank

To Port P in Pilot
Steering Valve

To Regulator
Port Pi1

12

Charging
Block

15

13
6 - Test Hose

2 - Test Hose

7 - Flange

3 - Adapter (G1 UNF1-7/8)

(ST 6146)
4 - Hydraulic Tester

8 - Split Flange (4085560)

12

13

14

1 - Pipe

5 - Adapter (G1 UNF1-7/8)

(ST 6146)

18

Port E

9 - Bolt (J781240) (4 Used)

10 - Tee (7/16-20UNF x G1/4)

11

10

11 - Adapter (9/16 UNF x G1/4)

(A852123)
12 - Hose (9/16 UNF)
(4304905)
13 - Adapter (9/16 UNF x G3/8)
(A852133)
14 - Pressure Reducing Valve
(4325439)
15 - Tee (9/16 UNF x G1/4)

T4-5-19

T1F3-04-05-009

16 - Pressure Gauge
17 - Tee
18 - Adapter
19 - Hose

OPERATIONAL PERFORMANCE TEST / Component Test

REGULATOR ADJUSTMENT
6

7
8

10
T4GB-04-05-016

1 - Lock Nut (For Minimum

Flow Rate)
2 - Adjusting Screw (For
Minimum Flow Rate)
3 - Lock Nut (For Maximum
Flow Rate)

Adjustment Item
1. Maximum Flow Rate

4 - Adjusting Screw (For

Maximum Flow Rate)
5 - Lock Nut
(For Pilot Pressure
Characteristic)
6 - Adjusting Screw
(For Pilot Pressure
Characteristic)

7 - Lock Nut
(For P-Q Control)
8 - Adjusting Screw
(For P-Q Control)

9-

Lock Nut
(For P-Q Control)
10 - Adjusting Screw
(For P-Q Control)

Adjustment Procedure
Remarks
ZW220
1) Do not turn adjusting screw (6) more
Loosen lock nut (5) and turn
than two turns.
adjusting screw (6).
2) Do not increase the maximum flow
Rotate adjusting screw (6) 1/4 a
rate.
turn clockwise and the maximum
In other words, do not turn adjusting
pump flow rate decreases by
screw (6) counterclockwise.
11.26 cm3/rev. (0.69 in3/rev).
3) Secure tighten lock nut (5) after the
: 32 mm
adjustment.
: 40 Nm
(4.1 kgfm, 30 lbfft)

ZW250
1) Do not turn the adjusting screw (4)
Loosen lock nut (3) and turn
more than two turns.
adjusting screw (4).
2) Do not increase the maximum flow
Rotating adjusting screw (4) 1/4
rate.
a turn clockwise and maximum
In other words, do not turn adjusting
pump flow rate decreases by
screw (4) counterclockwise.
12.58 cm3/rev. (0.77 in3/rev).
3) Securely retighten lock nut (3) after
: 22 mm
the adjustment.
: 20 Nm
(2 kgfm, 15 lbfft)

T4-5-20

OPERATIONAL PERFORMANCE TEST / Component Test

Adjustment Item
Adjustment Procedure
Remarks
2. Pilot Pressure Characteristics Loosen lock nut (1) and turn 1) Do not turn the adjusting screw (2)
adjusting screw (2).
more than one turn.
Rotate adjusting screw (2) 1/4 a 2) Securely tighten lock nut (1) after
turn clockwise and the pump flow
the adjustment.
Q
rate decreases by X cm3/rev. (X
in3/rev).
ZW220: X=8.08 (0.49)
ZW250: X=9.22 (0.56)
: 17 mm
: 20 Nm
(2 kgfm, 15 lbfft)
Pi

3. P-Q Control
(Torque Adjustment)
Q

Pd

A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws (8,
adjusting screw (8).
10) more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws (8, 10)
1/4 a turn clockwise increases
while
watching
the
engine
and the pump flow rate
performance.
increase by Y cm3/rev. (Y 3) Securely tighten lock nuts (7, 9)
after the adjustment.
in3/rev.).
ZW220: Y=13.6 (0.83)
ZW250: Y=15.5 (0.95)
: 30 mm
: 30 Nm
(3.1 kgfm, 22 lbfft)

Pd

B: Loosen lock nut (9) and turn

adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise and the
pump flow rate increases by Z
cm3/rev. (Z in3/rev).
ZW220: Z=3.9 (0.24)
ZW250: Z=4.2 (0.26)
: 13 mm
: 10 Nm
(1 kgfm, 7.5 lbfft)

T4-5-21

OPERATIONAL PERFORMANCE TEST / Component Test

SERVICE BRAKE PRESSURE (FRONT
AND REAR)
(The pressure can be measured by using Dr. ZX.)
CAUTION: If air is mixed in the brake system,
the brake function is reduced and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
Refer to Troubleshooting B in Group T5-6.
Summary:
Measure the pressure at the brake valve pressure
check port when the brake pedal is depressed.
Preparation:
CAUTION: Set the block onto the front and
rear tires in order not to move the machine.
Keep away from the machine.
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Install the measuring devices to the front and rear
wheel brake circuits.
4-1. Front wheel brake circuit pressure: Remove
plug (1) from the pressure check port in brake
valve. Install a nipple and a pressure gauge to
the pressure check port.
: 19 mm, 22 mm
: 6 mm
4-2. Rear wheel brake circuit pressure: Remove
plug (2) from the pressure check port in brake
valve. Install a nipple and a pressure gauge to
the pressure check port.
: 19 mm, 22 mm
: 6 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 505 C
(12241 F).

T4GB-04-05-017

Block

Brake Valve

T4-5-22

2
T4GB-04-05-018

OPERATIONAL PERFORMANCE TEST / Component Test

Conditions for Measurement:
1. Set engine speed at fast idle.
2. Depress the accelerator pedal fully.
Measurement:
1. Measure the pressure when fully depressing the
brake pedal at left side to the floor.
2. Repeat the measurement three times and
calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.
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.

T4-5-23

OPERATIONAL PERFORMANCE TEST / Component Test

PARKING BRAKE PRESSURE
CAUTION: If air is mixed in the brake system,
the brake function is reduced and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
Refer to Troubleshooting B in Group T5-6.
Summary:
1. Measure the parking brake release pressure in
the parking brake release circuit.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.

Preparation:

1.
2.
3.

4.
5.

CAUTION: Set the block onto the front and

rear tires in order not to move the machine.
Keep away from the machine.
Stop the engine.
Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
Remove brake hose (1) from the parking brake
side. Install a pressure gauge to the removed
hose.
: 19 mm, 22 mm
Start the engine. Check for any oil leaks at the
pressure gauge connection.
Maintain the hydraulic oil temperature at 505 C
(12241 F).

Conditions for Measurement:

1. Set engine speed at fast idle.
2. Depress the accelerator pedal fully.

T4GB-04-05-017

Block

Measurment:
1. Release the parking brake and measure the
pressure at this time.
2. Repeat the measurement three times and
calculate the average values.

T4GB-04-05-020

T4-5-24

OPERATIONAL PERFORMANCE TEST / Component Test

(Blank)

T4-5-25

OPERATIONAL PERFORMANCE TEST / Component Test

BRAKE ACCUMLATED PRESSURE
(The pressure can be measured by using Dr. ZX.)

CAUTION: If air is mixed in the brake system,

the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to the Troubleshooting B in Group T5-6.
Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:
T4GB-04-05-017

CAUTION: Set the block onto the front and

rear tires in order not to move machine. Keep
away from the machine.
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Remove plug (1) from the pressure check port of
charging block in bottom of the cab.
Install a nipple and a pressure gauge to the
pressure check port.
: 19 mm, 22 mm
: 6 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 505 C
(12241 F).

Block

T4GB-04-05-019

T4-5-26

OPERATIONAL PERFORMANCE TEST / Component Test

Conditions for Measurement:
1. Set engine speed at fast idle.
2. Depress the accelerator pedal fully.
Measurement:
1. Measure maximum pressure when depressing
the brake pedal slowly several times.
2. Repeat the measurement three times and
calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.

T4-5-27

OPERATIONAL PERFORMANCE TEST / Component Test

BRAKE WARNING
(DECREASE)

SET

PRESSURE

(The pressure can be measured by using Dr. ZX.)

CAUTION: If air is mixed in the brake system,
the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to the Troubleshooting B in Group T5-6.
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, measure the pressure
at the output port of accumulator.
Preparation:
CAUTION: Set the block onto he front and
rear tires in order not to move the machine.
Keep away from the machine.
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Remove plug (1) from the charged pressure
check port in brake valve. Install a nipple and a
pressure gauge to the pressure check port.
: 19 mm, 22 mm
: 6 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 505 C
(12241 F).

T4GB-04-05-017

Block

Blake Valve

1
T4GB-04-05-018

T4-5-28

OPERATIONAL PERFORMANCE TEST / Component Test

Conditions for Measurement:
1. Select the following switch positions.
Forward/Reverse Lever Parking Brake Switch
N
ON
Measurement:
1. Stop the engine. Turn the key switch to ON
position.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
3. Repeat the measurement three times and
calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.

T4-5-29

OPERATIONAL PERFORMANCE TEST / Component Test

BRAKE WARNING SET PRESSURE
(INCREASE)
(The pressure can be measured by using Dr. ZX.)
CAUTION: If air is mixed in the brake system,
the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to the Troubleshooting B in Group T5-6.
Summary:
When sounding of the warning buzzer stops by
increasing the accumulated brake pressure, measure
the pressure at the output port of accumulator.
Preparation:
CAUTION: Set the block onto the front and
rear tires in order not to move machine. Keep
away from the machine.
4. Stop the engine.
5. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
6. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
5. Remove plug (1) from the charged pressure
check port in brake valve. Install a nipple and a
pressure gauge to the pressure check port.
: 19 mm, 22 mm
: 6 mm
6. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain the hydraulic oil temperature at 505 C
(12241 F).

T4GB-04-05-017

Block

Blake Valve

1
T4GB-04-05-018

T4-5-30

OPERATIONAL PERFORMANCE TEST / Component Test

Conditions for Measurement:
1. Select the following switch positions.
Forward/Reverse Lever Parking Brake Switch
N
ON
Measurement:
1. Stop the engine. Turn the key switch to ON
position.
2. Set the engine control dial to slow idle.
3. Depress the brake pedal several times and make
the warning buzzer sound.
4. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge as the pressure
increases rapidly.
5. Repeat the measurement three times and
calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to Troubleshooting B in Group T5-6.

T4-5-31

OPERATIONAL PERFORMANCE TEST / Component Test

TRANSMISSION CLUTCH PRESSURE
Summary:
Measure each operating pressure of the tansmission
clutch at each port of the transmission control valve.
Preparation:
1. Stop the engine.
2. Remove the plug from the port. Install a hose, an
adapter and a pressure gauge.
: 6 mm
NOTE: Although the pressure can be measured by
using one pressure gauge, all pressures
can be measured by using six pressure
gauges at the same time.
3. Start the engine. Check for any oil leaks at the
pressure gauge connection.
4. Maintain the torque converter oil temperature at
80 to 95 C (176 to 203 F).
Measurement:
CAUTION: Set the block onto the front and
rear tires in order not to move machine. Keep
away from the machine.
1. Select the following switch positions.
Accelerator
Clutch Cut-Off
Brake Pedal
Travel Mode
Pedal
Position Switch
Fully
Fully
M
OFF
Depressed
Depressed
2. Operate the forward/reverse lever and the shift
switch. Measure each clutch pressure.
(As for the cmbination of clutch pack, refer to the
following page.)
3. Repeat the measurement three times and
calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-5-32

T4GB-04-05-017

Parking Brake
Switch
OFF

Block

OPERATIONAL PERFORMANCE TEST / Component Test

4
1
5
2

T4GB-04-05-021

1 - Second Gear
2 - Slow Forward

Combination of Transmission Clutch Pack

Direction Control Clutch Pack
Slow Forward Fast Forward
Reverse
Speed Stage
(2)
(4)
(5)
Forward First

Gear (F1)
Forward
Second Gear

(F2)
Forward
Third Gear

(F3)
Forward
Fourth Gear

(F4)
Reverse First

Gear (R1)
Reverse
Second Gear

(R2)
Reverase
Thir Gear

(R3)

34-

Third Gear
Fast Forward

56-

Reverse
First Gear

Speed Control Clutch Pack

First Gear
Second Gear
Third Gear
(6)
(1)
(3)

NOTE: When the forward/reverse lever and shift switch are turned to each speed stage, operating pressure is
applied to the clutch with mark .

T4-5-33

OPERATIONAL PERFORMANCE TEST / Component Test

TORQUE CONVERTER PRESSURE (INLET
AND OUTLET)
Summary:
Measure inlet pressure and outlet pressure of the
torque converter pressure at the port of torque
converter housing.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Preparation:
1. Stop the engine.
2. Inlet pressure:
Remove the plug from the port of transmission
control valve (1). Install a hose, an adapter and a
pressure gauge to the open part.
: 5 mm
Outlet pressure:
Remove the temperature sensor from torque
converter housing (2). Install a hose, an adapter
and a pressure gauge to the open part.
: 19 mm
3. Start the engine. Check for any oil leaks at the
pressure gauge connection.
4. Maintain the torque converter oil temperature at
80 to 95 C (176 to 203 F).
Measurement:
CAUTION: Set the block onto the front and
rear tires in order not to move the machine.
Keep away from the machine.
1. Select the following switch positions:
Accelerator
Clutch Cut-Off
Brake Pedal
Travel Mode
Pedal
Position Switch
Fully
Fully
M
OFF
Depressed
Depressed
2. Set the front/reverse lever to F (Forward) and
the shift switch to 4 (Fourth Gear). Measure the
pressure.
3. Repeat the measurement three times and
calculate the average values.

T4-5-34

T4GB-04-05-017

Block

Parking Brake
Switch
OFF

OPERATIONAL PERFORMANCE TEST / Component Test

Inlet Pressure
of Torque
Converter

T4GB-04-05-021

View X
View Y

Outlet Pressure
of Torque
Converter

T4GB-04-05-022

T4-5-35

OPERATIONAL PERFORMANCE TEST / Component Test

(Blank)

T4-5-36

OPERATIONAL PERFORMANCE TEST / Adjustment

TRANSMISSION LEARNING
Relay Box

After removing and/or replacing the components as

described below for repair, perform the transmission
learning (calibration).

Replacement or repair of the transmission

assembly, transmission control valve or clutch
pack
Replacement or repair of TCU (Transmission
Control Unit)
Preparation:
1. Start the service mode in monitor. Start the engine.
(Refer to T5-1-6.)
2. Select the transmission oil temperature on the
monitor. (Refer to T5-1-7.)
3. Heat transmission oil.
3-1. Disconnect connector (1) (6-pole, gray) in the
relay box from dummy connector.
3-2. Start the engine with the transmission oil
temperature displayed on the monitor.
3-3. Select or operate the switches from the left item
in the table below.

T4GB-04-06-007

T4GB-04-06-001

Clutch Cut-Off
Position Switch

Shift Switch

Parking Brake
Switch

Brake Pedal

OFF

Second Gear

OFF

Fully
Depressed

3-4. Stall the transmission and heat transmission oil

to 118 C (244 F).
3-5. When transmission oil temperature on the
monitor reaches 118 C (244 F), return the
forward/reverse lever to neutral (N) and stop the
engine.

T4-6-1

Accelerator
pedal
Fully
Depressed

Forward/Reverse
Lever
F

OPERATIONAL PERFORMANCE TEST / Adjustment

Learning
1. Install the calibration switch to the connector
(6-pole, gray) in relay box in 10 seconds after
turning the key switch OFF (the battery relay is
tuned OFF).
IMPORTANT: It takes 10 seconds to turn the
battery relay OFF after turning the
key switch OFF. If the battery relay is
not turned OFF, calibration cannot
be performed.

Calibration Switch

2. Start the engine. Set engine speed at idling speed.

IMPORTANT: Do not operate each switch and lever
until calibration finishes.
3. Push the calibration start switch. Continue
pushing the calibration start switch unitl the start
of learning display as illustrated in the right is
selected on the monitor.

Calibration Start
Switch

T4GB-04-06-002

Start of Learning

4. After the start of learning display is selected,

release the calibration start switch.
5. Wait until learning finishes. When learning finishes,
the end of learning display as illusrated in the right
is selected on the monitor.
6. After calibration finishes, remove the calibration
switch from the connector and stop the engine.

T4GB-04-06-005

The speed stage during learning is displayed on the

monitor.
C1: First Gear, C2: Second Gear, C3: Third Gear,
C4: Fast Forward, C5: Slow Forward, C6: Reverse
End of Learning

T4GB-04-06-006

T4-6-2

OPERATIONAL PERFORMANCE TEST / Adjustment

Error Display
When calibration fails, the error is displayed on the
monitor.
The error consists of two types; when start of
calibration fails, when calibration is aborted during
calibration.

Error display when start of calibration fails

If the error display as figure 1 is displayed before
starting calibration, calibration cannot be
continued. After the trouble correspoding to error
No. is solved, start calibration again.
Error
No.
2
3
4

Error Display

Figure 1

Error

The forward/reverse lever is not in N.

The parking brake is not in ON.
The machine is driving.
T/M temperature is lower than
5
specification. *1
T/M temperature is higher than
6
specification. *1
Engine speed is lower than specification.
7
*2
Engine
speed
is
higher
than
8
specification. *2
*1: Error No. and T/M temperature at this time (figure
2) are displayed alternately.
*2: Error No. and engine speed at this time (figure 3)
are displayed alternately.
NOTE: If error No. 2, 3 or 4 is displayed, set the
switch and lever corresponding to this error
to the correct position so that SR is
displayed on the monitor.
If error No. 6 is displayed, wait until
transmission oil temperature reaches
specification so that SR is displayed on the
monitor.
When SR is displayed, push the calibration
start switch again and start calibration.

Error No.

T4GB-04-06-009

Figure 2

T/M
Temperature

T4GB-04-06-010

Figure 3

Engine Speed

T4-6-3

T4GB-04-06-011

OPERATIONAL PERFORMANCE TEST / Adjustment

NOTE: If error No. 5, 7 or 8 is displayed, stop the
engine. Remove the calibration switch from
the connector and solve the trouble.
Then, start calibration again.

T4-6-4

OPERATIONAL PERFORMANCE TEST / Adjustment

Error display when calibration is aborted during
calibration
When calibration is aborted during calibration, the error
display as illustrated in the right is selected.
After the trouble is solved, start calibration again.
Error
No.
000009
000010
000011
000012
000013
000014

Error
Failure of learning at first
gear
Failure of learning at
second gear
Failure of learning at third
gear
Failure of learning at fast
forward
Failure of learning at slow
forward
Failure of learning at
reverse

T4GB-04-06-012

Error No.

Cause of Error
The forward/reverse lever is operated during
calibration for the clutch at speed stage in which
error occurs.
The parking brake switch is turned OFF during
calibration for the clutch at speed stage in which
error occurs.
The machine travels during calibration for the
clutch at speed stage in which error occurs.
The transmission oil temperature is lower than
specification (100 C (212 F)) during calibration
for the clutch at speed stage in which error occurs.
Engine speed is beyond specificated range during
calibration for the clutch at speed stage in which
error occurs. (Ex. The accelerator pedal is
depressed.)
The key switch is turned OFF during calibration for
the clutch at speed stage in which error occurs.
The clutch at speed stage in which error occurs is
beyond the correctable range. (Malfunction of the
parts in drive unit)

T4-6-5

OPERATIONAL PERFORMANCE TEST / Adjustment

LIFT ARM ANGLE SENSOR LEARNING
(OPTIONAL)
After removing and/or replacing the components as
described below for repair, perform the left arm angle
learning (calibration).

Removal and installation of angle sensor,

Replacement of angle sensor

Replacement or repair of MC (Main Controller)

Preparation:
1. Install Dr. ZX and start the engine.
Select Boom Anlge and Angle Sensor Learning
Status on the main controller screen in Dr. ZX.

2. Raise the lift arm to the highest position.

At this time, check if voltage at Boom Angle on the
display in Dr. ZX is 3.780.5 V.
3. If voltage 3.780.5 V is not displayed, the
followings may be caused. Conduct the remedy.
The rotation shaft in angle sensor (1) turns with
sensor lever (2) not together.
Angle sensor (1) failure
4. Set control lever lock (3) to LOCK position and
stop the engine.

T4GB-04-06-008

3
LOCK

M4GB-01-050

T4-6-6

OPERATIONAL PERFORMANCE TEST / Adjustment

5. Install calibration switch (5) to connector (4)
(6-pole, gray) in relay box in 10 seconds after
turning the key switch OFF (the battery relay is
tuned OFF). At this time, return calibration start
switch (6) to neutral.
IMPORTANT: If the battery relay is not turned OFF,
calibration cannot be performed. It
takes 10 seconds to turn the battery
relay OFF after turning the key
switch OFF.

Relay Box

6. Lay down calibration start switch (6) to the lift arm

side. Start the engine at idling speed.
7. If Finish in Angle Sensor Learning Status on Dr.
ZX is turned into black, learning finishes. Return
calibration start switch (6) to OFF (neutral).
If Failed or Not Learn in Angle Sensor Learning
Status on Dr. ZX is turned into black, repeat the
procedures from step 1.

T4GB-04-06-007

8. Return the control lever lock to UNLOCK. Lower

the lift arm onto the ground. Stop the engine.
9. After learning of the lift arm angle sensor, set the
stop position of lift arm. (Refer to the Operators
Manual.)

T4GB-04-06-001

Lift Arm
T/M

T4GB-04-06-003

T4-6-7

OPERATIONAL PERFORMANCE TEST / Adjustment

DRIVE BELT TENSION ADJUSTMENT
Summary:
If the drive belt is loosened, the charge is defective of
the battery or wear-out at early stage of drive belt
occurs.
If the drive belt is too tense, the water pump and the
bearing of alternator are damaged.
Adjust the drive belt within specification.
Measurement:
Push the drive belt between water pump (1) and
alternator (2) pulley by finger. Measure slack of the
drive belt.

1
Push Here

Pushing force: Approx. 98 N (10 kgf, 72 lbf)

CAUTION: As soon as the machine is
operated, the engine is too hot. When
measureing, take a good care.

Evaluation:
Slack of drive belt: 6 to 8 mm (0.24 to 0.31 in)
M4GB-07-082

Adjustment:
1. Loosen nut (3) and bolt (5).
2. Adjust tension of the drive belt to specification with
bolt (4).
3. Tighten nut (3) and bolt (5).
After tightening, check slack of the drive belt.

3
4

NOTE: When the drive belt is replaced with the

new one, the drive belt does not fit first.
After the engine is running at slow idle for 3
to 5 minutes, check slack of the drive belt.

T4-6-8

T4GB-04-03-001

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SECTION 5

TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure

Monitor Display (TCU Controller) ............ T5-2-50

Introduction .............................................. T5-1-1

Recorded Data Display (TCU Controller) T5-2-54

Diagnosing Procedure .............................. T5-1-2

Password Change (TCU Controller)........ T5-2-55

How to Operate Service Made of

Monitor ..................................................... T5-1-6
Display List of Monitor Service Mode ........ T5-1-7

Group 3 e-Wheel
Outline ...................................................... T5-3-1
List of Daily Report Data ........................... T5-3-2

Group 2 Dr.ZX

List of Frequency Distribution Data ........... T5-3-3

Outline ...................................................... T5-2-1

List of Total Operationg Hours................... T5-3-4

Operation ................................................. T5-2-2

List of Alarm .............................................. T5-3-5

Self-Diagnosing Result ............................. T5-2-4

List of failure ............................................. T5-3-6

Select Controller....................................... T5-2-6

How to Download and Upload Data of

Main Controller ....................................... T5-2-7

ICF............................................................ T5-3-7

Main Menu Monitor Display (Main

Various Setup if ICF and Satellite

Controller) ................................................ T5-2-8

Communication Terminal by Using

Setting (Main Controller)......................... T5-2-12

Dr.ZX ...................................................... T5-3-10

Record Data Display (Main Controller) ... T5-2-19

List of ICF Fault Code ............................. T5-3-22

Password Change (Main Controller)....... T5-2-20

List of Fault Code of Sattellite

Engine Controller.................................... T5-2-21

Communication Terminal......................... T5-3-23

Monitor Display (Engine Controller) ........ T5-2-22

Recorded Data Display (Engine

Group 4 Component Layout

Controller) .............................................. T5-2-26

Main Component Layout (Overview) ......... T5-4-1

Password Change (Engine Controller) ... T5-2-27

Main Component Layout (Upper-

ICF Controller ......................................... T5-2-29

structure) .................................................. T5-4-2

ICF Various Setup (ICF Controller) ......... T5-2-30

Main Component Layout (Travel

Save Data Check (ICF Controller) .......... T5-2-40

System) .................................................... T5-4-3

Password Change (ICF Controller)......... T5-2-41

Electric Component Layout (Overview) ..... T5-4-4

Monitor Unit ............................................ T5-2-43

Electrical System (Cab) ............................ T5-4-5

Monitoring (Monitor Unit) ........................ T5-2-44

Engine and Fan Pump ............................. T5-4-10

Various Settings (Monitor Unit) ............... T5-2-46

Pump Device, Drive Unit ......................... T5-4-11

Internal Hour Meter Synchronization ...... T5-2-47

Control Valve .......................................... T5-4-12

Password Change (Monitor Unit)............ T5-2-48

Ride Control Valve ,Charging Block,

TCU Controller ....................................... T5-2-49

Fan Motor, Parking Brake Solenoid

Valve ....................................................... T5-4-13

4GBT-5-1

Steering Valve, Emergency

CAN Data Reception Failure

Steering Pump ........................................ T5-4-14

MC Fault Codes 11910, 11920................ T5-5-97

Components in Control Valve ................. T5-4-16

CAN Harness Check

Components in Steering Valve................ T5-4-28

(MC Fault Codes 11910, 11920) .......... T5-5-98

Components in Charging Block .............. T5-4-32

MC Fault Code 11914 ........................... T5-5-101

Components in Ride Control Valve ......... T5-4-38

CAN Harness Check

(MC Fault Code 11914) ..................... T5-5-102

Side View of Transmission...................... T5-4-42

Front View of Transmission .................... T5-4-43

MC Fault Codes 11912, 11913,

Pressure Sensor Ports of

11916, 11917 ........................................ T5-5-105

Transmission .......................................... T5-4-44

CAN Harness Check

Cross-Sectional Drawing of

(MC Fault Codes 11912, 11913,

Transmission .......................................... T5-4-45

11916, 11917).................................... T5-5-106

Cross-Sectional Drawing of Torque

Other Failures

Converter ............................................... T5-4-46

MC Fault Code 11901 ........................... T5-5-109

Cross-Sectional Drawing of

Proportional Solenoid Valve Truble

Transmission Control Valve .................... T5-4-47

Check ................................................... T5-5-110

Circuit of Drive Unit ................................ T5-4-48

ECM, Sensor System

ECM Fault Codes 100, 102, 105, 108,

Group 5 Troubleshooting A
Troubleshooting A Procedure ................... T5-5-1
MC Fault Code List................................... T5-5-2
ECM Fault Code List .............................. T5-5-16
TCU Fault Code List ............................... T5-5-40
ICF Fault Code List................................. T5-5-58
Satellite Terminal Fault Code List ........... T5-5-60
Monitor Unit Fault Code List ................... T5-5-62
Controller Hardware Failure
MC Fault Codes 11000 to 11002 ............ T5-5-63
MC Fault Code 11003............................. T5-5-64
MC Fault Code 11004............................. T5-5-65
CAN Harness Check .............................. T5-5-66
Engine Failure
MC Fault Code 11103 ............................. T5-5-91
Pump Failure
MC Fault Code 11204............................. T5-5-92
MC Fault Code 11209............................. T5-5-93
Pilot Failure
MC Fault Code 11313............................. T5-5-94
Proportional Solenoid Valve Failure
MC Fault Code 11412............................. T5-5-95
MC Fault Code 11413............................. T5-5-96

110, 157, 172 ........................................ T5-5-113

ECM Fault Codes 174, 636, 723,
10001.................................................... T5-5-114
ECM, External Device System
ECM Fault Codes 651, 652, 653, 654,
655, 656, 1347, 10002 .......................... T5-5-115
ECM, Fuel System
ECM Fault Codes 157, 633, 1239,
1240...................................................... T5-5-116
ECM, Engine Protection
ECM Fault Codes 110, 190 ................... T5-5-117
ECM, External Circuit System
ECM Fault Codes 987, 1485 ................. T5-5-118
ECM, Internal Circuit System
ECM Fault Codes 628, 1077, 1079,
1080, 10003, 10004, 10005 .................. T5-5-119
ECM Fault Codes 10006, 10007,
10008, 10009, 10010, 10011, 10013..... T5-5-120
ECM, Communication System
ECM Fault Codes 639........................... T5-5-121
Role and Connection of Each
Terminal in TCU .................................... T5-5-122

4GBT-5-2

ICF, Satellite Terminal Fault Codes

Malfunction of Hazard Light Indicator...... T5-7-13

14000 to 14003 .....................................T5-5-125

Malfunction of High Beam Indicator ........ T5-7-14

ICF, Satellite Terminal Fault Codes

Malfunction of Working Light Indicator .... T5-7-16

14006, 14008, 14100 to 14106 ..............T5-5-129

Malfunction of Forward/Reverse

Monitor Unit Fault Codes 13306,

Switch Indicator ...................................... T5-7-18

13308 ....................................................T5-5-131

Malfunction of Maintenance Indicator ..... T5-7-20

Monitor Unit Fault Code 13312 ..............T5-5-132

Malfunction of Preheat Indicator ............. T5-7-21

Monitor Unit Fault Code 13314 ..............T5-5-133

Malfunction of Transmission Oil

Temperature............................................ T5-7-22

Group 6 Troubleshooting B

Malfunction of Hydraulic Oil

Troubleshooting B Procedure ................... T5-6-1

Temperature Indicator ............................. T5-7-24

Relationship between Machine Trouble

Malfunction of Transmission Warning

Symptoms and Related Parts ................... T5-6-2

Indicator.................................................. T5-7-26

Correlation between Trouble

Malfunction of Air Filter Restriction

Symptoms and Part Failures .................. T5-6-18

Indicator.................................................. T5-7-28

Engine System Troubleshooting ............. T5-6-32

Malfunction of Engine Oil Pressure

Front Attachment System

Indicator.................................................. T5-7-30

Troubleshooting ...................................... T5-6-41

Malfunction of Overheat Indicator ........... T5-7-32

Travel System Troubleshooting .............. T5-6-60

Malfunction of Engine Warning

Brake System Troubleshooting ............... T5-6-76

Indicator.................................................. T5-7-34

Steering System Troubleshooting ........... T5-6-84

Malfunction of Stop Indicator................... T5-7-35

Other System Troubleshooting ............... T5-6-87

Malfunction of Service Indicator .............. T5-7-36

Exchange Inspection .............................T5-6-109

Malfunction of Parking Brake Indicator ... T5-7-38

Bleeding Air from Brake (Axle)............... T5-6-111

Malfunction of Clearance Light

One Part of Data, Daily Report

Indicator.................................................. T5-7-40

Data, Distribution Data, Total

Malfunction of Brake Low Oil Pressure

Operationg Hours and Alarm is

Indicator.................................................. T5-7-41

Not Recorded ........................................T5-4-112

Malfunction of Brake Low Oil Level

Indicator.................................................. T5-7-42

Group 7 Troubleshooting C

Malfunction of Emergency Steering

Troubleshooting C (Trouble Shooting

for Monitor) Procedure.............................. T5-7-1
Malfunction of Indicator Light Check
System ..................................................... T5-7-2
Malfunction of Buzzer in Monitor .............. T5-7-4
Malfunction of Coolant Temperature
Gauge ...................................................... T5-7-6
Malfunction of Transmission Oil
Temperature Gauge.................................. T5-7-8
Malfunction of Fuel Gauge...................... T5-7-10

Indicator (Optional) ................................. T5-7-44

Malfunction of Low Steering Oil
Pressure Indicator (Optional) .................. T5-7-46
Malfunction of Discharge Warning
Indicator.................................................. T5-7-48
Malfunction of Monitor Display ................ T5-7-50
Malfunction of Ride Control Indicator ...... T5-7-51
Malfunction of Engine Coolant
Temperature Display ............................... T5-7-52

Malfunction of Turn Signal Indicators

(Left and Right)....................................... T5-7-12

4GBT-5-3

Group 8 Electrical System Inspection

Precautions for Inspection and
Maintenance ........................................... T5-8-1
Instructions for Disconnecting
Connectors ............................................. T5-8-3
Fuse Inspection ........................................ T5-8-6
Fusible Link Inspection ............................. T5-6-8
Battery Voltage Check .............................. T5-6-9
Alternator Check..................................... T5-6-10
Continuity Check .................................... T5-6-12
Voltage and Current Measurement ......... T5-6-14
Check by False Signal ............................ T5-6-17

4GBT-5-4

TROUBLESHOOTING / Diagnosing Procedure

INTRODUCTION
Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The
inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of
8 groups; Diagnosing Procedure, Dr. ZX, e-Wheel,
Component Layout, Troubleshooting A (base machine
diagnosis by using fault codes), Troubleshooting B
(base machine diagnosis starting with inspection of
abnormal operational status), Troubleshooting C
(monitor diagnosis) and Electrical System Inspection.

Dr. ZX

Troubleshooting A (base machine diagnosis by

This group contains the operating procedures for

Dr. ZX.

using fault codes)

Refer to these procedures if any fault codes are
displayed when each controller of ICF (information controller) is diagnosed by using Dr. ZX (or
the service mode of monitor).

e-Wheel
Refer to these procedures if any fault codes are
displayed when ICF (information controller) and
satellite communication controller are diagnosed
by using Dr. ZX. (ICF and satellite communication
controller self-diagnosing functions retain a record of the electrical signal system malfunction in
the form of fault codes. At the same time, as the
satellite communication controller sends information onto CAN, the fault code of satellite communication controller can be checked by using ICF.)
This group contains as follows.
Download data from ICF and Upload
Various setting procedures when starting satellite
communication, when installing the satellite
communication controller and when replacing
ICF
Explanation for the satellite communication system

IMPORTANT: Each
controller self-diagnosing
function retains a record of the electrical signal system malfunction in
the form of fault codes. At the same
time, as each controller sends information onto CAN, the fault code
of all controllers can be checked by
using ICF.)
ICF records the fault code of each
controller and the date when the
malfunction occurs.

Component Layout
Refer to this group when required to check where
the components and inner parts are located.

Troubleshooting B (base machine diagnosis

starting with inspection of abnormal operational
status)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with
Dr. ZX (or the service mode of monitor).

Troubleshooting C (monitor diagnosis)

Refer to these procedures when gauges and/or
indicators are malfunctioning.

Electrical System Inspection

Refer to this group when required to obtain precautions and/or information for the electrical system inspection.

T5-1-1

TROUBLESHOOTING / Diagnosing Procedure

DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System
Study the machines technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator
Before inspecting, get the full
malfunctions from the operator below.

story

of

T4GB-05-01-001

(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what
types of work the machine doing at that
time?
(c) What are the details of the trouble? Is the
trouble getting worse, or did it appear
suddenly for the first time?
(d) 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 machines daily maintenance points, as
shown in the operator's manual.

T4GB-05-01-002

Also, check the electrical system, including the

batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.

T4GB-05-01-003

T5-1-2

TROUBLESHOOTING / Diagnosing Procedure

4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed (this states
are repeated that the trouble is resolved later
altough the trouble sometimes occurs), stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of
the wire harnesses correponding to the trouble.
NOTE: It should take time to required to find the
malfunction according to the trouble during
the troubleshooting. The malfunction may
occur due to up and down of hydraulic
temperature, weather and under the
special condition including expansion by
heat and shorted harness by moisture. The
informations of weather when the
mulfunction occurs, time from the engine
start to the trouble occurrence are also
important.

T5-1-3

TROUBLESHOOTING / Diagnosing Procedure

5. Perform troubleshooting
CAUTION: 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 Dr. ZX to the
machine or by using the service mode of monitor.
In case any fault code has been displayed by diagnosis by using Dr. ZX or the service mode 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 Dr. ZX or the service mode of monitor,
write the fault code. Delete the fault code once
and retry self-diagnosis again. If the fault code is
displayed again, check the cause of the trouble
by referring to Troubleshooting A in this section.
After the machine trouble has been corrected, the
fault code (displayed by the service mode of
monitor) will be deleted. Therefore, in case problems, which are not easily re-predicable, are encountered (this states are repeated that the
trouble is resolved later altough the troubole
sometimes occurs), check the fault code by using
Dr. ZX.
NOTE: As for teach controller, the fault code and
date when the trouble occurred, which are
recorded by ICF, are effective in order to
resolve the problem which are not easily
re-predicable. (Refer to e-Wheel in this
section.)

T4GB-05-01-004

T4GB-05-01-005

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 Dr.ZX or the service mode of monitor.

T4GB-05-01-006

T5-1-4

TROUBLESHOOTING / Diagnosing Procedure

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 disconnections 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.
6. Trace possible causes
Before reaching a conclusion, check the most
likely 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.

T5-1-5

TROUBLESHOOTING / Diagnosing Procedure

HOW TO OPERATE SERVICE MODE OF
MONITOR
In case the engine starts in normal, the monitor is
started in normal mode and only the items, which can
be displayed in normal mode, are displayed on the
liquid crystal display (LCD). (Refer to the next page.)

How to Used Monitor in Service Mode

1. Whenever pushing the monitor display selector
(up) in the monitor, the display in information display is changed.

When the monitor is started in service mode according to the following procedures, the items that can be
displayed in normal mode, the fault code and one part
of monitor items can be displayed. (Refer to the next
page.)

NOTE: The fault code is indicated in the display

order 11. All fault codes can be indicated.
In case more than one fault code is indicated, they will be displayed with an interval of 1 second in order. After the machine
malfunction has been repaired, the fault
codes are automatically deleted. Accordingly, if any trouble, which is not reproducible, is encountered (this states are
repeated that the trouble is resolved later
altough the troubole sometimes occurs), it
is recommended to use Dr. ZX in order to
check the fault code history.

How to Start Monitor in Service Mode

1. Push the monitor display selector (up) and
(down) in the monitor at the same time and the
key switch is turned ON.
NOTE: The engine can start in normal.

Liquid Crystal
Display (LCD)

Information
Display

T4GB-01-02-001

Monitor Display
Selector (Down)

Monitor Display
Selector (Up)

T5-1-6

Mode Selection
Switch

TROUBLESHOOTING / Diagnosing Procedure

DISPLAY LIST OF MONITOR SERVICE MODE
Display
Order
1
2
3
4
4-1

Description
Model
Clock (24 hour)
Hour Meter
Fuel
Consumption
Amount
Average Fuel Consumption Amount

Monitored Result
{{{{{{
{{:{{
{{{{{.{ h
{{{{{.{

Unit
hh:mm
hour
L/h

{{{{{.{

L/h

Remark
Service Mode
Normal Mode
Normal Mode
Normal Mode
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
4 displayed, Re-set when
pushing the mode selection
switch)
Normal Mode
Normal Mode (Displayed
when pushing the monitor
display selector down) with
5 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-1 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-2 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-3 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-4 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-5 displayed)
Normal Mode (Displayed
when pushing the monitor
display selector (down) with
5-6 displayed)
Service Mode (Mile is displayed when pushing the
mode selection switch.)
Service Mode
Service Mode
Service Mode

5
5-1

Other Information
Remainder Time when
Hydraulic Oil can be
used

InFo
{{{{{.{

hour

5-2

Remainder Time when

Hydraulic Oil Filter can
be used

{{{{{.{

hour

5-3

Remainder Time when

Transmission Oil can be
used

{{{{{.{

hour

5-4

Remainder Time when

Transmission Oil Filter
can be used

{{{{{.{

hour

5-5

Remainder Time when

Engine Oil can be used

{{{{{.{

hour

5-6

Remainder Time when

Engine Oil Filter can be
used

{{{{{.{

hour

5-7

Remainder Time when

Fuel Filter can be used

{{{{{.{

hour

Odometer

{{{{{{

km or mile

7
8
9

Engine Speed
Coolant Temperature
Transmission Oil Temperature
Hydraulic Oil Temperature
Fault Code

{{{{{
{{{{{
{{{{{

min-1
C
C

{{{{{

Service Mode

ERROR

Service Mode

10
11

{{{{{{

T5-1-7

TROUBLESHOOTING / Diagnosing Procedure

(Blank)

T5-1-8

TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is used for diagnosis of electrical system
including MC (main controller), ECM (engine control
module), ICF (information controller), monitor unit and
TCU (transmission control unit).
Dr. ZX is connected to ICF and failure of each
controller and each sensor is displayed as a fault code.
(Self-Diagnostic Result)
Dr. ZX displays the input status of sensors and
switches connected to each controller and the output
status to actuator including solenoid valve from
controller with the machine operated in real time.
(Controller Diagnosis)

T5-2-1

TROUBLESHOOTING / Dr. ZX
Operation
1. Connect Palm (Dr. ZX) to the diagnosing
connector in the cab by using the Hot Sync cable
and connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.

Fuse Box

Dr. ZX Connector

1-1. Initial Screen

Select Dr. ZX icon.
1-2. Password Setup Screen (When the password
has unset)
Set the password.
1-3. Service Software Selection Screen
+ Select ZX-3 Mid.

T4GB-05-01-007

1-4. Function Selection Screen

+ Self-Diagnostic Result
+ Select Controller
4. Select Self-Diagnostic Result and operate
according to the instruction under display screen.

Palm
Dr. ZX

Hot Sync Cable

Download
Cable for
Portable
Communication
T1V1-05-07-002

T5-2-2

TROUBLESHOOTING / Dr. ZX

Start

Initial Screen

Password Setup Screen

Input Password

Input
the
former
password (6 characters
or more).
Next time, input the
same password in order
to check and push OK.

When the password has unset

Communication
Error

Check Communication Harness

Check Fuse

When the password

has set

Service Software
Selection Screen
Select ZX-3 Mid

Self-Diagnostic
Result Function

Self-Diagnostic
Result of Each
Controller

Select
Function

Record

T1V7-05-03-165

Select Controller
Main
Controller
Main Menu
Monitor Display

Setup

Disp. Record
Select Controller

Password

Engine
Controller
Main Menu
Monitor Display
Disp. Record
Password
Change

Transmission
Controller
Main Menu
Monitor Display
Disp. Record
Password
Change

Monitor
Controller

ICF
Controller

Main Menu
Monitoring

Main Menu
Information C/U

Password
Change

Data Download
Save
Data

Various Setup

Various Setup

Check
Password
Change

Change
Op. Manual.
Retry B

Self-Diagnostic
Result

T5-2-3

TROUBLESHOOTING / Dr. ZX
Self-Diagnostic Result
The self-diagnostic result of each controller is
displayed.
After starting Dr. ZX, push Self-Diagnostic Result.

T1V7-05-03-001

T1V7-05-03-008

T4GB-05-02-003

Controller Self- Diagnosis Screen

Function Selection Screen

NOTE: Main C/U:

Engine C/U:
Transmission C/U:
Monitor Unit:
Information C/U:

MC
ECM
TCU
Monitor Unit
ICF

NOTE: Self-diagnosis of ICF controller is done on

the next page.

T5-2-4

TROUBLESHOOTING / Dr. ZX
Self-Diagnosis

After starting Dr. ZX,

Self-Diagnostic Result.

Push T and ICF Select Function

Screen is displayed.
Push Fault of ICF Controller. In
case of no faulty, No Fault is
displayed.

push

To the
lower

T1V7-05-03-001

T4GB-05-02-002

T1V7-05-03-008

Controller Self- Diagnosis Screen

By changing the page, the forward or
backward controller is displayed.

Function Selection Screen

By changing the page, the

forward or backward fault Push Retry B and return to
code is displayed.
Controller Self-Diagnosis Screen
after executing Retry B.
Push ESC and return to Controller
Push ESC and Retry B Screen is
Self-Diagnosis Screen directly.
displayed.

Push Details, and Details of the

fault code and Corrective Action
are displayed.
Push ESC and Retry B Screen is
displayed.

Trouble

Retry B

ESC

ESC

T1V7-05-03-003

T1V7-05-03-005

Fault Code Screen

T1V7-05-03-007

Retry B Screen
If the message of Details is
long, push the arrow and
change the screen.

Retry B
ESC

T4GB-05-02-003

Controller Self- Diagnosis Screen

T5-2-5

TROUBLESHOOTING / Dr. ZX
SELECT CONTROLLER
Select the failure-diagnosis controller.
After starting Dr. ZX, push Select Controller.

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

NOTE: Main C/U:

Engine C/U:
Transmission C/U:
Monitor Unit:
Information C/U:

Controller Selection Screen

MC
ECM
TCU
Monitor Unit
ICF

T5-2-6

TROUBLESHOOTING / Dr. ZX
MAIN CONTROLLER
Main Menu
Monitor Display
Displays the control signals of MC and the input
signals from each switch and sensor.
Setup
Adjusts target engine idling speed, engine
warming-up speed and so on.

Title Screen

Recorded Data
Displays data recorded in MC by one day by using Dr.
ZX.
Password Change
Changes the password input when setting.
T1V7-05-03-011

Password
Change

Return to Controller
Selection Screen.
Disp. Record

Main Menu Screen

T1V7-05-03-012

Monitor Display

This function is not

available.

Setup

T5-2-7

TROUBLESHOOTING / Dr. ZX
MAIN MENU MONITOR DISPLAY
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC.
List of Monitor Item
Item
Required Engine Speed
Hydraulic Fan Target Speed
Actual Engine Speed
Engine Speed Deviation

Data
Control instruction value of engine speed to ECM
Control instruction value to fan flow rate control valve
Detected valve of torque converter input rotation sensor
Difference between required engine speed and actual engine speed

min-1
min-1
min-1
min-1

Unit

Torque Converter Speed Ratio of the detected value of torque converter out- No unit
Ratio
put rotation sensor in that of torque converter input
rotation sensor
Travel Speed
Value converted the detected value of travel speed Km/h
sensor into speed per hour
Pump Pressure

Detected value to main pump delivery pressure sensor

Pump Displacement Proportional Valve Output

Hydraulic Drive Fan Proportional Valve
Ride Control Proportional
Valve Output (Optional)
Pump Displacement Proportional Valve FB
Hydraulic Drive Fan Proportional Valve FB
Ride Control Proportional
Valve Output FB (Optional)
Accelerator Pedal
Parking Brake Pressure
Lift Cylinder Bottom Pressure (Optional)
Lift Cylinder Rod Pressure
(Optional)
Implement Pressure

Control instruction value to pump displacement proportional solenoid valve

Control instruction value to hydraulic drive fan flow
rate control solenoid valve
Control instruction value to ride control solenoid
valve
Feedback value from pump displacement proportional solenoid valve
Feedback value from hydraulic drive fan flow rate
control solenoid valve
Feedback value from ride control solenoid valve

Boom Angle (Optional)

Key switch

Output valve of lift arm angle sensor

Key ON signal from key switch to each controller

Output value of accelerator pedal

Detected value of parking brake pressure sensor
Detected value of lift arm cylinder bottom pressure
sensor
Detected value of lift arm cylinder rod pressure sensor
Detected value of implement pressure sensor

Ride Control Switch (Op- Continuity status in ride control switch

tional)
A/C Clutch SW
Continuity status in air conditioner switch
Fan Reversing SW
Continuity status in hydraulic drive fan reversing
switch
Boom Height Kickout SW Continuity status in lift arm auto leveler switch (raise)
(Optional)
Boom
Height
Kickout Continuity status in lift arm auto leveler switch (raise)
Setup SW (Optional)
set switch
Lift Arm Auto Leveler SW Continuity status in lift arm auto leveler switch (lower)
(Optional)
Lift Arm Auto Leveler Continuity status in lift arm auto leveler switch (lower)
Setup SW (Optional)
set switch

T5-2-8

MPa
MPa

mA
MPa

mA
mA
mA
V
MPa
MPa
MPa
MPa
V
ON OFF
ON OFF
ON
ON

OFF
OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

TROUBLESHOOTING / Dr. ZX

Item

Engine Torque Selection

Pump Torque Selection
Auto/Manual Selection
Auto Gear Shifting Mode
Clutch Cut-Off Switch
Clutch Cut-Off Mode
Hydraulic Drive Fan Reversing Valve
Boom Height Kickout (Optional)
Lift Arm Auto Leveler (Optional)
Parking brake Light
Ambient Temperature
Hydraulic Oil Temperature
Angle Sensor Learning
Status

Data

Instruction signal of engine torque selection to ECM

Selection status of work mode selection switch

Unit

1234
LD/Cry Normal
Power
Selection status (auto/manual) of travel mode selec- Manual Auto
tion switch
Selection status (gear shifting timing) of travel mode Low
Normal
selection switch
High
Selection status (ON/OFF) of clutch cut-off position ON OFF
switch
Selection status (clutch cut-off position) of clutch Low Medium
cut-off position switch
High
Instruction signal to hydraulic drive fan reversing so- ON OFF
lenoid valve
Magnetizing Status of solenoid valve at lift arm raise ON OFF
side in pilot valve
Magnetizing Status of solenoid valve at lift arm lower ON OFF
side in pilot valve
Magnetizing status of parking brake relay 1 and con- ON OFF
tinuity status to parking brake indicator
Detected value of ambient temperature sensor
C
Detected value of hydraulic oil temperature sensor
C
Lift arm angle sensor learning status
Not Learn
Finish Failure

T5-2-9

TROUBLESHOOTING / Dr. ZX
Monitor Display

After starting Dr. ZX, push Select

Controller.

Push OK.

Push Main C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Controller Selection Screen

Push Start.

Push Monitor Display.

T4GB-05-02-004

Main Controller Screen

To the
lower

T4GB-05-02-005

T1V7-05-03-012

T1V7-05-03-011

Title Screen

Main Menu Screen

Enter Model and Serial No. Screen

Input the model code and serial

No. and push OK. If this procedure
is not done, monitor data cannot
recorded. Push ESC and return to
Main Menu Screen.

Push the item for Monitor Display

and push OK. Refer to T5-2-8 as
for the monitor item. Push ESC
and return to Main Menu Screen.

Push Hold and the monitor are

stopped temporarily. When the monitor
is started again, push Hold again.
Push ESC and return to Display Item
Selection Screen.

T4GB-05-02-008

T4GB-05-02-007

T4GB-05-02-006

Enter Model and Serial No. Screen

Display Item Selection Screen

Monitor Screen
To the next page

T5-2-10

TROUBLESHOOTING / Dr. ZX

Push Rec. No. and the recording

screen for Rec. No. is made.

Push Record.

To the
lower

T4GB-05-02-008

T1V7-05-03-096

Monitor Screen
If Rec. No. has already been
recorded and push Over Write,
data is overwritten. Push ESC and
return to Main Menu Screen.

If Rec. No. has not been recorded

yet and push Write, data is written
to the recording screen. Push ESC
and return to Main Menu Screen.

Select Write Data-Bank Screen

T1V7-05-03-097

Push Comment.
Push ESC and return to Main
Menu Screen.

To the
lower

T4GB-05-02-009

Recording Screen

T4GB-05-02-010

T1V7-05-03-100

Recording Screen

Input weather and persons name

in change and push OK.

Push OK and the recording screen

(making) is finished.

T4GB-05-02-011

T4GB-05-02-012

Recording Screen (Comment

Input)

T5-2-11

Push Re-Input and return to

Recording
Screen
(Comment
Input).
Push ESC and return to Monitor
Screen.

T4GB-05-02-013

TROUBLESHOOTING / Dr. ZX
SETTING
Target engine idling speed, engine warming-up speed
and so on can be adjusted.
MC List of Parameter Change Item
Item
Unit
Request Speed Calibration
min-1
Warning Up Speed Calibration
min-1
Warming Up Control Deactivation
ON, OFF
Flag
Set Torque Calibration
Nm

Data
Adjustment of engine idling speed
Adjustment of engine warming-up speed
Selection (enable/ disable) of engine warming-up control
Adjustment of main pump target torque

MC List of Adjustment Data

Data
Request Speed Calibration
Warning Up Speed Calibration
Warming Up Control Deactivation
Flag
Set Torque Calibration

Adjustment
Minimum Unit
1 min-1
1 min-1

0 to 200
-200 to 200

Adjustment Value
When Delivering
0 min-1
0 min-1

ON or OFF

ON

3 Nm

-45 to 45

0 Nm

Adjustable Range

T5-2-12

Remark

TROUBLESHOOTING/ Dr. ZX
Setting
Parameter Change

After starting Dr. ZX, push Select

Controller.

Push OK.

Push Main C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Controller Selection Screen

Push Start.

Push Setup.

T4GB-05-02-004

Main Controller Screen

To the
lower

T1V7-05-03-011

T1V7-05-03-012

Title Screen

Main Menu Screen

Input the password and push OK.

Push Cancel and return to Main
Menu Screen.

Push Parameter Change.

Push ESC and return to Main
Menu Screen.

T1V7-05-03-016

Refer to T5-2-12 as for the item of

Parameter Change. Push Engine
Control.

To the
Next Page

T1V7-05-03-022

Setup Password Input Screen

T4GB-05-02-014

Setup Item Selection Screen

T5-2-13

Parameter Change Selection

Screen

T4GB-05-02-015

TROUBLESHOOTING/ Dr. ZX
Parameter Input
Example: Engine Control
Correction
Input Value = Normal Value

Push Request Speed I Calibration..

Target

Speed

Input the value and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

Check Adjustment and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

To the
lower

T4GB-05-02-016

Parameter Change Selection

Screen

T4GB-05-02-017

Parameter Input Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-2-14

T4GB-05-02-018

TROUBLESHOOTING/ Dr. ZX
Input Value = Current Value

Push Request Speed I Calibration.

Input the value and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

Push Exec. Push ESC and return

to Parameter Change Selection
Screen.

To the
lower

T4GB-05-02-016

Parameter Change Selection

Screen

T4GB-05-02-019

Parameter Input Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-2-15

T1V7-05-03-108

TROUBLESHOOTING/ Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)

Push Request Speed I Calibration.

Input the value and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

Push Re-Input and return to

Parameter Input Screen. Push Max
and the maximum value is input.
Push ESC and return to Parameter
Change Selection Screen.

To the
lower

T4GB-05-02-016

Parameter Change Selection

Screen

T4GB-05-02-020

Parameter Input Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-2-16

T4GB-05-02-021

TROUBLESHOOTING/ Dr. ZX
When the input value cannot be divided
Example: Pump Control Set Torque Calibration

Push Set Torque Calibration.

Input the value and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

Push Re-Input and return to

Parameter Input Screen. Push A or
B and the value of A or B is input.
Push ESC and return to Parameter
Change Selection Screen.

To the
lower

T4GB-05-02-022

Parameter Change Selection

Screen

T4GB-05-02-023

Parameter Input Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-2-17

T4GB-05-02-024

TROUBLESHOOTING/ Dr. ZX
Status Selection
Example: Engine Control Warming Up Control
Deactivation Flag

Push
Warming
Deactivation Flag.

Up

Ctrl

Push OFF and push Exec. Push

ESC and return to Parameter
Change Selection Screen.

Check contents and push Exec.

Push ESC and return to Parameter
Change Selection Screen.

To the
lower

T4GB-05-02-016

Parameter Change Selection

Screen

T4GB-05-02-025

Status Selection Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-2-18

T4GB-05-02-026

TROUBLESHOOTING/ Dr. ZX
Recorded Data Display
After starting Dr. ZX, push Select
Controller.

Push OK.

Push Main C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Push and select No. Push

Regeneration and the recorded
data are regenerated.Push DEL
and data of selected No. is
d l t d

Push Start to record.

Push Hold and the monitor are

stopped temporarily. Push Hold
again and restart regeneration.
Push ESC and Recorded Data
Selection Screen is displayed.

T1V7-05-03-124

T1V7-05-03-011

Title Screen

T4GB-05-02-004

Main Controller Screen

Controller Selection Screen

Recorded Data Selection Screen

T5-2-19

Recorded Data Regeneration

Screen

T4GB-05-02-027

TROUBLESHOOTING/ Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.

Push OK.

Push Main C/U.

To the
lower

Function Selection Screen

T1V7-05-03-001

Controller Selection Screen

T4GB-05-02-003

Input the registered password and

push OK.

Push Password.

Main Controller Screen

T4GB-05-02-004

Input the new password and push

OK.

To the
lower

T1V7-05-03-126

T1V7-05-03-011

Title Screen
Input the new password again and
push OK.

Push OK
Screen.

and

return

to

Title

T1V7-05-03-128

T1V7-05-03-169

T5-2-20

T1V7-05-03-127

TROUBLESHOOTING / D r. ZX
ENGINE CONTROLLER
Main Menu
Monitor Display
Dr. ZX displays the input signals from sensors and
the control signals of ECM.

Recorded Data Display

Data recorded in ECM is displayed by one day by
using Dr. ZX.
Password
The password can be changed.

T1V7-05-03-079

T5-2-21

TROUBLESHOOTING / D r. ZX
MONITOR DISPLAY
ECM List of Monitor Item
Item
Selecting
Engine Torque
Actual Engine Speed
(Engine Speed)
Target Engine Speed
Glow Signal
Coolant
Temperature
(Engine
Coolant
Temperature)
Fuel Temperature
Engine Oil Pressure
Fuel Flow Rate
Atmospheric Pressure
Suction
Temperature
(Intake Air Temperature)
Boost Pressure
Boost Temperature
Battery Voltage
Total Amount of Fuel Use

Unit
Monitoring
Engine Torque
%
Actual Engine
min-1
Speed
Target Engine
min-1
Speed
Glow Signal
OFF, ON
Coolant
Temperature
C
(E)
Fuel
C
Temperature
Engine
Oil
kPa
Pressure
Fuel Flow
L/h
Barometric
kPa
Pressure
Intake Air
C
Temperature
Boost Pressure
kPa
Boost
C
Temperature
Battery Voltage
V
Total
Used
L
Fuel

Data
Input signal from ECM
Input signal from crank speed sensor and cam angle
sensor
Input signal from accelerator pedal
Glow relay ON/OFF status
Input signal from coolant temperature sensor
Input signal from fuel sensor
Input signal from engine oil pressure sensor
Input signal from ECM
Input signal from atmospheric pressure sensor
Input signal from intake-air temperature sensor
Input signal from boost pressure sensor
Input signal from boost temperature sensor
Input signal from ECM
Input signal from ECM

T5-2-22

TROUBLESHOOTING / D r. ZX
(Blank)

T5-2-23

TROUBLESHOOTING / D r. ZX
Monitor Display

After starting Dr. ZX, push Select

Controller.

Push OK.

Push Engine C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Controller Selection Screen

Push Start.

Push Monitor Display.

T4GB-05-02-004

Engine Controller Screen

To the
lower

Title Screen

T4GB-05-02-028

T1V7-05-03-011

Input the model code and serial

No. and push OK. If this procedure
is not done, monitor data cannot
recorded. Push ESC and return to
Main Menu Screen.

T4GB-05-02-005

Main Menu Screen

Enter Model and Serial No. Screen

Push the item for Monitor Display

and push OK. Refer to T5-2-22 as
for the monitor item.
Push ESC and return to Main
Menu Screen.

Push Hold and the monitor are

stopped temporarily. When the
monitor is started again, push Hold
again. Push ESC and return to
Display Item Selection Screen.

Start
recoding.
To the
next page

T1V7-05-03-132

T4GB-05-02-006

Enter Model and Serial No. Screen

Display Item Selection Screen

T5-2-24

T1V7-05-03-133

Monitor Screen

TROUBLESHOOTING / D r. ZX

Push Rec. No. and the recording

screen for Rec. No. is made.

Push Record.

To the
lower

Monitor Screen

T1V7-05-03-133

If Rec. No. has already been

recorded and push Over Write,
data is overwritten.
Push ESC and return to Main
Menu Screen.

T1V7-05-03-134

If Rec. No. has not been recorded

yet and push Write, data is written
to the recording screen.
Push ESC and return to Main
Menu Screen.

Select Write Data-Bank Screen

T1V7-05-03-135

Push Comment.
Push ESC and return to Main
Menu Screen.

To the
lower

T4GB-05-02-009

Recording Screen

T4GB-05-02-030

T4GB-05-02-031

Recording Screen

Input weather and persons name

in change and push OK.

Push OK and the recording screen

(making) is finished.

T4GB-05-02-032

T4GB-05-02-033

Recording Screen (Comment

Input)

T5-2-25

Push Re-Input and return to

Recording
Screen
(Comment
Input).
Push ESC and return to Main
Menu Screen.

T4GB-05-02-034

TROUBLESHOOTING / D r. ZX
RECORDED DATA DISPLAY
After starting Dr. ZX, push Select
Controller.

Push OK.

Push Engine C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

T1V7-05-03-010

Function Selection Screen

Controller Selection Screen

Engine Controller Screen

Push Disp. Record.

Push and select No. Push

Regeneration and the recorded
data is regenerated. Push DEL and
data of selected No. is deleted.
Push ESC and return to Title
Screen.

Push Hold and the monitor is

stopped temporarily
When the monitor is started again,
push Hold again.
Push ESC and return to Recored
Data Selection Screen.

T1V7-05-03-124

T1V7-05-03-011

Title Screen

Recorded Data Selection Screen

T5-2-26

T1V7-05-03-141

Recorded Data Regeneration

Screen

TROUBLESHOOTING / D r. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.

Push Engine C/U.

Push OK.

To the
lower

T1V7-05-03-001

T4GB-05-02-003

T4GB-05-02-004

Function Selection Screen

Controller Selection Screen

Engine Controller Screen

Push Password.

Input the registered password and

push OK.

Input the new password and push

OK.

To the
lower

T1V7-05-03-126

T1V7-05-03-011

Title Screen

Input the new password again and

push OK.

Push OK
Screen.

and

return

to

Title

T1V7-05-03-128

T1V7-05-03-169

T5-2-27

T1V7-05-03-127

TROUBLESHOOTING / D r. ZX
(Blank)

T5-2-28

TROUBLESHOOTING / Dr. ZX
ICF CONTROLLER
Main Menu
Information C/U Various Setup
Initialization of information C/U, setting of model,
serial No. and time, and initialization of control
data can be done.
Data Download
Daily report data, frequency distribution data, total
operating hours, alarm and fault code, which are
recorded in ICF, can be downloaded to Dr. ZX.
Save Data Check
Daily report data, frequency distribution data, total
operating hours, alarm and fault code, which are
saved in ICF, can be checked by using Dr. ZX.
Password
The password can be changed.

T1V7-05-03-166

T5-2-29

TROUBLESHOOTING / Dr. ZX
INFORMATION C/U VARIOUS SETUP
ICF List of Controller Data Setting Item
Item
Information C/U: Initialize
Enter Model and Serial No.

Range of Data
Model
Serial No.

Enter Date and Time

YY
MM
DD
HH
MM

Date
Time
Control Data: Initialize
Satellite Terminal: Initialize
Satellite Terminal No. Confirmation
Communicating State Check

ICF < = > Satellite

Terminal
Satellite Terminal

Connect
Comm.
Power
Comm.

Rod Aerial
GPS Aerial
Wave State
Un-Transmit Data Number
Last Transmitting Time
Enter Satellite Comm.
Start/Stop

T5-2-30

Initialize/ESC
ASCII (4 characters) 0 to 9, A to Z
000000 to 999999
2000 to 2100
1 to 12
1 to 31
0 to 23
0 to 59
Initialize/ESC
DEL/ESC
12 digits: 0 to 9, A to Z
Conn/UnConn
OK/NG
ON/OFF
Enable/Stop
OK/NG
OK/NG
ON/OFF
099
YYYY/MM/DD hh: mm: ss
Start/Stop

TROUBLESHOOTING / Dr. ZX
INFORMATION C/U: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

Function Selection Screen

T1V7-05-03-001

Controller Selection Screen

Push Information
Setup.

Push Start.

C/U:

T4GB-05-02-035

Various

ICF Controller Screen

T4GB-05-02-036

Push Information C/U: Initialize.

To the
lower

Title Screen

T1V7-05-03-025

Push Init and the controller

operating data is initialied. Push
ESC and return to Information C/U:
Various Setup Screen.

Main Menu Screen

T1V7-05-03-026

T1V7-05-03-027

Information C/U: Various Setup

Screen

Push OK and return to Information

C/U: Various Setup Screen.

Push ESC and return to Main

Menu Screen.

Init

ESC

T1V7-05-03-029

T1V7-05-03-028

T1V7-05-03-027

Information C/U: Various Setup

Screen

Information C/U: Initialize Screen

T5-2-31

TROUBLESHOOTING / Dr. ZX
ENTER MODEL AND SERIAL No.
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

T4GB-05-02-035

T1V7-05-03-001

T4GB-05-02-036

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Start.

Push Information
Setup.

Push Enter Model and Serial No.

C/U:

Various

To the
lower

T1V7-05-03-026

T1V7-05-03-025

Title Screen

Main Menu Screen

Push Exec and model and serial

No. can be input.
Push ESC and return to
Information C/U: Various Setup
Screen.

Push OK after inputting model and

serial No. and return to Enter
Model and Serial No. Screen.
Push ESC and return to
Information C/U: Various Setup
Screen.

T1V7-05-03-027

Information C/U: Various Setup

Screen

Push ESC and return to Main

Menu Screen.

ESC

Exec

ESC
OK

T4GB-05-02-037

T4GB-05-02-038

T1V7-05-03-027

Information C/U: Various Setup

Screen

Enter Model and Serial No. Screen

T5-2-32

TROUBLESHOOTING / Dr. ZX
ENTER DATE AND TIME
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

Function Selection Screen

T4GB-05-02-035

T1V7-05-03-001

Controller Selection Screen

Push Information
Setup.

Push Start.

C/U:

Various

ICF Controller Screen

T4GB-05-02-036

Push Enter Date and Time.

To the
lower

T1V7-05-03-026

T1V7-05-03-025

Title Screen

T1V7-05-03-027

Information C/U: Various Setup

Screen

Main Menu Screen

Push Set and the focused item is

YY. Push ESC and return to
Information C/U: Various Setup
Screen.
YY, MM, DD, HH and MM
The focused item is displayed reversely.
At first, the focused item is YY.

YY, MM, DD, HH and MM

Move the focused item.
No repeat input.
T1V7-05-03-032

Enter Date and Time Screen

YY, MM, DD, HH and MM

Value of the focused item is increased or
decreased one by one.
In case value is beyond maximum one: Change
value into the minimum one
In case value is below minimum one: Change
value into the maximum one
No repeat input.

T5-2-33

TROUBLESHOOTING / Dr. ZX
CONTROL DATA: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

Function Selection Screen

T4GB-05-02-035

T1V7-05-03-001

Controller Selection Screen

Push Information
Setup.

Push Start.

C/U:

T4GB-05-02-036

ICF Controller Screen

Various

Push Control Data: Initialize.

To the
lower

Title Screen

T1V7-05-03-025

Push Init and the controller control

data is initialied. Push ESC and
return to Information C/U: Various
Setup Screen.

T1V7-05-03-026

Main Menu Screen

Information C/U: Various Setup

Screen

Push OK and return to Information

C/U: Various Setup Screen.

Push ESC and return to Main

Menu Screen.

T1V7-05-03-027

Init

ESC

T1V7-05-03-034

T1V7-05-03-033

T1V7-05-03-027

Information C/U: Various Setup

Screen

Control Data: Initialize Screen

T5-2-34

TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL: INITIALIZE
Push T and ICF controller
Selection Screen is displayed.
Push ICF Controller.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

T4GB-05-02-035

T1V7-05-03-001

Function Selection Screen

Push Start.

T4GB-05-02-036

Controller Selection Screen

ICF Controller Screen

Push Information
Setup.

Push T and move to the next

screen of Information C/U: Various
Setup Screen. Push Satellite
Terminal: Initialize.

C/U:

Various

To the
lower

T1V7-05-03-026

T1V7-05-03-025

Title Screen

Main Menu Screen

Push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

T1V7-05-03-035

Information C/U: Various Setup

Screen

Exec

ESC

T1V7-05-03-145

T1V7-05-03-036

T5-2-35

Information C/U: Various Setup

Screen

T1V7-05-03-035

TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL No. CONFIRMATION

After starting Dr. ZX, push Select

Controller.

Push T and ICF controller

Selection Screen is displayed.
Push Information C/U.

Push OK.

To the
lower

T4GB-05-02-035

T1V7-05-03-001

Function Selection Screen

Push Start.

T4GB-05-02-036

Controller Selection Screen

ICF Controller Screen

Push Information
Setup.

Push T and move to the next

screen of Information C/U: Various
Setup Screen. Push Satellite
Terminal No. Confirmation.

C/U:

Various

To the
lower

T1V7-05-03-026

T1V7-05-03-025

Main Menu Screen

Title Screen

Confirm serial No. (12 digits). Push

ESC and return to Information C/U:
Various Setup Screen.

T1V7-05-03-035

T1V7-05-03-037

T5-2-36

T1V7-05-03-035

Information C/U: Various Setup

Screen

TROUBLESHOOTING / Dr. ZX
COMMUNICATING STATE CHECK
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

T1V7-05-03-001

Function Selection Screen

Push Start.

T4GB-05-02-035

Controller Selection Screen

ICF Controller Screen

Push Information
Setup.

Push T and move to the next

screen of Information C/U: Various
Setup
Screen.
Push
Communicating State Check.

C/U:

Various

T4GB-05-02-036

To the
lower

T1V7-05-03-026

T1V7-05-03-025

Title Screen

Main Menu Screen

Check communicating state.

Unconn: Faulty harness
NG: Faulty harness for Comm.
OFF: Faulty harness, Faulty controller
Stop: Enter Satellite Comm. Start/Stop
Push ESC and return to Information
C/U: Various Setup Screen.

Push T and move to the next

screen. Check communicating
state of Rod Aerial and GPS Aerial.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

T1V7-05-03-035

Information C/U: Various Setup

Screen

Push ESC and return to Main

Menu Screen.

ESC

T1V7-05-03-143

T1V7-05-03-142

T1V7-05-03-035

When electrical wave of the satellite is caught,

the items are turned into OK.

Check the enclosed state.

IMPORTANT: Check this with the key of machine

ON in outdoor. According to state
of electrical wave, it may take a
little longer time.

T5-2-37

TROUBLESHOOTING / Dr. ZX
ENTER SATELLITE COMM. START / STOP
Push T and ICF controller
Selection Screen is displayed.
Push Information C/U.

After starting Dr. ZX, push Select

Controller.

Push OK.

To the
lower

T1V7-05-03-001

Function Selection Screen

T4GB-05-02-035

Controller Selection Screen

Push Information
Setup.

Push Start.

C/U:

Various

ICF Controller Screen

T4GB-05-02-036

Push T and move to the next

screen of Information C/U: Various
Setup Screen. Push Enter Satellite
Comm. Start/Stop.

To the
lower

Title Screen

T1V7-05-03-026

T1V7-05-03-025

When starting Satellite Comm., push

Start and push Exec. When stopping
Satellite Comm., push Stop and push
Exec.
Push ESC and return to Information
C/U: Various Setup Screen.

T1V7-05-03-035

Main Menu Screen

Information C/U: Various Setup

Screen

Push OK and return to Information

C/U: Various Setup Screen.

Push ESC and return to Main

Menu Screen.

Exec

ESC

T1V7-05-03-147

T1V7-05-03-146

T5-2-38

Information C/U: Various Setup

Screen

T1V7-05-03-035

TROUBLESHOOTING / Dr. ZX
DATA DOWNLOAD

After starting Dr. ZX, push Select

Controller.

Push T and ICF controller

Selection Screen is displayed.
Push Information C/U.

Push OK.

To the
lower

Function Selection Screen

T1V7-05-03-001

Push Start.

Controller Selection Screen

T4GB-05-02-035

ICF Controller Screen

T4GB-05-02-036

While downloading data, Download

Screen is displayed.

Push Data Download.

To the
lower

Title Screen

T1V7-05-03-025

When downloading is completed

normally, Normal End Screen is
displayed. Push OK and return to
Main Menu Screen.

Main Menu Screen

If pushing Cancel on Data

Download Screen, Alarm Screen is
displayed. Push OK and return to
Main Menu Screen.

Data Download Screen

Alarm Screen

T1V7-05-03-026

Main Menu Screen

T5-2-39

T1V7-05-03-038

Push ESC and return to Title

Screen.

T1V7-05-03-148

T1V7-05-03-039

Normal End Screen

T1V7-05-03-026

TROUBLESHOOTING / Dr. ZX
SAVE DATA CHECK
After starting Dr. ZX, push Select
Controller.

Push T and ICF controller

Selection Screen is displayed.
Push Information C/U.

Push OK.

To the
lower

T4GB-05-02-035

T1V7-05-03-001

Function Selection Screen

Push Start.

ICF Controller Screen

Push Save Data Check.

Data saved in ICF is displayed.

Push OK and return to Main Menu
Screen.

T1V7-05-03-026

T1V7-05-03-025

Title Screen

T4GB-05-02-036

Controller Selection Screen

Main Menu Screen

T5-2-40

T1V7-05-03-040

Save Data Check Screen

TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.

Push T and ICF controller

Selection Screen is displayed.
Push Information C/U.

Push OK.

To the
lower

T4GB-05-02-035

T1V7-05-03-001

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Password.

Input the registered password and

push OK.

Input the new password and push

OK.

T4GB-05-02-036

To the
lower

T1V7-05-03-126

T1V7-05-03-025

Title Screen
Input the new password again and
push OK.

Push OK
Screen.

and

return

to

Title

T1V7-05-03-128

T1V7-05-03-169

T5-2-41

T1V7-05-03-127

TROUBLESHOOTING / Dr. ZX
(Blank)

T5-2-42

TROUBLESHOOTING / Dr. ZX
MONITOR UNIT
Main Menu
Monitoring
Dr. ZX displays the input signals from each sensor
and switch.
Various Settings
Dr. ZX can set inner hour meter synchronization.
Password
The password can be changed.

T4GB-05-02-039

T5-2-43

TROUBLESHOOTING / Dr. ZX
MONITORING
List of Monitoring Item
Item
Radiator Coolant Temperature
Fuel Level
T/M Torque Converter Oil
Temperature
Steering Pressure
Brake Oil Level Switch of
Service Brake

Data
Signal to coolant temperature gauge
Signal to fuel gauge
Signal to transmission oil temperature gauge

Continuity status in emergency steering pressure switch

Continuity status to brake oil level indicator

Unit
C
%
C
ON OFF
ON OFF

Emergency Steering Pump Continuity status in emergency steering pump delivery

Pressure Switch
pressure switch

ON OFF

Service Brake Pressure

Overheat Switch
Engine Oil Pressure Switch
Air Filter Restriction
Heated
Window
Switch
(Optional)

MPa
ON OFF
ON OFF
ON OFF
ON OFF

Detected value in brake primary pressure sensor

Continuity status to overheat indicator

Continuity status to engine oil pressure indicator
Continuity status to air filter restriction indicator
Continuity status in heated window switch (optional)

Emergency
Steering Continuity status in emergency steering check switch
Operation Check Switch
Front Wiper Switch
Continuity status in front wiper switch
Engine Warning Switch
Continuity status to engine warning indicator
Engine STOP Switch
Continuity status to stop indicator
Model Selector Switch 1
Model Selector Switch 2
Glow Switch
T/M Warning Switch
Buzzer Output
Load Dump Relay Output
Emergency Steering Relay
Output
Front Wiper Relay Output
Heated Window Relay Output
Parking Brake Signal Output
Parking
Brake
Pressure
Switch
Neutral Signal
Axle Oil Temperature

ON OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON

OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF

Continuity status in parking brake pressure switch

ON
ON
ON
ON

OFF
OFF
OFF
OFF

Excited status in neutral relay

Detected value in axle oil temperature sensor

ON OFF
C

Switch 1 OFF, switch 2 OFF: ZW220/250

Switch 1 ON, switch 2 OFF: ZW310

Continuity status to glow signal

Continuity status to transmission warning indicator
Continuity status to buzzer
Excited status in load dump relay
Excited status in emergency steering relay
Excited status in front wiper relay
Excited status in heated window relay
Sending status of parking brake operating signal to TCU

T5-2-44

TROUBLESHOOTING / Dr. ZX
Monitoring

After starting Dr. ZX, push Select

Controller.

Push OK.

Push Monitor Unit.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Push Start.

T4GB-05-02-040

Controller Selection Screen

Monitor Controller Screen

Push Monitoring.

Push item for monitoring and push

OK. Refer to T5-2-44 as for the
monitoring item.
Push ESC and return to Main Menu
Screen.

To the
lower

Title Screen

T1V7-05-03-025

T1V7-05-03-042

Main Menu Screen

When pushing Hold, the monitor is

stopped temporarily.
When re-starting the monitor, push
Hold again. Push ESC and return
to Monitoring Item Selection
Screen.

T4GB-05-02-042

Monitoring Screen

T5-2-45

T4GB-05-02-041

Monitoring Item Selection Screen

TROUBLESHOOTING / Dr. ZX
VARIOUS SETTINGS
Monitor Unit List of Setup Item
Item
Internal Hour Meter Sync.

Data
Synchronization of hour meter data in both monitor unit and ICF

MC List of Adjustment Data

Data
Internal Hour Meter Sync.

Adjustment
Minimum Unit
-

Adjustable Range

T5-2-46

ON only

Adjustment
Minimum Unit
-

Remark

TROUBLESHOOTING / Dr. ZX
INTERNAL
HOUR
SYNCHRONIZATION
After starting Dr. ZX, push Select
Controller.

METER

Push Monitor Unit.

Push OK.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

T4GB-05-02-040

Function Selection Screen

Controller Selection Screen

Monitor Controller Screen

Push Start.

Push Various setting.

Push Internal Hour Meter Sync.

To the
lower

T1V7-05-03-042

T1V7-05-03-025

Title Screen

Main Menu Screen

Push Sync. Push ESC and return

to the former screen.

Push ESC and return to Various

Setup Item Screen.

T1V7-05-03-086

T1V7-05-03-085

Maintenance Set Item Screen

T5-2-47

T4GB-05-02-043

Various Setup Item Screen

TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.

Push Monitor Unit.

Push OK.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

T4GB-05-02-040

Function Selection Screen

Controller Selection Screen

Monitor Controller Screen

Push Password.

Input the registered password and

push OK.

Input the new password and push

OK.

To the
lower

T1V7-05-03-126

T1V7-05-03-025

Title Screen

Main Menu Screen

Input the new password again and

push OK.

Push OK
Screen.

and

return

to

Title

T1V7-05-03-128

T1V7-05-03-169

T5-2-48

T1V7-05-03-127

TROUBLESHOOTING / D r. ZX
TCU CONTROLLER
Main Menu
Monitor Display
Dr. ZX displays the control signals of TCU and the
input signals from each sensor.

Recorded Data Display

Dr. ZX recorded in TCU by one day.
Password
The password can be changed.

T1V7-05-03-079

T5-2-49

TROUBLESHOOTING / D r. ZX
MONITOR DISPLAY
TCU List of Monitor Display Item

Item
T/C Output Speed
T/M Output Speed
Actual Engine Speed
Selected Gear

Data
Detected value in torque converter output rotation
sensor
Detected value in travel speed sensor
Detected value in torque converter input rotation sensor
Selected speed stage

Current Gear

Speed stage actually operated

FNR Switch
OPT FNR Switch
Selected Gear
Pedal Brake Pressure
DSS Switch
USS Switch
Hold Switch
OPT FNR Replace Switch
Hold Mode
OPT FNR Mode

Selected status of forward/reverse lever

Selected status of forward/reverse switch
Selected status of shift switch
Detected value in service brake pressure sensor
Selected status of down-shift switch
Selected status of up-shift switch
Continuity status hold switch
Continuity status in forward/reverse selector switch
Status (enable/disable) of hold mode
Status (enable/disable) of mode when using
forward/reverse switch
Progress code of transmission learning and cause code
of learning failure

AEB main status info

AEB sub status info

Advisability code of transmission learning start

Transmission Oil Temperature Detected value in transmission oil temperature sensor

AEB Cycle Num
Transmission increasing-pressure number (This is used
at the service.)

T5-2-50

Unit
Min-1
Min-1
Min-1
R3 R2 R1 N F1 F2
F3 F4
R3 R2 R1 N F1 F2
F3 F4
F N R
F N R
1 2 3 4
Mpa
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
OPE mode 1st
2nd
3rd
4th
F
R
Finish
Abort
1st Abort
2nd Abort
3rd Abort
4th Abort
F Abort
R Abort
Go Calib
FNR is not N
PB is not ON
Speed Not 0 km
TC Oil Tmp Low
TC Oil Tmp High
Eng Speed Low
Eng Speed High
C
0 to 50 dig

TROUBLESHOOTING / D r. ZX
(Blank)

T5-2-51

TROUBLESHOOTING / D r. ZX
Monitor Display

After starting Dr. ZX, push Select

Controller.

Push OK.

Push Transmission C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

Function Selection Screen

Controller Selection Screen

Push Start.

Push Monitor Display.

T4GB-05-02-004

Transmission Controller Screen

To the
lower

Title Screen

T4GB-05-02-028

T1V7-05-03-011

Input the model code and serial

No. and push OK. Push ESC and
return to Main Menu Screen.

T4GB-05-02-005

Main Menu Screen

Enter Model and Serial No. Screen

Push the item for Monitor Display

and push OK. Refer to T5-2-50 as
for the monitor item.
Push ESC and return to Main
Menu Screen.

Push Hold and the monitor are

stopped temporarily. When the
monitor is started again, push Hold
again. Push ESC and return to
Monitoring Item Selection Screen.

Start
recoding.
To the
next page

T4GB-05-02-044

T4GB-05-02-006

Enter Model and Serial No. Screen

Display Item Selection Screen

T5-2-52

T4GB-05-02-045

Monitor Screen

TROUBLESHOOTING / D r. ZX

Push Rec. No. and the recording

screen for Rec. No. is made.

Push Record.

To the
lower

Monitor Screen

T4GB-05-02-045

If Rec. No. has already been

recorded and push Over Write,
data is overwritten.
Push ESC and return to Main
Menu Screen.

T1V7-05-03-134

If Rec. No. has not been recorded

yet and push Write, data is written
to the recording screen.
Push ESC and return to Main
Menu Screen.

Select Write Data-Bank Screen

T1V7-05-03-135

Push Comment.
Push ESC and return to Main
Menu Screen.

To the
lower

T4GB-05-02-046

Recording Screen

T4GB-05-02-047

T1V7-05-03-136

Recording Screen

Input weather and persons name

in change and push OK.

Push OK and the recording screen

(making) is finished.

T4GB-05-02-048

T4GB-05-02-049

Recording Screen (Comment

Input)

T5-2-53

Push Re-Input and return to

Recording
Screen
(Comment
Input).
Push ESC and return to Main
Menu Screen.

T4GB-05-02-050

TROUBLESHOOTING / D r. ZX
RECORDED DATA DISPLAY
After starting Dr. ZX, push Select
Controller.

Push OK.

Push Transmission C/U.

To the
lower

T4GB-05-02-003

T1V7-05-03-001

T4GB-05-02-004

Function Selection Screen

Controller Selection Screen

Transmission Controller Screen

Push Disp. Record.

Push and select No. Push

Regeneration and the recorded
data is regenerated. Push DEL and
data of selected No. is deleted.
Push ESC and return to Title
Screen.

Push Hold and the monitor is

stopped temporarily
When the monitor is started again,
push Hold again.
Push ESC and return to Recorded
Data Selection Screen.

T1V7-05-03-124

T1V7-05-03-011

Title Screen

Recorded Data Selection Screen

T5-2-54

T1V7-05-03-141

Recorded Data Regeneration

Screen

TROUBLESHOOTING / D r. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.

Push Transmission C/U.

Push OK.

To the
lower

T1V7-05-03-001

T4GB-05-02-003

T4GB-05-02-004

Function Selection Screen

Controller Selection Screen

Transmission Controller Screen

Push Password.

Input the registered password and

push OK.

Input the new password and push

OK.

To the
lower

T1V7-05-03-126

T1V7-05-03-011

Title Screen
Input the newpassword again and
push OK.

Push OK
Screen.

and

return

to

Title

T1V7-05-03-128

T1V7-05-03-169

T5-2-55

T1V7-05-03-127

TROUBLESHOOTING / D r. ZX
(Blank)

T5-2-56

TROUBLESHOOTING / e-Wheel
OUTLINE
ICF (Information Controller) saves the input signals
from various sensors and switches of the machine as
data by using CAN bus line from each controller.
Various input signals are recorded as list of daily
report data, list of frequency distribution data, list of
total operating hours, list of alarm and list of failure
in ICF.
The recorded data is downloaded to the personal
computer and is uploaded to the center server via
LAN, so that the data can be used as e-Service.
The machine equipped with the optional satellite
communication terminal can send the data to center
server by using satellite communication. (As for the
satellite communication system, refer to T5-3-24.

T5-3-1

TROUBLESHOOTING / e-Wheel
LIST OF DAILY REPORT DATA

Item
1.

Date

2.

Fuel Level

3.
4.
5.
6.
7.

Fuel Usage Amount

Machine Hour Meter
Engine Operating Hours
Operating Distance
Manual Transmission Operating Hours

8.

Automatic Transmission Operating Hours

9.

L Mode Operating Hours

Details
Date of daily report data
The value of the final remained fuel during a day when
the engine stops
The value of fuel used during a day
Hour meter cumulative hours
Total engine operating hours during a day
Traveling distance during a day
Total manual transmission operating hours during a day
Total automatic transmission operating hours during a
day
Total hours operating L mode of work mode selection
switch during a day
Total hours operating N mode of work mode selection
switch during a day
Total hours operating P mode of work mode selection
switch during a day
The highest radiator coolant temperature during a day
The highest hydraulic oil temperature during a day
The highest intake air temperature during a day
The highest fuel temperature during a day
The highest torque converter oil temperature during a
day
Engine operating hour distribution during a day
(Operating hours are recorded only when alternator
output signal is continuously delivered for more than 10
minutes.)

10. N mode Operating Hours

11. P mode Operating Hours
12.
13.
14.
15.

Radiator Coolant Temperature

Hydraulic Oil Temperature
Intake Air Temperature
Fuel Temperature

16. Torque Converter Oil Temperature

17. Engine Operating Hour Distribution

NOTE: The daily operation in this table is

equivalent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated
beyond 0:00, such data are recorded as
those for the following day.

T5-3-2

TROUBLESHOOTING / e-Wheel
LIST OF FREQUENCY DISTRIBUTION DATA
1.
2.
3.
4.
5.
6.
7.
8.
9.

Item
Fuel Temperature Distribution
Pump Load Distribution
Travel Load Distribution
Radiator Coolant Temperature Distribution
Hydraulic Oil Temperature Distribution
Torque converter oil Temperature Distribution
Radiator Coolant Temperature - Intake Air
Temperature Distribution
Hydraulic Oil Temperature - Intake Air
Temperature Distribution
Torque Converter Oil Temperature - Intake
Air Temperature Distribution

10. Radiator Coolant Temperature/Intake Air

Temperature
11. Hydraulic
Oil
Temperature/Intake
Air
Temperature
12. Torque Converter Oil Temperature / Intake Air
Temperature
13. Manual Transmission Speed Distribution
14. Automatic Transmission Speed Distribution
15. Engine Load Rate

Details
Frequency distribution of fuel temperature
Frequency distribution of main pump delivery pressure
Frequency distribution of travel torque
Frequency distribution of coolant temperature
Frequency distribution of hydraulic oil temperature
Frequency distribution of torque converter oil
temperature
Frequency distribution on temperature in which intake air
temperature is pulled from coolant temperature
Frequency distribution on temperature in which intake air
temperature is pulled from hydraulic oil temperature
Frequency distribution on temperature in which intake air
temperature is pulled from torque converter oil
temperature
Frequency distribution of coolant temperature and intake
air temperature
Frequency distribution of hydraulic oil temperature and
intake air temperature
Frequency distribution of torque converter oil
temperature and intake air temperature
Frequency distribution of speed in manual transmission
Frequency distribution of speed in automatic
transmission
Frequency distribution of engine speed and engine
torque

T5-3-3

TROUBLESHOOTING / e-Wheel
LIST OF TOTAL OPERATING HOURS
1.
2.
3.
4.
5.
6.
7.

Item
Hour Meter (ICF)
Hour Meter (Monitor Unit)
Engine Operating Hour
Traveling Distance
Manual Transmission Operating Hours
Automatic Transmission Operating Hours
L mode Operating Hours

8.

N mode Operating Hours

9.

P mode Operating Hours

Details
Hour meters value accumulated inside ICF
Hour meters value accumulated in monitor unit
Total engine operating hours
Total traveling Distance
Total manual transmission operating hours
Total automatic transmission operating hours
Total hours operating L mode of work mode selection
switch
Total hours operating N mode of work mode selection
switch
Total hours operating P mode of work mode selection
switch

T5-3-4

TROUBLESHOOTING / e-Wheel
LIST OF ALARM

1.
2.
3.
4.
5.
6.
7.
8.
9.

Item
Overheat Alarm
Engine Warning Alarm
Engine Oil Pressure Alarm
Alternator Indicator Alarm
Air Filter Restriction Alarm
Water Separator Alarm
Service Brake Oil Level Alarm
Service Brake Oil Pressure Alarm
Emergency Steering Operation Alarm

Details
Date when the overheat indicator lights
Date when the engine warning indicator lights
Date when the engine oil pressure indicator lights
Date when the alternator indicator lights
Date when the air filter restriction indicator lights
Date when the water separator indicator lights
Date when the service brake oil level indicator lights
Date when the service brake oil pressure indicator lights
Date when the emergency steering operation indicator
lights
Date when the steering oil pressure indicator lights
Date when the transmission oil temperature indicator
lights
Date when the hydraulic oil temperature indicator lights
Date when the transmission filter restriction indicator
lights
Date when the transmission failure indicator lights

10. Steering Oil Pressure Alarm

Transmission Oil Temperature Alarm
11.
12. Hydraulic Oil Temperature Alarm
Transmission Filter Restriction Alarm
13.
14. Transmission Failure Alarm
NOTE: When the alarm above is recorded, check
each item.
If the monitor is faulty, refer to
Troubleshooting C.

T5-3-5

TROUBLESHOOTING / e-Wheel
LIST OF FAILURE
When the fault code occurs, ICF records the fault
code and the date.
Use the list of failure when the malfunction, which is
difficult to identify, occurs as the remedy information.
Refer to Troubleshooting A.
If the machine is operated properly with the fault code
recorded, the machine can continue to be operated.

T5-3-6

TROUBLESHOOTING / e-Wheel
HOW TO DOWNLOAD AND UPLOAD DATA
OF ICF
After the data saved in ICF is downloaded to Dr. ZX, is
uploaded to the personal Computer, and is uploaded
to the center server by using LAN, the data can be
used as e-Service.
Dr.ZX Connector

How to Download Data from Machine to Dr. ZX

1. Connect Dr. ZX to the machine by using the Hot
Sync cable and download cable for portable
communication system.
2. Turn Dr. ZX ON and start downloading the data.
(Refer to the next page.)

T4GB-05-01-007

Dr. ZX
(Palm)

Hot Sync
Cable

Download Cable
for Portable
Communication
System

T1V1-05-07-002

T5-3-7

TROUBLESHOOTING / e-Wheel
Data Download
After starting Dr. ZX, push Select
Controller.
Select Function
+

Select failure-diagnosis
controller

Self-Diagnostic Result

Push OK.

Push ICF Controller.

Select Controller

Engine Controller

Main Controller

Monitor Controller

ICF Controller

ESC

ICF
controller Ver.: XXYY
Satellite terminal Controller
Ver.: XXYY
Is it correct?

ESC

OK

ESC

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Start.

Push Date Download.

While downloading data, Download

Screen is displayed.

Select Item

Password

Dr. ZX SerVice Soft

(C)Hitachi Construction
Machinery Co., ltd

Data Download

Information C/U: Various

Setup

Data Download

Save Data Check

Downloading.
Do not turn off the Palm or
disconnect the download
cable.
27%

+
Op. Manual
Start

Back

ESC

Cancel

Title Screen

Main Menu Screen

Data Download Screen

When downloading is completed

normally, Normal End Screen is
displayed.
Push OK and return to Main Menu
Screen.

If pushing Cancel on Data

Download Screen, Alarm Screen is
displayed. Push OK and return to
Main Menu Screen.

Push ESC and return to Title

Screen.
Select Item

Initialization has been

completed.
The
download
is
completed.

CAUTION
Initialization has been
The completed.
download has been
interrupted.

You may disconnect the

download cable.

No
data
has
been
transferred to the Dr. ZX

OK
Normal End Screen

To the
lower

Information C/U: Various

Setup

Data Download

Save Data Check

OK

ESC
Main Menu Screen

Alarm Screen

T5-3-8

To the
lower

TROUBLESHOOTING / e-Wheel
How to Upload Data from Dr. ZX (Palm) to
Personal Computer
1. Set Dr. ZX (Palm) to the cradle. Connect the USB
cable to the personal computer.
2. Push the Hot Sync button.
NOTE: When pushing the Hot Sync button and
uploading the data to the personal
computer, the Palm Desktop software
attached with Dr. ZX (Palm) need to be
installed.

Dr. ZX
(Palm)

Cradle
Hot Sync
Button

T178-05-07-033

T5-3-9

TROUBLESHOOTING / e-Wheel
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the
satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures

Start Dr. ZX

1.1

Select Information Controller

1.2

Select Information C/U: Various Setup

1.3

Enter Date and Time

1.4

Enter Model and Serial No.

1.5

Information C/U: Initialize

Communication

1.6

Satellite Terminal: Initialize

1.7

Satellite Terminal Serial No. Check

1.8

Satellite Terminal, Communicating State Check

No Communication

2. Self-Diagnosing

T5-3-10

TROUBLESHOOTING / e-Wheel
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup

1.1 Select Information Controller

After starting Dr. ZX, push Select
Controller.

Push ICF Controller.

Push OK.

Select failure-diagnosis
controller

Select Function
+

Self-Diagnostic Result

Select Controller

Engine Controller

Main Controller

Monitor Controller

ICF Controller

ESC
Function Selection Screen

ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY

To the
lower

Is it correct?

ESC
Controller Selection Screen

OK

ESC

ICF Controller Screen

1.2 Select Information C/U: Various Setup

Push Information
Setup.

Push Start.

C/U:

Various

Select Item

Password

+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd

+
+

Select Item

Information C/U: Various

Setup
Data Download

Information C/U: Initialize

Enter Model and Serial

No.

Save Data Check

Enter Date and Time

Control Data: Initialize

Op. Manual
Start
Title Screen

Back

ESC
Main Menu Screen

T5-3-11

ESC
Information C/U: Various Setup
Screen

TROUBLESHOOTING / e-Wheel
1.3 Enter Date and Time
Push Enter Date and Time.
Push ESC and return to Main
Menu Screen.

Push Set and the focused item is

YY.
Push ESC and return to Information
C/U: Various Setup Screen.
Enter Date and Time

Select Item
+

Information C/U: Initialize

YY 2004 MM

01

HH

01

01

Enter Model and Serial

No.
Enter Date and Time

Control Data: Initialize

MM

DD

Set

ESC
Information C/U: Various Setup
Screen

01

ESC

YY, MM, DD, HH and MM

The focused item is displayed reversely.
At first, the focused item is YY.

YY, MM, DD, HH and MM

Move the focused item.
No repeat input.

Enter Date and Time Screen

YY, MM, DD, HH and MM

Value of the focused item is increased or
decreased one by one.
In case value is beyond maximum one: Change
value into the minimum one
In case value is below minimum one: Change
value into the maximum one
No repeat input.

Select Item
+

Information C/U: Various

Setup

Data Download

Save Data Check

ESC
Main Menu Screen

T5-3-12

TROUBLESHOOTING / e-Wheel
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: Initialize

To the
lower

ESC
Information C/U: Various Setup
Screen
After inputting model and serial No.,
push OK and return to Enter Model
and Serial No. Screen.
Push ESC and return to Information
C/U: Various Setup Screen.

Push Exec, and model and serial

No. can be input.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
Enter Model and Serial No.

Model

Enter Model and Serial No.

04GB

Select Item

Model |
Exec

Serial No. 000001

Exec

Push ESC and return to Main

Menu Screen.

ESC

ESC

Ex. Mach.No.(HCM4GB00P00
0001) Model(01G6)

Serial No.
Ex. Mach.No.(HCM4GB00P00
0001) Serial No.(000001)

OK

ESC

ESC
OK

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: Initialize

ESC
Information C/U: Various Setup
Screen

Enter Model and Serial No.

T5-3-13

TROUBLESHOOTING / e-Wheel
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: Initialize

To the
lower

ESC
Information C/U: Various Setup
Screen
Push Init and the controller
operating data are initialized.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

Information C/U: Initialize

Select Item

Is operation data erased?

Init

Initialization has been

completed.
Initialization has been
completed.

ESC

Init

ESC

Push ESC and return to Main

Menu Screen.

OK

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: initialize

ESC
Information C/U: Various Setup
Screen

Information C/U: Initialize Screen

T5-3-14

TROUBLESHOOTING / e-Wheel
1.6 Satellite Terminal: Initialize
Display the next screen of
Information C/U: Various Setup
Screen.

Push Satellite Terminal: Initialize.

Push ESC and return to Main
Menu Screen.
Select Item

Select Item
+ Information C/U: Initialize

+ Enter Model and Serial

No.

+ Enter Date and Time

+ Control Data: Initialize

Information C/U: Various Setup

Screen

Satellite Terminal: Initialize

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

ESC

Push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

ESC
Next Screen of Information C/U:
Various Setup Screen

Is Un-Transmit data erased?

Exec

ESC

Satellite Terminal: Initialize

Push OK and return to Information

C/U: Various Setup Screen.
Satellite Terminal: Initialize

Select Item
+

Un-Transmit data is erased.

+
+
+

OK

Select Item

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

Information C/U: Various

Setup

Data Download

Save Data Check

ESC
Information C/U: Various Setup
Screen

T5-3-15

ESC
Main Menu Screen

To the
lower

TROUBLESHOOTING / e-Wheel
1.7 Satellite Terminal Serial No. Check
Push
Satellite
Terminal
No.
Confirmation.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

Confirm serial no. (12 digits). Push

ESC and return to Information C/U:
Various Setup Screen.
Satellite Terminal No.
Confirmation

Select Item
+
+

Serial No. 8GBDA701862

+
+

ESC

ESC

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

ESC
Information C/U: Various Setup
Screen

Information C/U: Various Setup

Screen

Select Item
+

Information C/U: Various

Setup

Data Download

Save Data Check

ESC
Main Menu Screen

T5-3-16

TROUBLESHOOTING / e-Wheel
1.8 Satellite
Check

Terminal,

Push
Communicating
State
Check.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+

Communicating State

Check communicating state.

Communicating State Check

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

Comm.

UnCon

UnCon

OK

NG

Satellite Terminal
Power

ON

OFF

Comm.

Enable

Stop

ESC
Information C/U: Various Setup
Screen

Check the enclosed state.

ICFSatellite Terminal
Conn

UnCon: Faulty harness

NG: Faulty harness for Comm.
OFF: Faulty harness, Faulty controller
Stop: 1.9 Enter Satellite Comm. Start/Stop is
performed.

ESC
Communicating State Check
Rod Aerial

OK

NG

GPS Aerial

OK

NG

Wave State

ON

OFF

Un Transmit Data Number

0

Last Transmitting Time

When electrical wave of the satellite is caught,

the items are turned into OK.
IMPORTANT: Check this with the key of
machine ON in outdoor.
According to state of electrical
wave, it may take a little longer
time.

2004/07/01 135000

ESC

Select Item

Select Item

Information C/U: Various

Setup

Data Download

Save Data Check

ESC

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

ESC
Information C/U: Various Setup
Screen

Main Menu Screen

T5-3-17

TROUBLESHOOTING / e-Wheel
1.9 Enter Satellite Comm. Start/Stop
Push and move to the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+
+
+
+

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

To the
lower

ESC
Information C/U: Various Setup
Screen

In normal, Start is selected. When

stopping Satellite Comm., due to
some reasons, push Stop and
push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

Enter Satellite Comm. Start/Stop

Satellite Terminal UnTrasmit

State

Stop

Setting has been completed

ESC

Exec

ESC

Select Item
+
+

Exec
Start

Push ESC and return to Main

Menu Screen.

+
+

OK

Satellite Terminal: Initialize

Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop

ESC
Information C/U: Various Setup
Screen

CAUTION: This procedure need not be done

in normal.

T5-3-18

TROUBLESHOOTING / e-Wheel
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
+

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: Initialize

ESC
Information C/U: Various Setup
Screen

Push Init and the controller

operating data are initialized.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

Push ESC and return to Main

Menu Screen.
Select Item

Control Data: Initialize

+ Information C/U: Initialize

Is control data initialized?
Init

Initialization has been

completed.
Initialization has been
completed.

ESC

Init

ESC

+ Enter Model and Serial

No.
+ Enter Date and Time
+ Control Data: Initialize

OK

ESC
Information C/U: Various Setup
Screen

Control Data: Initialize Screen

T5-3-19

TROUBLESHOOTING / e-Wheel
2. Self-Diagnosing
After starting Dr. ZX,
Self-Diagnostic Result.

Push Fault of ICF Controller. If

there is no trouble, No Problem is
displayed.

push

Self-diagnosing of controllers
below hasn completed.

Select Function
+

Self-Diagnostic Result

Select Controller
Self-Diagnosing

Engine Controller

No Problem

Main Controller

Fault

To the
lower

Monitor Controller No Problem

ICF Controller

ESC

ESC

ESC

Function Selection Screen

Change the page and

the fault code in back
and forth is displayed.

Push Details, and Details and

Corrective Action are displayed.
Push ESC and Retry B Screen is
Displayed.

Push ESC and Retry B Screen is

Displayed.

ICF Controller
Problem was detected.
14000

Fault

Controller Self-Diagnosing Screen

Push Retry B and return to Controller

Self-Diagnosing Screen after controller
self-diagnsing.
Push ESC and return to Controller
Self-Diagnosing Screen.

Fault Code 14000-2

14001

Details

Details
CAN Communication Error

ESC

Corrective Action
1)Retry B
2)Check Harness
3)

Retry B
Do you want to escape?

ESC

Details

ESC

ESC

Fault Code Screen

Retry B
Retry B Screen

Execute
Retry B

Self-diagnosing of controllers
below hasn completed.
Engine Controller
Main Controller

ESC

No Problem
Fault

Monitor Controller No Problem

ICF Controller

Fault
ESC

Controller Self-Diagnosing Screen

T5-3-20

ESC

TROUBLESHOOTING / e-Wheel
(Blank)

T5-3-21

TROUBLESHOOTING / e-Wheel
LIST OF ICF FAULT CODE
Fault Code

Details

14000-2

Abnormal CAN Communication

CAN Communication Error

14001-2

Abnormal Flash Memory

Read / Write Error

14002-2

Abnormal External RAM

Read / Write Error

14003-2

Abnormal EPROM
Sum Check Error

Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Check the CAN communication line (check the
h retry) B in self-diagnosing and execute the following
Execute
item.
Execute 1.5 Information C/U: Initialize (T5-3-14).

Execute retry B in self-diagnosing.

If this error code is displayed after re-try, check the following
item.
1. Execute 1.4 Enter Model and Serial No. (T5-3-13).
2. Execute 1.10 Control Data: Initialize (T5-3-19).
Then, execute self-diagnosing and execute retry B.

14006-2

Communication Error
Execute retry B in self-diagnosing.
Impossible to communicate with MC If this error code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
Then, execute self-diagnosing and execute retry B.

14008-2

Abnormal RAM
Road / Write Error

Execute retry B in self-diagnosing.

If this error code is displayed after re-try, replace the
controller.

T5-3-22

TROUBLESHOOTING / e-Wheel
LIST OF FAULT CODE OF SATELLITE
COMMUNICATION TERMINAL
Fault Code

Details

14100-2

Inside Error
Abnormal EPROM

14101-2

Inside Error
Abnormal IB/OB Queue

14102-2

Inside Error
Abnormal Local Loup Back

14103-2

Communication Error
The satellite is not found.

14104-2

Inside Error
Fail 1 of Remote Loup Back

14105-2

Communication Error
Fail 2 of Remote Loup Back

14106-2

Abnormal Harness
Sending and receiving data are
unmatched.

Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, replace the
controller.

T5-3-23

TROUBLESHOOTING / e-Wheel
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for
maintenance of the machine, e-Service by
transmitting various data of the machine regularly via
a low earth orbit satellite.

Communication
Aerial
GPS
Aerial

NOTE: 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 satellite communication system using
a low earth orbit satellite 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 satellite communication system consists of
satellite communication terminal, GPS aerial and
communication aerial.
The functions of each equipment are:

Satellite Communication Terminal

T4GB-05-07-001

Satellite
Communication
Terminal

Receives the data from ICF and GPS aerial, and

sends the data to the communication aerial.
GPS Aerial
Receives location information of the machine
from a low earth orbit satellite.
Communication Aerial
Communicates the data with a low earth orbit
satellite.

T4GB-05-07-002

T5-3-24

TROUBLESHOOTING / e-Wheel
On the machine equipped with the satellite
communication system, the data are sent according to
the condition as follows:
Kinds of data sent from the machine by using satellite
communication:
Items
Kinds of Data
Periodical
Daily Report Data, Latest
Transmission
Information, Fuel Level

Condition
Location The data are sent once a day. In order to
avoid
congested
traffic
in
the
communication line, the data is sent
randomly between 0:00 and 02:00.
Transmitting Data at Latest Location Information
The data is sent only when the machine
Engine Start
is moved more than 5 km from the place
where it is recorded lastly.
Emergency
Alarm and Error Information
The transmission starts immediately
Transmission
when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information
The data is sent when the hour meter
Transmission
exceeds every 100 hours.

T5-3-25

TROUBLESHOOTING / e-Wheel
(Blank)

T5-3-26

TROUBLESHOOTING / Component Layout

MAIN COMPONENT LAYOUT (OVERVIEW)
1

4
5

12
7
11

10
9

T4GB-01-02-005

1 - Bucket
2 - Bell Crank

4 - Head Light
5 - Front Working Light

3 - Bucket Cylinder

6 - Rear Working Light

(Optional)

7 - Rear Working Light

8 - Rear Combination Light
(Turn Signal, Hazard Light
Clearance Light and Brake
Light)
9 - Turn Signal, Hazard Light
and Clearance Light

T5-4-1

10 - Lift Arm Cylinder

11 - Lift Arm

12 - Bucket Link

TROUBLESHOOTING / Component Layout

MAIN COMPONENT LAYOUT (UPPERSTRUCTURE)

20

21

19
18
17
16
15

6
7
8
9
10
14

13

12

11
T4GB-01-02-002

123456-

Charging Block
Pilot Valve
Brake Valve
Steering Pilot Valve
Steering Valve
Control Valve

78910 11 12 -

Stop Valve
Pilot Shutoff Valve
Engine Oil Filter
Pilot Filter
Engine
Fuel Tank

13 14 15 16 17 18 -

T5-4-2

Torque Converter Cooler

Oil Cooler
Fan Motor
Radiator
Inter Cooler
Reserve Tank

19 - Muffler
20 - Air Cleaner
21 - Hydraulic Tank

TROUBLESHOOTING / Component Layout

MAIN COMPONENT LAYOUT (TRAVEL SYSTEM)

2
3
4

7
T4GB-01-02-004

1 - Front Axle
2 - Propeller Shaft (Front)
3 - Steering Cylinder

45-

Pump Device
Transmission

5 - Rear Axle
6 - Propeller Shaft (Rear)

T5-4-3

7 - Steering Accumulator
8 - Brake Pressure Sensor

TROUBLESHOOTING / Component Layout

ELECTRIC COMPONENT LAYOUT (OVERVIEW)

14

Cab
(Refer to T5-4-5)

13
12

Engine and Fan Pump

(Refer to T5-4-10)

11

3
4

8
Pump Device
(Refer to T5-4-11)
Drive Unit
(Refer to T5-4-11)

10

T4GB-01-02-019

1 - Hydraulic Oil Level Switch

5-

Battery

2 - Air Filter Restriction Switch

3 - ECM

67-

Boost Pressure Sensor

Fuel Level Sensor

4 - Reverse Buzzer

8-

Hydraulic Oil
Temperature Sensor

7 - Emergency Steering
Pump Delivery Pressure
Switch
8 - Lift Arm Angle Sensor
(Optional)
9 - Bucket Proximity Switch

T5-4-4

10 - Lift Arm Proximity Switch

11 - Implement Pressure Sensor
12 - Out Side Temperature
Sensor

TROUBLESHOOTING / Component Layout

ELECTRICAL SYSTEM (CAB)

1
2
3
Monitor and Switches
(Refer to T5-4-8)

Right Consol
(Refer to T5-4-7)

Controller and Relays

(Refer to T5-4-6)
T4GB-01-02-006

1 - Radio
2 - Auxiliary Switch Panel
(Optional)

3 - Speaker
4 - Rear Wiper Motor

5 - Brake Lamp Switch

T5-4-5

6 - Front Wiper Motor

TROUBLESHOOTING / Component Layout

Controller and Relays

T4GB-01-02-006

11

15

16

17

18

19

20

21

22

23

24

12

13

14

10

1 - Flasher Relay
2 - Option Controller
(Optional)
3 - TCU

10 - Front Window Heater

Relay
11 - Neutral Relay
12 - Rear Window Heater Relay
13 - Wiper Relay (Left)

5 - ICF

14 - Wiper Relay (Right)

6 - Dr.ZX Connector

15 - Reverse Light Relay

(A-R5)
16 - Brake Light Relay (A-R4)

8 - Fog Light Relay (Optional)

9 - Auxiliary

26

27

28

29

30

31

32

33

34

T4GB-01-02-021

4 - MC

7 - Fuse Box

25

17 - High Beam Relay (A-R3)

18 - Head Light Relay (Right)
(A-R2)

T4GB-01-02-022

19 - Head Light Relay (Left)

(A-R1)
20 - Emergency Steering Relay
(A-R10)
21 - Hone Relay (A-R9)
22 - Turn Signal Relay (Right)
(A-R8)
23 - Working Light Relay (Rear)
(A-R7)
24 - Working Light Relay
(Front) (A-R8)
25 - Front Wiper Relay (B-R5)
26 - Neutral Relay (B-R4)

T5-4-6

27 - Load Dump Relay (B-R3)

28 - Parking Brake Relay
(B-R2)
29 - Parking Brake Relay
(B-R1)
30 - Fuel Pump Relay (B-R10)
31 - Main Relay (B-R9)
32 - Rear Washer Relay (B-R8)
33 - Turn Signal Relay (Left)
(B-R7)
34 - Rear Wiper Relay (B-R6)

TROUBLESHOOTING / Component Layout

Right Console

T4GB-01-02-006

9
10

18
17

16
15
14
13
12
T4GB-01-02-023

11
1 - Down Shift Switch
2 - Bucket Control Lever
3 - Lift Arm Control Lever
4 - Forward/Reverse Switch
5 - Hone Switch

6 - Auxiliary Control Lever

(Optional)
7 - Quick Coupler Switch (Optional)
8 - Lift Arm Auto Leveler Downward
Set Switch (Optional)
9 - Lift Arm Auto Leveler Upward
Set Switch (Optional)
10 - Front Control Lock Lever

11 - Emergency Steering Check

Switch
12 - Fan Reversing Switch
13 - Fog Light Switch (Optional)

15 - Forward/Reverse Selector
Switch
16 - Cigar Lighter
17 - Up-shift/Down-shift Switch

14 - Ride Control Switch

(Optional)

18 - Hold Switch

T5-4-7

TROUBLESHOOTING / Component Layout

Monitor and Switches

T4GB-01-02-006

14

13
12

4
5
11

6
7

10
9
8

1 - Monitor Panel
(Refer to T5-4-9)
2 - Driving Mode Switch
3 - Turn Signal Lever/Head Light
Switch/Dimmer Switch
4 - Parking Brake Switch

T4GB-01-02-024

5 - Work Mode Selector Switch

9 - Front Wiper Switch

12 - Rear Wiper Switch

6 - Clutch Cat Position Switch

10 - Forward/Reverse Lever and

Shift Switch
11 - Air Conditioner Switch
Panel

13 - Working Light Switch

7 - Ignition Key
8 - Steering Column Tilt
/Telescopic Lever

T5-4-8

14 - Hazard Light Switch

TROUBLESHOOTING / Component Layout

Monitor Panel

10

11

34

12

33

13
14
32

15

31

T4GB-01-02-001

30

29

28

1 - Coolant Temperature
Gauge
2 - Transmission Oil
Temperature Gauge
3 - Turn Signal Indicator
(Left)
4 - High Beam Indicator
5 - Working Light Indicator
6 - Turn Signal Indicator
(Right)
7 - Monitor Display
8 - Stop Indicator
9 - Service Indicator

27

26

25

24 23

22

10 - Parking Brake Indicator

21

20

19

18

11 - Clearance Light Indicator

19 - Lever Steering Indicator

(Optional)
20 - Monitor Mode Selector

12 - Fuel Gauge

21 - Glow Signal

13 - Brake Low Oil Pressure

Indicator
14 - Brake Low Oil Level
Indicator
15 - Emergency Steering
Indicator
16 - Low Steering Oil Pressure
Indicator
17 - Seat Belt Indicator

22 - Monitor Display Selector (Up)

23 - Maintenance Indicator
24 - Monitor Display selector
(Down)
25 - Forward/Reverse Switch
Indicator
26 - Water Separator Indicator

18 - Discharge Warning
Indicator

T5-4-9

17

16

27 - Engine Warning Indicator

28 - Overheat Indicator
29 - Engine Low Oil Pressure
Indicator
30 - Air Filter Restriction Indicator
31 - Transmission Warning
Indicator
32 - Transmission Oil Filter
Restriction Indicator
33 - Hydraulic Oil Temperature
Indicator
34 - Transmission Oil
Temperature Indicator

TROUBLESHOOTING / Component Layout

ENGINE AND FAN PUMP
1

10
11

4
14

13

12

T4GB-01-02-025

1 - Glow Plug

9 - EGR Valve

12 - Crank Revolution Sensor

2 - Injector

5 - Coolant Temperature
Sensor
6 - Overheat Switch

10 - Supply Pump

3 - Cam Angle Sensor

7 - Boost Pressure Sensor

11 - Fuel Temperature Sensor

13 - Engine Oil Pressure

Sensor
14 - Common Rail Pressure
Sensor

4 - Fan Pump

8 - Boost Temperature Sensor

T5-4-10

TROUBLESHOOTING / Component Layout

PUMP DEVICE

T4GB-01-02-009

DRIVE UNIT
7
View A

12

8
18
11

17

10

16

13
14
15

T4GB-01-02-026

1 - Main Pump

6 - Steering Relief Valve

2 - Regulator

7 - Air Breather

3 - Priority Valve

8 - Transmission Control
Valve
9 - Oil Filter

4 - Pump Delivery
Pressure Switch
5 - Pilot Pump

11 - Transmission Middle Shaft

Sensor
12 - Torque Converter Input Speed
Sensor
13 - Proportional Solenoid Valve Y1
(For High Speed Forward Clutch)
14 - Proportional Solenoid Valve Y2
(For Reverse Clutch)

10 - Torque Converter
Output Speed Sensor

T5-4-11

15 - Proportional Solenoid Valve Y3

(For 1st Speed Clutch)
16 - Proportional Solenoid Valve Y4
(For 3rd Speed Clutch)
17 - Proportional Solenoid Valve Y5
(For Low Speed Forward Clutch)
18 - Proportional Solenoid Valve Y6
(For 2nd Speed Clutch)

TROUBLESHOOTING / Component Layout

CONTROL VALVE
ZW220

5
4
1
2

3
T4GB-01-02-027

ZW250
5

T4GB-03-02-002

1 - Over Load Relief Valve

(Lift Arm: Bottom)
2 - Over Load Relief Valve
(Bucket: Bottom)

3 - Over Load Relief Valve

(Bucket: Rod)

4 - Make-up Valve
(Lift Arm: Rod)

T5-4-12

5 - Main Relief Valve

TROUBLESHOOTING / Component Layout

RIDE CONTROL VALVE (OPTIONAL)
1

CHARGING BLOCK

3
4

Unused

T4GB-01-02-014

FAN MOTOR
10

11

T4GB-01-02-013

PARKING BRAKE SOLENOID VALVE

12

14

13
15
T4GB-01-02-012

1 - Overload Relief Valve

2 - Ride Control Solenoid
Valve
3 - Ride Control Accumulator
4 - Pilot Accumulator

5 - Service Brake Accumulator

(Front)
6 - Service Brake Accumulator
(Rear)
7 - Relief Valve
8 - Pilot Relief Valve

T4GB-01-02-011

9 - Pump Torque Control

Solenoid Valve
10 - Reverse Control Solenoid
Valve
11 - Relief Valve
12 - Flow Control Solenoid
Valve

T5-4-13

13 - Parking Brake Pressure

Sensor
14 - Parking Brake Solenoid
Valve
15 - Parking Brake Accumulator

TROUBLESHOOTING / Component Layout

STEERING VALVE

T4GB-01-02-020

EMERGENCY STEERING PUMP

6
T4GB-01-02-010

1 - Overload Relief Valve

2 - Overload Relief Valve

3 - Electric Motor
4 - Gear Pump

5 - Check Valve

T5-4-14

6-

Relief Valve

TROUBLESHOOTING / Component Layout

(Blank)

T5-4-15

TROUBLESHOOTING / Component Layout

COMPONENTS IN CONTROL VALVE
ZW220

11

7
7

10

T5-4-16

T4GB-03-02-003

TROUBLESHOOTING / Component Layout

B
C
D

T4GB-03-02-004

1 - Bucket Flow Control Valve

2 - Negative Control Valve
3 - Overload Relief Valve
(Bucket: Bottom End)

4 - Overload Relief Valve

(Bucket: Rod End)
5 - Overload Relief Valve
(Lift Arm: Bottom End)
6 - Make-up Valve
(Lift Arm: Rod End)

7 - Restriction Valve
8 - Low-pressure Relief Valve
9 - Main Relief Valve

T5-4-17

10 - Load Check Valve

(Arm Lift Circuit)
11 - Load Check Valve
(Bucket Circuit)

TROUBLESHOOTING / Component Layout

ZW220

11

5
6

10

T5-4-18

T4GB-03-02-003

TROUBLESHOOTING / Component Layout

ZW220

9
Section A

T4GB-03-02-005

Section B
8

T4GB-03-02-006

1 - Bucket Flow Control Valve

2 - Negative Control Valve
3 - Overload Relief Valve
(Bucket: Bottom End)

4 - Overload Relief Valve

(Bucket: Rod End)
5 - Overload Relief Valve
(Lift Arm: Bottom End)
6 - Make-up Valve
(Lift Arm: Rod End)

7-

Restriction Valve

8-

Low-pressure Relief Valve

9-

Main Relief Valve

Refer to T5-4-17.

T5-4-19

10 - Load Check Valve

(Arm Lift Circuit)
11 - Load Check Valve
(Bucket Circuit)

TROUBLESHOOTING / Component Layout

ZW220

11

5
6

7
7

10

T5-4-20

T4GB-03-02-003

TROUBLESHOOTING / Component Layout

ZW220

Section C

10

Section D
4

11

Section E
2

T4GB-03-02-007

1 - Bucket Flow Control Valve

2 - Negative Control Valve
3 - Overload Relief Valve
(Bucket: Bottom End)

Refer to T5-4-17

4 - Overload Relief Valve

(Bucket: Rod End)
5 - Overload Relief Valve
(Lift Arm: Bottom End)
6 - Make-up Valve
(Lift Arm: Rod End)

7-

Restriction Valve

8-

Low-pressure Relief Valve

9-

Main Relief Valve

T5-4-21

10 - Load Check Valve

(Arm Lift Circuit)
11 - Load Check Valve
(Bucket Circuit)

TROUBLESHOOTING / Component Layout

ZW250

7
8

11

10
T4GB-03-02-008

T5-4-22

TROUBLESHOOTING / Component Layout

10
C
6

8
A

T4GB-03-02-009

1 - Flow Control Valve

(Poppet)
2 - Flow Control Valve
(Changeover Valve)
3 - Negative Control Valve

4 - Overload Relief Valve

(Bucket: Bottom End)
5 - Overload Relief Valve
(Bucket: Rod End)
6 - Overload Relief Valve
(Lift Arm: Bottom End)

7-

Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-

T5-4-23

Low-pressure Relief Valve

10 - Main Relief Valve

11 - Load Check Valve
(Lift Arm Circuit)

TROUBLESHOOTING / Component Layout

ZW250

6
8

7
8

11

10
T4GB-03-02-008

T5-4-24

TROUBLESHOOTING / Component Layout

Section A
11
7

Section B

5
4

T4GB-03-02-010

1 - Flow Control Valve

(Poppet)
2 - Flow Control Valve
(Changeover Valve)
3 - Negative Control Valve

4-

Overload Relief Valve

(Bucket: Bottom End)
5 - Overload Relief Valve
(Bucket: Rod End)
6 - Overload Relief Valve
(Lift Arm: Bottom End)

7-

Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-

Refer to T5-4-23
.

T5-4-25

Low-pressure Relief Valve

10 - Main Relief Valve

11 - Load Check Valve
(Lift Arm Circuit)

TROUBLESHOOTING / Component Layout

ZW250

7
8

10

11

T4GB-03-02-008

T5-4-26

TROUBLESHOOTING / Component Layout

Section C

10

Section D
C

Section E

T4GB-03-02-011

1 - Flow Control Valve

(Poppet)
2 - Flow Control Valve
(Changeover Valve)
3 - Negative Control Valve

4-

Overload Relief Valve

(Bucket: Bottom End)
5 - Overload Relief Valve
(Bucket: Rod End)
6 - Overload Relief Valve
(Lift Arm: Bottom End)

7-

Make-up Valve
(Lift Arm: for Rod)
8 - Restriction Valve
9-

Refer to T5-4-23.

T5-4-27

Low-pressure Relief Valve

10 - Main Relief Valve

11 - Load Check Valve
(Lift Arm Circuit)

TROUBLESHOOTING / Component Layout

COMPONENTS IN STEERING VALVE

Port T

Port A

Port B

Port Pa

Port Pb

Port A: Pressure for Steering

Right
Port P: From Main Pump

Port DR

Port P
Port LS

Port B: Pressure for Steering

Left
Port T: Return to Hydraulic Oil
Tank

Port Pa: Pilot Pressure for

Steering Right
Port LS: To Port LS of Priority
Valve

T5-4-28

T4GB-03-04-002

Port Pb: Pilot Pressure for

Steering Left
Port DR: Return to Hydraulic Oil
Tank

TROUBLESHOOTING / Component Layout

C
B

T4GB-03-04-001

1 - Spool
2 - Overload Relief Valve

3 - Overload Relief Valve

4 - Lord Check Valve

5 - Variable Orifice
6 - Fixed Orifice

T5-4-29

TROUBLESHOOTING / Component Layout

Port T

Port A

Port B

Port Pa

Port Pb

Port A: Pressure for Steering

Right
Port P: From Main Pump

Port DR

Port P
Port LS

Port B: Pressure for Steering

Left
Port T: Return to Hydraulic Oil
Tank

Port Pa: Pilot Pressure for

Steering Right
Port LS: To Port LS of Priority
Valve

T5-4-30

T4GB-03-04-002

Port Pb: Pilot Pressure for

Steering Left
Port DR: Return to Hydraulic Oil
Tank

TROUBLESHOOTING / Component Layout

Section A

Port P

Port DR

Port T
Section B

Port LS

Port B

Port A

2
Port Pb

Port Pa

Section C

T4GB-03-04-003

T4GB-03-04-006

1 - Spool
2 - Overload Relief Valve

3 - Overload Relief Valve

4 - Lord Check Valve

56-

: Refer to T5-4-29.

T5-4-31

Variable Orifice
Fixed Orifice

7 - Passage A

TROUBLESHOOTING / Component Layout

COMPONENTS IN CHARGING BLOCK

22

9
10
11

21

12
13
14
15

20

16
17

18

19

1 - Service Brake Accumulator

(Rear)
2 - Adaptor

9-

Priority Valve

3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor

11 - Port DR (To Hydraulic Oil Tank)

10 - Pilot Relief Valve

12 - Port DR2 (To Hydraulic Oil Tank)

13 - Port PS1
(To Steering Pilot Valve)
14 - Port X
To Main Pump Regulator
15 - Port S3 (To be adopted in EU
Specification Machines)

8 - Port P (From Pilot Pump)

T5-4-32

T4GB-03-06-002

16 - Port BR3 (to be adopted in EU

Specification Machines)
17 - Port PS2
(To Main Pump Regulator
and Ride Control Valve (Optional))
18 - Pilot Accumulator
19 - Port PP To Pilot Shutoff Valve
20 - Parking Brake Solenoid Valve
(To be adopted in EU Specification
Machines)
21 - Pump Torque Control Proportional
Solenoid Valve
22 - Relief Valve

TROUBLESHOOTING / Component Layout

Port for Attaching

Service Brake
Accumulator
(Rear)

Pump Torque
Control
Proportional
Solenoid Valve

Port for Attaching

Service Brake
Accumulator
(Front)

13

17
Port for Attaching
Pilot Accumulator

T4GB-03-06-001

T5-4-33

TROUBLESHOOTING / Component Layout

22

9
10
11

21

12
13
14
15

20

16
17

18

19

1 - Service Brake Accumulator

(Rear)
2 - Adaptor

9-

Priority Valve

3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor

11 - Port DR (To Hydraulic Oil Tank)

10 - Pilot Relief Valve

12 - Port DR2 (To Hydraulic Oil Tank)

13 - Port PS1
(To Steering Pilot Valve)
14 - Port X
To Main Pump Regulator
15 - Port S3 (To be adopted in EU
Specification Machines)

8 - Port P (From Pilot Pump)

T5-4-34

T4GB-03-06-002

16 - Port BR3 (to be adopted in EU

Specification Machines)
17 - Port PS2
(To Main Pump Regulator
and Ride Control Valve (Optional))
18 - Pilot Accumulator
19 - Port PP To Pilot Shutoff Valve
20 - Parking Brake Solenoid Valve
(To be adopted in EU Specification
Machines)
21 - Pump Torque Control Proportional
Solenoid Valve
22 - Relief Valve

TROUBLESHOOTING / Component Layout

11
Section V-V

10
Section U-U

14
12

21

Section T-T

15

16

20

19

Section S-S

18

T4GB-03-06-003

Refer to T5-4-33

T5-4-35

TROUBLESHOOTING / Component Layout

22

9
10
11

21

12
13
14

20

15
16
17

18

19

1 - Service Brake Accumulator

(Rear)
2 - Adaptor

9-

Priority Valve

3 - Port M2
(To Rear End of Brake Valve)
4 - Check Valve
5 - Port M1
(To Front End of Brake Valve
and Parking Brake)
6 - Service Brake Accumulator
(Front)
7 - Service Brake Pressure Sensor

11 - Port DR (To Hydraulic Oil Tank)

10 - Pilot Relief Valve

12 - Port DR2 (To Hydraulic Oil Tank)

13 - Port PS1
(To Steering Pilot Valve)
14 - Port X
To Main Pump Regulator
15 - Port S3 (To be adopted in EU
Specification Machines)

8 - Port P (From Pilot Pump)

T5-4-36

T4GB-03-06-002

16 - Port BR3 (To be adopted in EU

Specification Machines)
17 - Port PS2
(To Main Pump Regulator
and Ride Control Valve (Optional))
18 - Pilot Accumulator
19 - Port PP To Pilot Shutoff Valve
20 - Parking Brake Solenoid Valve
(To be adopted in EU Specification
Machines)
21 - Pump Torque Control Proportional
Solenoid Valve
22 - Relief Valve

TROUBLESHOOTING / Component Layout

Section Z-Z

Section Y-Y

Section X-X

Section W-W

22

Refer to T5-4-33

T5-4-37

T4GB-03-06-004

TROUBLESHOOTING / Component Layout

COMPONENTS IN RIDE CONTROL VALVE

Lift Arm
Cylinder

Ride Control
Accumulator

Ride Control Valve

SP

Pi

4
B
A

2
To Hydraulic Oil Tank
T

From Charging
Block
T4GB-03-08-002

1 - Ride Control Solenoid Valve

2 - Charge-cut Spool

3 - Overload Relief Valve

4 - Spool

5 - Drain Plug

T5-4-38

TROUBLESHOOTING / Component Layout

5
1

T4GB-03-08-001

T5-4-39

TROUBLESHOOTING / Component Layout

Lift Arm
Cylinder

Ride Control
Accumulator

Ride Control Valve

SP

Pi

4
B
A

2
To Hydraulic Oil Tank
T

From Charging
Block
T4GB-03-08-002

1 - Ride Control Solenoid Valve

2 - Charge-cut Spool

34-

Overload Relief Valve

Spool

5-

T5-4-40

Drain Plug

TROUBLESHOOTING / Component Layout

Section A

Port Pi

To Ride Control
Accumulator

Port SP

Port B

Port A

Port T

Refer to T5-4-39

T5-4-41

T4GB-03-08-003

TROUBLESHOOTING / Component Layout

SIDE VIEW OF TRANSMISSION
2

10
15

14

11

13
12

1 - Torque Converter
2 - Torque Converter Housing
3 - Torque Converter Input
Speed Sensor
4 - Breather

5 - Torque Transmission Middle

Shaft Sensor
6 - Torque Converter Output
Speed Sensor
7 - Transmission Case Cover
8 - Adaptor for Remote Filter

9-

Filter

10 - Parking Brake
11 - Front Accelerator Output
Flange
12 - Nameplate

T5-4-42

T4GB-03-09-002

13 - Drain Plug with Magnet

(M381.5)
14 - Rear Accelerator Output
Flange
15 - Transmission Case

TROUBLESHOOTING / Component Layout

FRONT VIEW OF TRANSMISSION
1

5
4

T4GB-03-09-003

1 - Main Pump Drive Shaft

3 - Parking Brake

2 - Transmission Control Valve

4 - Transmission Mount
Base

5 - Front Accelerator Output

Flange
6 - Filter

T5-4-43

7-

Adaptor for Remote Filter

TROUBLESHOOTING / Component Layout

PRESSURE SENSOR PORTS OF TRANSMISSION
1

10
5

6
7

View Y
11

11

12
Y
13

12
13

T4GB-03-09-009

1 - System Main Pressure

Measurement Port
2 - Torque Converter Input
Pressure Sensor Port

5 - Forward High-speed Clutch

Pressure Sensor Port
6 - Reverse Clutch Pressure
Sensor Port

8 - Three -speed Clutch

Pressure Sensor Port
9 - Forward Low-speed Clutch
Pressure Sensor Port

11 - Transmission Oil Cooler

Return Oil Sensor Port
12 - Transmission Oil Cooler
Output Oil Sensor

3 - Reduced Oil Pressure

Sensor Port
4 - Harness Connector

7 - Single-speed Clutch
Pressure Sensor Port

10 - Two -speed Clutch

Pressure Sensor Port

13 - Torque Converter Outlet

Temperature Sensor Port

T5-4-44

TROUBLESHOOTING / Component Layout

CROSS-SECTIONAL DRAWING OF TRANSMISSION

Section A-A (Refer to T5-4-43)

11

10
9

T4GB-03-09-004

123-

Single-speed Clutch
High-speed Forward Clutch
Reverse Switch

456-

Hydraulic Pressure Pump Drive

Low-speed Forward Clutch
Two-speed Clutch

T5-4-45

789-

Three-speed Clutch
Front Output Flange
Output Shaft

10 - Rear Output Flange

11 - Torque Converter

TROUBLESHOOTING / Component Layout

CROSS-SECTIONAL DRAWING OF TORQUE CONVERTER
4

On Main Pump
End

On Engine
End

11

12

10

13
T4GB-03-09-001

1 - Turbine
2 - Stator
3 - Impeller

456-

Oil Seal
Transmission Pump
Seal Ring

789-

T5-4-46

Impeller Shaft
High-speed Drive Gear
Low-speed Drive Gear

10 11 12 13 -

Turbine Shaft
Notch Ring
Drive Tube
Torque Converter Input
Shaft

TROUBLESHOOTING / Component Layout

CROSS-SECTIONAL DRAWING OF TRANSMISSION CONTROL VALVE

Valve Body

Pressure Control Valve

Pressure Reducing Valve

Connector

Middle Plate

System Main Pressure Oil

Reduced Pressure Oil

Return Oil

Converter Pressure Oil

Plate

Channel Plate

T107151

Pressure
Reducing Valve

Pressure
Control Valve

Proportional
Solenoid Valve
(6 Units)

Connector

Cover

Modulation
Circuit
Valve Body

Housing
Spool

Damper
Valve
T107153

T5-4-47

TROUBLESHOOTING / Component Layout

CIRCUIT OF DRIVE UNIT

High Speed
Forward Clutch

Damper
Valve

Reverse
Clutch

Speed 1
Clutch

Speed 3
Clutch

Low Speed
Forward Clutch

Speed 2
Clutch

Booster Valve

Y1
Proportional
Solenoid Valve

Y2

Y3

Y4

Transmission Oil
Temperature Sensor

Main Relief
Valve

Y5

Y6

Reducing
Valve

Torque Converter
Torque Converter
Relief Valve
Oil
Filter

Torque Converter
Back Pressure Valve

Oil Filter
By-pass Valve

Torque Converter
Oil Cooler
(Installed on the
Drive Unit)
Torque Converter
Oil Cooler
(Installed on the
Rear of Vehicle)

Oil Filter
Restriction Switch
Charging
Pump

T4GB-03-09-010

T5-4-48

TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing by using Dr. ZX
or the service mode of monitor unit.

How to Read Troubleshooting Flow Charts

YES (OK)

(2)

After completing the checking and/or measuring procedures in box (1),

select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1)
NO (NOT OK)

Key switch: ON

(3)

Instructions, reference, and/or inspection methods and/or measurements are occasionally

described under the box. If incorrectly checked or measured, not only will troubleshooting
be unsuccessful but also damage to the components may result.
Use Dr. ZX for descriptions in the double-line box.

Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.

NOTE: Harness end connector viewed from the

open end side by the all connectors image
shown in this section.

Harness
Open End
Side

Harness End Connector

T158-05-03-001

T5-5-1

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE LIST
Controller Hardware Failure
Fault
Trouble
Code
11000-2 Abnormal EPROM

Cause
Faulty MC

All Control

Faulty MC

All Control

11001-2

Abnormal RAM

11002-2

Abnormal A/D (Analog to Digi- Faulty MC

tal) Converter
Abnormal Sensor Voltage
Faulty sensor because
shorted circuit in harness
Faulty MC
CAN Communication Error
Faulty sensor because
shorted circuit in harness
Faulty MC

11003-3

11004-2

Influenced Control

T5-5-2

All Control
of All Control

of All Pump Control

All Transmission Control
All Engine Control
Hydraulic Drive Fan Cooling
Control
Ride Control
CAN Cycle Data Communication

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs

There is something wrong with machine operation.

Remark

Retrial B
Replace MC
There is something wrong with machine operation.
Retrial B
Replace MC
As the latest, normal value AD (analog to digital) is enabled, the Retrial B
machine may be operated incorrectly or slowly.
Replace MC
Inputs from all sensors are uncertain.
Retrial B
Check Harness
Replace MC
-1
As engine speed is kept at 1000 min (1000 rpm), the work may Retrial B
be inoperable.
Check CAN Harness
Replace MC

T5-5-3

TROUBLESHOOTING / Troubleshooting A
Engine Failure
Fault
Trouble
Code
11103-3 Abnormal Accelerator
High Voltage

11103-4

Abnormal Accelerator
Low Voltage

Cause

Influenced Control

Pedal Voltage: 4.75 V or higher

Pump Torque Decrease Control

Engine Accelerator Pedal
Control

Pedal Voltage: Less than 0.25 V

Pump Torque Decrease Control

Engine Accelerator Pedal
Control

T5-5-4

TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs

Remedy

The accelerator pedal is inoperable.

Retrial B
Engine speed kept at 1000 min-1 (1000 rpm), the work may be Check Harness
inoperable.
Replace Accelerator Pedal
Replace MC
The accelerator pedal is inoperable.
Retrial B
Engine speed kept at 1000 min-1 (1000 rpm), the work may be Check Harness
inoperable.
Replace Accelerator Pedal
Replace MC

T5-5-5

TROUBLESHOOTING / Troubleshooting A
Pump Failure
Fault
Trouble
Cause
Influenced Control
Code
11204-3 Abnormal Pump Delivery Output voltage: 4.75 V or Disable Pump Torque Decrease
Pressure Sensor High Volt- higher
Control
age

11204-4

Abnormal Pump Delivery Output voltage: Less than Disable Pump Torque Decrease
Pressure Sensor Low Voltage 0.25 V
Control

11209-3

Abnormal Implement Pres- Output voltage: 4.75 V or Disable Pump Torque Decrease
sure Sensor High Voltage
higher
Control

11209-4

Abnormal Implement Pres- Output voltage: Less than Disable Pump Torque Decrease
sure Sensor Low Voltage
0.25 V
Control

T5-5-6

TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs

Remedy

As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Pump Delivery Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Pump Delivery Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Implement Pressure Sensor
Replace MC
As the pump is controlled by pump standard torque control, work ef- Retrial B
ficiency of the front attachment becomes low.
Check Harness
Fuel consumption becomes bad.
Replace Implement Pressure Sensor
Replace MC

T5-5-7

TROUBLESHOOTING / Troubleshooting A
Pilot Failure
Fault
Trouble
Cause
Code
11313-3 Abnormal Parking Brake Pres- Output voltage: 4.75 V or higher
sure Sensor High Voltage
11313-4

Influenced Control
Parking Brake Indicator Control

Abnormal Parking Brake Pres- Output voltage: Less than 0.25 Parking Brake Indicator Consure Sensor Low Voltage
V
trol

T5-5-8

TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs

Remedy

As the parking brake is forcibly released, the machine can travel Retrial B
with the parking brake switch ON.
Check Harness
Replace Parking Brake Pressure Sensor
Replace MC
As the parking brake is forcibly released, the machine can travel Retrial B
with the parking brake switch ON.
Check Harness
Replace Parking Brake Pressure Sensor
Replace MC

T5-5-9

TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Failure
Fault
Trouble
Code
11412-2 Abnormal Feedback of Hydraulic
Drive Fan Flow Rate Control Solenoid Valve

Cause

Influenced Control

The feedback current Hydraulic Drive Fan Cooling Conto MC becomes the trol
uncertain value

11412-3

Abnormal Feedback High Current of The feedback current Hydraulic Drive Fan Cooling ConHydraulic Drive Fan Flow Rate Con- to MC exceeds the trol
trol Solenoid Valve
upper limit

11412-4

Abnormal Feedback Low Current of While the command Hydraulic Drive Fan Cooling ConHydraulic Drive Fan Flow Rate Con- from MC is output, the trol
trol Solenoid Valve
feedback current to MC
is 56 mA or less

11413-2

Abnormal Feedback of Pump Torque The feedback current Pump Standard Torque Control
Control Solenoid Valve
to MC becomes the
uncertain value

11413-3

Abnormal Feedback High Current of The feedback current Pump Standard Torque Control
Pump Torque Control Solenoid Valve to MC exceeds the
upper limit

11413-4

Abnormal Feedback Low Current of While the command Pump Standard Torque Control
Pump Torque Control Solenoid Valve from MC is output, the
feedback current to MC
is 56 mA or less

T5-5-10

TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
As the fan rotation is kept at maximum, the machine starts slowly.
Fuel consumption becomes bad.

Remedy

Retrial B
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the fan rotation is kept at maximum, the machine starts slowly. Retrial B
Fuel consumption becomes bad.
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the fan rotation is kept at maximum, the machine starts slowly. Retrial B
Fuel consumption becomes bad.
Check Harness (Feedback line from the
flow rate control solenoid valve to MC)
Replace Hydraulic Drive Fan Flow Rate
Control Solenoid Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC
As the pump is kept at minimum displacement, work efficiency of Retrial B
the front attachment becomes low.
Check Harness (Feedback line from the
torque control solenoid valve to MC)
Replace Pump Torque Control Solenoid
Valve
Replace MC

T5-5-11

TROUBLESHOOTING / Troubleshooting A
CAN Data Reception Failure
Fault
Trouble
Cause
Code
11910-2 Actual Engine Speed Receive Faulty Harness
Error
Faulty ECM
Received from ECM

Influenced Control
Pump Torque Decrease Control
Hydraulic Drive Fan Cooling
Control

11912-2

Torque Converter Rotation or Faulty Harness

Transmission Rotation Receive Faulty TCU
Error

Pump Torque Decrease Control

11913-2

Forward / Reverse Switch En- Faulty Harness

able Signal Receive Error
Faulty TCU

Engine Accelerator Pedal

Control (only when the forward / reverse switch is used)

11914-2

Radiator Coolant Temperature Faulty Harness

Receive Error
Faulty Monitor Unit
Received from Monitor Unit

Hydraulic Drive Fan Cooling

Control

11916-2

Selected Speed Position Re- Faulty Harness

ceive Error
Faulty TCU

Engine Speed Decrease Control

11917-2

Actual Speed Position Receive Faulty Harness

Error
Faulty TCU

Engine Speed Decrease Control

11920-2

Fuel Flow Rate Receive Error

Received from ECM

Faulty Harness
Faulty ECM

T5-5-12

TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs

Remedy

As the pump is controlled by standard torque control, work

efficiency of the front attachment becomes low.
As the fan rotation is always kept at maximum, the machine
starts slowly.
Fuel consumption becomes bad.
As the pump is controlled by standard torque control, work
efficiency of the front attachment becomes low.
Fuel consumption becomes bad.

Retrial B
Check CAN Communication Line
Replace ECM
Replace MC

The engine torque curve is not shifted.

Fuel consumption becomes bad.

Retrial B
Check CAN Communication Line
Replace TCU
Replace MC

Retrial B
Check CAN Communication Line
Replace TCU
Replace MC

As the fan rotation is always kept at maximum, the machine Retrial B

starts slowly.
Check CAN Communication Line
Fuel consumption becomes bad.
Replace Monitor Unit
Replace MC
As mode speed of the engine is disabled, the maximum rota- Retrial B
tion is selected.
Check CAN Communication Line
Fuel consumption becomes bad.
Replace TCU
Replace MC
As mode speed of the engine is disabled, the maximum rota- Retrial B
tion is selected.
Check CAN Communication Line
Fuel consumption becomes bad.
Replace TCU
Replace MC
The fuel consumption is not displayed on the monitor.

T5-5-13

Retrial B
Check CAN Communication Line
Replace ECM
Replace MC

TROUBLESHOOTING / Troubleshooting A
Other Failures
Fault
Trouble
Cause
Code
11901-3 Hydraulic
Oil
Temperature Voltage: 4.52 V or higher
Sensor High Voltage

11901-4

Hydraulic
Oil
Temperature Voltage: Less than 0.23 V
Sensor Low Voltage

T5-5-14

Influenced Control
Auto-Warming Up Control
Hydraulic Drive Fan Cooling
Control

Auto-Warming Up Control
Hydraulic Drive Fan Cooling
Control

TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs

Remedy

When temperature is low (hydraulic oil temperature is 0 C

(32 F) or less), the auto-warming up control is inoperable.
Fuel consumption becomes bad.
The hydraulic oil temperature calculating part is kept at
maximum.

Retrial B
Check Harness
Replace Hydraulic Oil Temperature Sensor
Replace MC

When temperature is low (hydraulic oil temperature is 0 C

(32 F) or less), the auto-warming up control is inoperable.
Fuel consumption becomes bad.
The hydraulic oil temperature calculating part is kept at
maximum.

Retrial B
Check Harness
Replace Hydraulic Oil Temperature Sensor
Replace MC

T5-5-15

TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODE LIST
Sensor System
Fault
Trouble
Code
636-2
Abnormal Cam Angle Sensor (No Signal)
636-2
723-2

723-2
636-7

172-3
172-4
110-3

Cause

Although the crank signal is present, the cam signal is

not present.
Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched.
Signal)
Abnormal Crank Speed Sensor (No Sig- Although the cam signal is present, the crank signal is
nal)
not present.
Abnormal Crank Speed Sensor (Abnor- The pulse of crank signal is not matched.
mal Signal)
Phase Mismatch of Cam Angle Sensor
The right cam pulse is not present at the gap in the
crank.

Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is beyond
(Abnormal High Voltage)
4.95 V in 3 minutes after the engine starts.
Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage)
0.1 V.
Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage)
4.85 V in 3 minutes after the engine starts.

110-4

Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below 0.1
(Abnormal Low Voltage)
V.

102-4

Abnormal Boost Pressure Sensor (Abnormal High Voltage)

Abnormal Boost Pressure Sensor (Abnormal Low Voltage)
Abnormal EGR Position (Brushless
spec.)

102-3
10001-3

108-4
108-3
174-3
174-4

Abnormal Atmospheric Pressure Sensor

(Abnormal High Voltage)
Abnormal Atmospheric Pressure Sensor
(Abnormal Low Voltage)
Abnormal Fuel Temperature Sensor (Abnormal High Voltage)
Abnormal Fuel Temperature Sensor (Abnormal Low Voltage)

Voltage at the boost pressure sensor is beyond 4.9 V.

Voltage at the boost pressure sensor is below 0.1 V
The condition which the output signal of EGR position
cannot be present in.

Voltage at the atmospheric pressure sensor is beyond

3.8 V.
Voltage at the atmospheric pressure sensor is below
0.5 V.
Voltage at the fuel temperature sensor is beyond 4.85
V in 3 minutes after the engine starts.
Voltage at the fuel temperature sensor is below 0.1 V.

T5-5-16

TROUBLESHOOTING / Troubleshooting A

FaultCode
(Tech 2)
While the engine runs, there is nothing abnormal While the engine runs, operate according to P0340
with machine operation.
standard of the crank sensor. When the enAfter the engine is stalled, the re-start is impossible. gine stops, the start is impossible (in order P0341
to prevent the engine from damaging).
The output power may decrease, white smoke may Operate according to standard of the cam P0335
occur and vibration may occur.
sensor.
The engine may be stalled. (If the cam senor is
P0336
normal, the engine can re-start.)
Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Backup

While the engine runs, there is nothing abnormal The timing chain and the belt do not turn P1345
with machine operation.
smoothly but turn in reverse.
After the engine is stalled, the re-start is impossible.
When starting: -10 C (14 F) (Start the engine although what state.)
When operating: 25 C (77 F) (Operate
normally.)
Normal temperature: When starting, dark smoke When starting: -20 C (-4 F) (Start the enmay occur and engine combustion sound may be- gine although what state.)
come loud.
When operating: 80 C (176 F) (Operate
While warming up with fresh air in low temperature: normally.)
Rough idle, engine stall or while smoke may occur.
Dark smoke occurs.
Boost pressure cannot be corrected.
Nothing special

P0113
P0112
P0118
P0117
P0238
P0237

There is influence to exhaust gas.

Dark smoke occurs at high altitude.

Nothing special

As the sensor input is not certain, it cannot P0487

be controlled. Exhaust gas becomes bad.
Operate the engine with EGR valve fully
close.
Atmospheric pressure 80 kPa (0.8 kgf/cm2, P0108
12 psi) (2000 m above the sea)
O0107
When starting: -20 C (-4 F) (Start the en- P0183
gine although what state.)
When operating: 70 C (158 F) (Operate P0182
normally.)

T5-5-17

TROUBLESHOOTING / Troubleshooting A

Fault
Code
157-3
157-4
100-4
100-3
105-3

105-4

Trouble

Cause

Abnormal Common Rail Pressure

(Abnormal High Voltage)
Abnormal Common Rail Pressure
(Abnormal Low Voltage)
Abnormal Engine Oil Pressure
(Abnormal High Voltage)
Abnormal Engine Oil Pressure
(Abnormal Low Voltage)
Abnormal Boost Temperature
(Abnormal High Voltage)

Sensor Voltage at the common rail pressure sensor is beyond

4.5 V.
Sensor Voltage at the common rail pressure sensor is below
0.7 V.
Sensor Voltage at the engine oil pressure sensor is beyond
4.85 V.
Sensor Voltage at the engine oil pressure sensor is below 0.1
V.
Sensor Voltage at the boost temperature sensor is beyond
4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 C (122 F).
Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1
(Abnormal Low Voltage)
V.

T5-5-18

TROUBLESHOOTING / Troubleshooting A

Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Backup

The engine may be stalled. The output power de- The supply pump can not be controlled.
creases.

Fault Code
(Tech 2)
P0193
P0192

There is no influence when operating the machine.

Nothing special

P0523
P0522

There is no influence when operating the machine.

Nothing special

P1113

P1112

T5-5-19

TROUBLESHOOTING/ Troubleshooting A

Fault Code
636-2
636-2
723-2
723-2
636-7

172-3
172-4
110-3
110-4
102-4
102-3
10001-3
108-4
108-3
174-3
174-4
157-3
157-4

Influence to Engine
Performance
(Presumption)
Abnormal Cam Angle Sensor (No No influence during
operation
Signal)
Abnormal Cam Angle Sensor After stopping, the
re-start is impossible.
(Abnormal Signal)
output
power
Abnormal Crank Speed Sensor (No No
decrease
Signal)
Abnormal Crank Speed Sensor
(Abnormal Signal)
Phase Mismatch of Cam Angle No influence during
Sensor
operation
After stopping, the
re-start is impossible.
output
power
Abnormal Intake-Air Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal Intake-Air Temperature
Sensor (Abnormal Low Voltage)
output
power
Abnormal
Coolant
Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal
Coolant
Temperature
Sensor (Abnormal Low Voltage)
output
power
Abnormal Boost Pressure Sensor No
decrease
(Abnormal High Voltage)
Abnormal Boost Pressure Sensor
(Abnormal Low Voltage)
Abnormal EGR Position (Brushless No
output
power
spec.)
change
output
power
Abnormal Atmospheric Pressure No
decrease
Sensor (Abnormal High Voltage)
Abnormal Atmospheric Pressure
Sensor (Abnormal Low Voltage)
output
power
Abnormal Fuel Temperature Sensor No
decrease
(Abnormal High Voltage)
Abnormal Fuel Temperature Sensor
(Abnormal Low Voltage)
power
Abnormal Common Rail Pressure Output
decrease: 70%
Sensor (Abnormal High Voltage)
Abnormal Common Rail Pressure
Sensor (Abnormal Low Voltage)
Trouble

T5-5-20

Operating Rank
(Current State)
A B C D

Remark

TROUBLESHOOTING/ Troubleshooting A

Fault Code
100-4
100-3
105-3
105-4

Influence to Engine
Operating Rank
Performance
(Current State)
(Presumption)
A B C D
output
power
Abnormal Engine Oil Pressure No

change
Sensor (Abnormal High Voltage)
Abnormal Engine Oil Pressure

Sensor (Abnormal Low Voltage)

Abnormal
Boost
Temperature

Sensor (Abnormal High Voltage)

Abnormal
Boost
Temperature

Sensor (Abnormal Low Voltage)

Trouble

Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.
IMPORTANT: When fault code 723-2 (abnormal
crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.

T5-5-21

Remark

TROUBLESHOOTING/ Troubleshooting A
External Device System
Fault Code

Trouble

Cause

10002-2

Abnormal EGR valve control

Difference between the target valve lift and actual position is

beyond 20%.

1347-0

Open circuit in suction control valve The suction control valve drive current is beyond 2400 mA or
drive system, Shorted circuit in + B or below 50 mA. Or, difference between the target current and
GND
actual current is 1000 mA or more.

651-3

Open circuit in injection nozzle 1 No monitor input signal of injector 1.

drive system

652-3

Open circuit in injection nozzle 2 No monitor input signal of injector 2.

drive system

653-3

Open circuit in injection nozzle 3 No monitor input signal of injector 3.

drive system

654-3

Open circuit in injection nozzle #4 No monitor input signal of injector 4.

drive system

655-3

Open circuit in injection nozzle 5 No monitor input signal of injector 5.

drive system

656-3

Open circuit in injection nozzle 6 No monitor input signal of injector 6.

drive system

987-3

Abnormal check engine lamp

No monitor signal of the check engine lamp

1485-2

Abnormal main relay system

Voltage in the main relay system is 1 V or less with the main

relay coil output ON.
Although the main relay coil output is turned OFF, the main
relay is kept ON.

T5-5-22

TROUBLESHOOTING/ Troubleshooting A

Presumptive Symptoms in Real Machine

Operation

Assumptive Conditions at Backup

Fault Code
(Tech 2)

There is influence to exhaust gas.

EGR cannot be controlled.

As exhaust gas becomes bad, EGR stops.

P0488

The engine may be stalled and the rotation

speed increases automatically and abnormally
according to open or shorted circuit condition.
Dark smoke occurs. Output power is too large.

The supply pump cannot be controlled.

Prevent the engine from increasing the rotation
speed automatically and abnormally (Protect the
engine).

P0090

Vibration of the engine is large, Rough idle, #1 injector cannot be controlled.

output power decrease, faulty increasing of Stop drive pulse output of #1 injector.
rotation speed, output power decrease
#2 injector cannot be controlled.
Stop drive pulse output of #2 injector.

P0201

#3 injector cannot be controlled.

Stop drive pulse output of #3 injector.

P0203

#4 injector cannot be controlled.

Stop drive pulse output of #4 injector.

P0204

#5 injector cannot be controlled.

Stop drive pulse output of #5 injector.

P0205

#6 injector cannot be controlled.

Stop drive pulse output of #6 injector.

P0206

There is no influence when operating the Nothing special

machine.
The engine cannot start.

P0202

P0650

Nothing

Electrical power is kept supplying to the Nothing

machine.

T5-5-23

P1625

TROUBLESHOOTING/ Troubleshooting A
Fuel System
Fault Code

Trouble

Cause
rail

pressure Common rail pressure is beyond 185 Mpa (1887 kgf/cm2,

26895 psi).

157-0

Abnormal common
(First stage)

157-0

Abnormal common rail pressure

(Second stage)

The first stage Abnormal common rail pressure is approved

and common rail pressure is beyond 190 Mpa (1938 kgf/cm2,
27622 psi).

157-2

Abnormal common rail pressure

(Pump over-pressure)

When DUTY to the suction control valve is 40 % or more, or

target pressure to the suction control valve is 90 mm3/sec or
less, actual rail pressure is 40 MPa (410 kgf/cm2, 5820 psi)
higher than the target rail pressure.

633-7

Pressure limiter open

The pressure limiter is open.

1239-1

No pressure to pump (Fuel leakage) When pressure to the suction control valve is 900 min-1 (900
rpm) or more, actual rail pressure is 15 Mpa (150 kgf/cm2,
2180 psi) or less.

T5-5-24

TROUBLESHOOTING/ Troubleshooting A

Presumptive Symptoms in Real Machine

Operation

Assumptive Conditions at Backup

Fault Code
(Tech 2)

Vibration of the engine may be large, Rough idle, Prevention the injection system (pump) from
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
occur, output power may be too large.

P0088

Vibration of the engine may be large, Rough idle, Prevention the injection system from damage
output power decrease may occur, faulty (Pressure is too much as PR is clogged.)
increasing of rotation speed, dark smoke may
occur, output power may be too large.

P0088

Vibration of the engine may be large, Rough idle, Prevention the injection system (pump) from
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
occur, output power may be too large.

P0089

Output power decrease

P1095

Common rail pressure is beyond the allowable

pressure.
Vibration of the engine may be large, Rough idle, Fuel leakage is too much.
output power decrease may occur, faulty Actual rail pressure does not increase to the
increasing of rotation speed, dark smoke may required pressure.
occur, output power may be too large.

T5-5-25

P0087
P1093

TROUBLESHOOTING/ Troubleshooting A

Fault
Code

Influence to Engine
Performance
(Presumption)

Trouble

Operating Rank
(Current)
A

10002-2 Abnormal EGR valve control

1347-0

651-3
652-3
653-3
654-3
655-3
656-3
987-3
1485-2

Fault
Code
157-0
157-0
157-2
633-7
1239-1

No
output
power

change
Open circuit in suction control valve Output
power
drive system, Shorted circuit in + B or decrease: 50%
GND

Open circuit in PCV1 drive system,

shorted circuit in GND
power
Open circuit in injection nozzle 1 Output

decrease: 15%
drive system
Open circuit in injection nozzle 2 (Five cylinders drive.)

drive system
Open circuit in injection nozzle 3

drive system
Open circuit in injection nozzle 4

drive system
Open circuit in injection nozzle 5

drive system
Open circuit in injection nozzle 6

drive system
Abnormal check engine lamp
No
output
power

change
Abnormal main relay system
The engine stops.
Nothing (The engine
cannot
re-start

according to battery
voltage.)

Remark

Influence to Engine
Performance
(Presumption)

Trouble

Abnormal common rail pressure (First Output

stage)
decrease: 50%
Abnormal common rail pressure
Output
(Second stage)
decrease: 50%
Abnormal common rail pressure
Output
(Pump over-pressure)
decrease: 50%
Pressure limiter open
Output
decrease: 50%
No pressure to pump (Fuel leakage)
Output
decrease: 50%

Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.

T5-5-26

power
power
power
power
power

Operating Rank
(Current)
A

Remark

TROUBLESHOOTING/ Troubleshooting A
(Blank)

T5-5-27

TROUBLESHOOTING/ Troubleshooting A
Engine Protection System
Fault Code

Trouble

110-0

Overheating

190-0

Overrunning

Cause
Coolant temperature is beyond 120 C (248 F) when
operating the engine.
In case the engine speed is beyond 2500 min-1 (2500 rpm)

T5-5-28

TROUBLESHOOTING/ Troubleshooting A

Presumptive Symptoms in Real Machine

Fault Code
Assumptive Conditions at Backup
Operation
(Tech 2)
There is no influence when operating the Nothing special (The history of overheating is
P1173
machine.
recorded.)
Engine speed of the wheel loader may not Mistake of gear change, etc.
P0219
increase 2500 min-1 (2500 rpm) or more.

T5-5-29

TROUBLESHOOTING/ Troubleshooting A

Fault
Code

Influence to Engine
Performance
(Presumption)

Trouble

110-0

Overheating

190-0

Overrunning

No
output
change
No
output
decrease

Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.

T5-5-30

power
power

Operating Rank
(Current)
A

Remark

TROUBLESHOOTING/ Troubleshooting A
(Blank)

T5-5-31

TROUBLESHOOTING/ Troubleshooting A
Internal Circuit System
Fault Code

Trouble

Cause

10005-1

Abnormal Charge Circuit (Bank 1)

In case voltage at bank 1 of charge circuit in ECM is low

10006-1

Abnormal Charge Circuit (Bank 2)

In case voltage at bank 2 of charge circuit in ECM is low

10008-2

1077-2

Abnormal A/D Converter (Analog to A/D conversion (analog to digital) cannot be done.
Digital)
Abnormal CPU
Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)CPU is recovered.
Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)CPU is not recovered.
Abnormal IC for CPU Watching
No change of RUN-SUB pulse in 20 msec

628-2

Abnormal ROM

ROM is broken.

10013-2

Abnormal EPROM

EPROM is broken.

1079-2

Abnormal 5 V Power Source 1

Voltage
Abnormal 5 V Power Source 2
Voltage
Abnormal 5 V Power Source 3
Voltage
Abnormal 5 V Power Source 4
Voltage
Abnormal 5 V Power Source 5
Voltage
Abnormal Injection Nozzle Common
1 Drive System
Abnormal Injection Nozzle Common
2 Drive System

When battery voltage is between 16 V and 32 V, voltage

IGKEY power source is 5.5 V or more or 4.5 V or less.
When battery voltage is between 16 V and 32 V, voltage
IGKEY power source is 5.5 V or more or 4.5 V or less.
When battery voltage is between 16 V and 32 V, voltage
IGKEY power source is 5.5 V or more or 4.5 V or less.
When battery voltage is between 16 V and 32 V, voltage
IGKEY power source is 5.5 V or more or 4.5 V or less.
When battery voltage is between 16 V and 32 V, voltage
IGKEY power source is 5.5 V or more or 4.5 V or less.
No monitor input signals of injectors 1, 3, 5

10007-2

1080-2
10009-2
10010-2
10011-2
10003-2
10004-2

No monitor input signals of injectors 2, 4, 6

T5-5-32

of
of
of
of
of

TROUBLESHOOTING/ Troubleshooting A

Presumptive Symptoms in Real Machine

Operation
Vibration of the engine may be large, Rough idle,
output power decrease may occur, faulty
increasing of rotation speed may occur, the
engine may be stalled.

The injector cannot be controlled.

Stop output of drive signal at broken common
side
(Protect the engine from damage)

Output power decrease, dark smoke occurs.

All analogue sensor cannot be used.

P1630

Output power decrease

CPU is broken.

P0606

Assumptive Conditions at Backup

The engine cannot start.

Fault Code
(Tech 2)
P0611
P0612

P0606

Output power decrease

Sub CPU is broken.

P0606

The engine stops.

Data of ROM cannot be read.

P1601

There is no influence when operating the Data cannot be written to EPROM.

machine.
Same as Abnormal accelerator sensor

P1603

Same as Abnormal atmospheric and in-take

temperature sensors
Same as Abnormal coolant temperature, fuel
temperature and hydraulic oil pressure sensors
Same as Abnormal boost pressure and boost
temperature sensors
Same as Abnormal rail pressure and EGR
position sensors
Vibration of the engine may be large, Rough idle,
output power decrease may occur, faulty
increasing of rotation speed may occur, the
engine may be stalled.

P1632

P1633

P1634

P1635

The injector cannot be controlled.

Stop output of drive signal at broken common
side
(Protect the engine from damage)

P1261

T5-5-33

P1631

P1262

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

10005-1
10006-1

Abnormal Charge Circuit (Bank 1)

Abnormal Charge Circuit (Bank 2)

10008-2

Abnormal A/D Converter

10007-2

Abnormal CPU

1077-2

Abnormal IC for CPU watching

628-2
10013-2

Abnormal ROM
Abnormal EPROM

1079-2
1080-2

Abnormal 5 V Power Source 1 Voltage

Abnormal 5 V Power Source 2 Voltage

10009-2

Abnormal 5 V Power Source 3 Voltage

10010-2

Abnormal 5 V Power Source 4 Voltage

10011-2

Abnormal 5 V Power Source 5 Voltage

10003-2

Abnormal Injection Nozzle Common 1

Drive System
Abnormal Injection Nozzle Common 2
Drive System

10004-2

Influence to Engine
Performance
(Presumption)
Output
power
decrease: 60%
(Three cylinders drive.)
Output
power
decrease: 50%
Output
power
decrease: 50%
The engine cannot
start.
Output
power
decrease: 50%
The engine stops.
No
output
power
decrease
Idle speed operation
No
output
power
decrease
No
output
power
change
No
output
power
decrease
Output
power
decrease: 50%
Output
power
decrease: 60%
(Three cylinders drive.)

Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.

T5-5-34

Operating Rank
(Current)
A B C D

Remark

TROUBLESHOOTING/ Troubleshooting A
(Blank)

T5-5-35

TROUBLESHOOTING/ Troubleshooting A
Communication System
Fault Code

Trouble

Cause

639-2

Abnormal CAN Bus Line

Detect the bus line off.

639-3

Abnormal CAN Time Out

In case the CAN data reception is not approved in prescribed

time

T5-5-36

TROUBLESHOOTING/ Troubleshooting A

Presumptive Symptoms in Real Machine

Operation
Speed is turned into idle speed.

Assumptive Conditions at Backup

CAN communication is inoperable.

Fault Code
(Tech 2)
U2104
U2106

T5-5-37

TROUBLESHOOTING/ Troubleshooting A

Fault
Code

Trouble

639-2
639-3

Abnormal CAN Bus Line

Abnormal CAN Time Out

Influence to Engine
Performance
(Presumption)
Idle speed

Operating Rank
A: Digging and travel are operable. (A few
performance decreases may occur.)
B: Machine can travel on flat and downward slope.
C: The engine can stop / start.
D: The engine cannot stop / start.

T5-5-38

Operating Rank
(Current)
A B C D

Remark

TROUBLESHOOTING/ Troubleshooting A
(Blank)

T5-5-39

TROUBLESHOOTING/ Troubleshooting A
TCU FAULT CODE LIST
Fault Code

Trouble

Cause

Broken harness between shift switch and TCU

Shorted circuit in power circuit or grounding to the vehicle

5000-12

Signal Error in Shift Switch

5010-12

Faulty shift switch

Signal Error in Forward/Reverse Broken harness between forward/reverse lever and TCU
Lever
Short in power circuit or grounding to the vehicle frame

5040-12

Faulty forward/reverse lever

Signal Error in Forward/Reverse Broken harness between forward/reverse switch and TCU
Switch
Short in power circuit or grounding to the vehicle frame

frame because of faulty harness

because of faulty harness

5110-3

Transmission
Oil
Sensor High Voltage

5110-4

Transmission
Oil
Sensor Low Voltage

Temperature

Temperature

5313-12

Brake Pedal Sensor Signal Error

5140-3

Abnormal Torque Converter Input

Shaft Sensor High Voltage
Feedback voltage to TCU: 7.00 V or
more

5140-4

because of faulty harness

Faulty forward/reverse switch
Short in power circuit because of faulty harness
No connection to TCU harness
Internal fault in the temperature sensor
Short in power circuit by the connector pin or broken
connector pin
Grounding to vehicle frame because of faulty harness
Internal fault in the temperature sensor
Grounding to vehicle frame by the connector pin
Faulty harness
Internal fault in the temperature sensor

Short in power circuit because of faulty harness

No connection to TCU harness
Internal fault in the rotation sensor
Short in power circuit by the connector pin or faulty
connection of connector pin
Abnormal Torque Converter Input Grounding to vehicle frame because of faulty harness
Shaft Sensor Low Voltage
Internal fault in the rotation sensor
Feedback voltage to TCU: 0.45 V or
less

5140-12

Torque Converter Input Shaft Sensor Faulty contact because of faulty harness or faulty
Signal Error
connector
Feedback voltage to TCU: Uncertain Internal fault in the rotation sensor
value
Sensor mounting space error

5150-3

Abnormal Torque Converter Output

Shaft Sensor High Voltage
Feedback voltage to TCU: 7.00 V or
more

Short in power circuit because of faulty harness

No connection to TCU harness
Internal fault in the rotation sensor
Short in power circuit by the connector pin or faulty
connection of connector pin

T5-5-40

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU
Fixed to neutral

Repair Procedure

Check the harness between TCU and shift switch

Check the combination signal at each speed stage in the
shift switch

Fixed to neutral

Check the harness between TCU and forward/reverse

lever

Check the combination signal of each position at F-N-R

speed stage in the forward/reverse lever
Fixed to neutral

Check the harness between TCU and forward/reverse

switch

Check the combination signal of each position at F-N-R

speed stage in the forward/reverse switch

Check the harness between TCU and sensor

Check the connectors
Check the sensor

Although fixed to neutral during clutch cut control,

when the clutch cut position switch is turned OFF,
machine can travel.
Connect the clutch according to the backup
program.
Shock when shifting travel speed may become
strong.

Check the harness between TCU and sensor

Check the connectors
Check the sensor
Check the harness between TCU and sensor
Check the connectors
Check the sensor
Check the harness between TCU and sensor
Check the connectors
Check the rotation sensor (1050 at 20 )

Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor (1050 at 20 )
strong.
Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor
strong.
Check the sensor gap (1050 at 20 )
Connect the clutch according to the backup Check the harness between TCU and sensor
program.
Check the connectors
Shock when shifting travel speed may become Check the rotation sensor (1050 at 20 )
strong.
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.

T5-5-41

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

Cause

5150-4

Abnormal Torque Converter Output Grounding to vehicle frame because of faulty harness
Shaft Sensor Low Voltage
Internal fault in the rotation sensor
Feedback voltage to TCU: 0.45 V or
less

5150-12

Torque Converter Output Shaft Faulty short because of faulty harness or faulty connector
Sensor Signal Error
Internal fault in the rotation sensor
Feedback voltage to TCU: Uncertain Sensor mounting space error
value

5160-3

Abnormal Transmission Intermediate

Shaft Sensor High Voltage
Feedback voltage to TCU: 7.00 V or
more

5160-4

Short in power circuit because of faulty harness

No connection to TCU harness
Internal fault in the rotation sensor
Short in power circuit by the connector pin or faulty
connection of connector pin
Abnormal Transmission Intermediate Grounding to vehicle frame because of faulty harness
Shaft Sensor Low Voltage
Internal fault in the rotation sensor
Feedback voltage to TCU: 0.45 V or
less

5160-12

Transmission Intermediate Shaft Faulty short because of faulty harness or faulty connector
Sensor Signal Error
Internal fault in the rotation sensor
Feedback voltage to TCU: Uncertain Sensor mounting space error
value

5170-3

Abnormal Travel Speed Sensor High

Voltage
Feedback voltage to TCU: 7.00 V or
more

5170-4

Short in power circuit because of faulty harness

No connection to TCU harness
Internal fault in the rotation sensor
Short in power circuit by the connector pin or faulty
connection of connector pin
Abnormal Travel Speed Sensor Low Grounding to vehicle frame because of faulty harness
Voltage
Internal fault in the travel speed sensor
Feedback voltage to TCU: 1.00 V or
less

5170-12

Travel Speed Sensor Signal Error

Faulty short because of faulty harness or faulty connector
Feedback voltage to TCU: Uncertain Internal fault in the travel speed sensor
value
Sensor gap dimension error

5180-2

Travel Speed Sensor Pulse Output Internal fault in the travel speed sensor
Error
Sensor gap dimension error

T5-5-42

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Connect the clutch according to the backup program.

Shock when shifting travel speed may become strong.
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.
Connect the clutch according to the backup program.
Shock when shifting travel speed may become strong.
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.
Connect the clutch according to the backup program.
Shock when shifting travel speed may become strong.

Check the harness between TCU and sensor

Check the connectors
Check the rotation sensor (1050 at 20 )

Connect the clutch according to the backup program.

Shock when shifting travel speed may become strong.

Check the harness between TCU and sensor

Check the connectors
Check the rotation sensor (1050 at 20 )

Check the harness between TCU and sensor

Check the connectors
Check the rotation sensor (1050 at 20 )

Connect the clutch according to the backup program.

Shock when shifting travel speed may become strong.

If the travel speed sensor is abnormal, return the
Connect the clutch according to the backup program.
Shock when shifting travel speed may become strong.

forward/reverse lever to neutral and operate again.

Then, machine can travel at first or second speed
Special mode when selecting the gear
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.
Special mode when selecting the gear
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.
Special mode when selecting the gear
If the travel speed sensor is abnormal, return the
forward/reverse lever to neutral and operate again.
Then, machine can travel at first or second speed
stage.

Check the harness between TCU and sensor

Check the connectors
Check the rotation sensor
Check the sensor gap (1050 at 20 )

Check the harness between TCU and sensor

Check the connectors
Check the rotation sensor
Check the sensor gap (1050 at 20 )
Check the harness between TCU and sensor
Check the connectors
Check the rotation sensor (1050 ohm at 20 )

Check the harness between TCU and sensor

Check the connectors
Check the travel speed sensor (1050 at 20 )

Check the harness between TCU and sensor

Check the connectors
Check the travel speed sensor (1050 at 20 )
Check the sensor gap

Check the travel speed sensor (1050 at 20 )

Check the sensor gap
Check the harness between TCU and sensor

T5-5-43

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

Cause

5480-3

Abnormal
First
Stage
Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

5480-4

Abnormal
First
Stage
Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Faulty short to other proportional solenoid valve output
circuit in TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve

5480-5

Open Circuit in First Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5490-3

Abnormal Second Stage Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

5490-4

Abnormal Second Stage Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU
Internal fault in the proportional solenoid valve

5490-5

Open Circuit in Second Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5500-3

Abnormal Third Stage Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

T5-5-44

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Turn TCU to neutral.

Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission

T5-5-45

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

Cause

5500-4

Abnormal Third Stage Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve

5500-5

Open Circuit in Third Stage Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5510-3

Abnormal Fast Forward Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

5510-4

Abnormal Fast Forward Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve

5510-5

Open Circuit in Fast Forward Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5520-3

Abnormal Slow Forward Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

T5-5-46

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Turn TCU to neutral.

Check the harness between TCU and control valve
After returning the forward/reverse lever to neutral,
transmission
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission

T5-5-47

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

Cause

5520-4

Abnormal Slow Forward Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve

5520-5

Open Circuit in Slow Forward Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5530-3

Abnormal
Reverse
Clutch Short in power circuit because of faulty harness or faulty
Proportional Solenoid Valve High
connector
Voltage
Internal fault in the proportional solenoid valve

5530-4

Abnormal
Reverse
Clutch Grounding to vehicle frame because of faulty harness or
Proportional Solenoid Valve Low
faulty connector
Voltage
Short to other proportional solenoid valve output circuit in
TCU because of faulty harness or faulty connector
Internal fault in the proportional solenoid valve

5530-5

Open Circuit in Reverse Clutch Faulty contact of harness, connector and TCU
Proportional Solenoid Valve
Internal fault in the proportional solenoid valve

5560-4

Abnormal Reverse Light

Exciting Circuit Low Voltage

Relay Grounding to vehicle frame because of faulty harness

Internal fault in the reverse light relay
Grounding connector pin to vehicle frame

5560-3

Abnormal Reverse Light

Exciting Circuit High Voltage

Relay Short in power circuit because of faulty harness

Internal fault in the reverse light relay
Short in power circuit by the connector pin

T5-5-48

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Turn TCU to neutral.

Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Turn TCU to neutral.
Check the harness between TCU and control valve
transmission
After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or Check the connector between TCU and control valve
second speed stage.
transmission
If other proportional solenoid valve is abnormal, TCU Check resistance in the proportional solenoid valve (19
is fixed to neutral.
at 20 )
Check the internal harness in control valve transmission
Check the harness between TCU and reverse light
relay
Check the connector between TCU and reverse light
relay
Check reverse light relay
Check the harness between TCU and reverse light
relay
Check the connector between TCU and reverse light
relay
Check reverse light relay

T5-5-49

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

Cause

5560-5

Faulty Open Circuit in Reverse Light Faulty connection of harness and TCU
Relay Exciting Circuit
Internal fault in the reverse light relay
TCU detects wrong voltage similar to Faulty contact of connector and TCU
voltage during faulty open circuit.

5620-4

Abnormal Output Signal Circuit of Grounding to vehicle machine because of faulty harness
Transmission Failure Low Voltage
Internal fault in the monitor unit
Grounding the connector pin to vehicle frame
Open Circuit in Output Signal Circuit Faulty connection of harness and TCU
of Transmission Failure
Internal fault in the monitor unit
Faulty connection of connector and TCU
Abnormal Output Signal Circuit of Short in power circuit because of faulty harness
Transmission Failure High Voltage
Internal fault in the monitor unit
Short in power circuit by the connector pin
First Stage Clutch Slipping
First stage clutch pressure is low.
When operating the first stage clutch, Main clutch pressure is low.
if the value calculated by the signal of Faulty transmission intermediate shaft sensor
transmission
intermediate
shaft Faulty travel speed sensor
sensor is different from the actual Sensor mounting space error
value of travel speed sensor, TCU Faulty clutch
determines that the clutch slipping
occurs.

5620-5

5620-3

5660-2

5665-2

Second Stage Clutch Slipping

When operating the second stage
clutch, if the value calculated by the
signal of transmission intermediate
shaft sensor is different from the
actual value of travel speed sensor,
TCU determines that the clutch
slipping occurs.

Second stage clutch pressure is low.

Main clutch pressure is low.
Faulty transmission intermediate shaft sensor
Faulty travel speed sensor
Sensor mounting space error
Faulty clutch

5670-2

Third Stage Clutch Slipping

When operating the third stage
clutch, if the value calculated by the
signal of transmission intermediate
shaft sensor is different from the
actual value of travel speed sensor,
TCU determines that the clutch
slipping occurs.

Third stage clutch pressure is low.

Main clutch pressure is low.
Faulty transmission intermediate shaft sensor
Faulty travel speed sensor
Sensor mounting space error
Faulty clutch

T5-5-50

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Check the harness between TCU and reverse light relay

Check the connector between reverse light relay and

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,

operate again. Then, machine can travel at first or

Check the harness between TCU and monitor unit

Check the connector between monitor unit and TCU
Check monitor unit
Check the harness between TCU and monitor unit
Check the connector between monitor unit and TCU
Check monitor unit
Check the harness between TCU and monitor unit
Check the connector between monitor unit and TCU
Check monitor unit
Check first stage clutch pressure
Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor

second speed stage.

If other clutch is abnormal, TCU is fixed to neutral.

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or
second speed stage.
If other clutch is abnormal, TCU is fixed to neutral.

Check second stage clutch pressure

Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor

Check the sensor gap in travel speed sensor

Check the signal of transmission intermediate shaft

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,

operate again. Then, machine can travel at first or
second speed stage.
If other clutch is abnormal, TCU is fixed to neutral.

TCU
Check reverse light relay

sensor
Check the signal of travel speed sensor

Check third stage clutch pressure

Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor

T5-5-51

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

5675-2

Fast Forward Clutch Slipping

When operating the fast forward
clutch, if the value calculated by the
signal of transmission intermediate
shaft sensor is different from the
actual value of travel speed sensor,
TCU determines that the clutch
slipping occurs.

Fast forward clutch pressure is low.

Main clutch pressure is low.
Faulty transmission intermediate shaft sensor
Faulty travel speed sensor
Sensor mounting space error
Faulty clutch

5680-2

Fast Slow Clutch Slipping

When operating the slow forward
clutch, if the value calculated by the
signal of transmission intermediate
shaft sensor is different from the
actual value of travel speed sensor,
TCU determines that the clutch
slipping occurs.

Slow forward clutch pressure is low.

Main clutch pressure is low.
Faulty transmission intermediate shaft sensor
Faulty travel speed sensor
Sensor mounting space error
Faulty clutch

5685-2

Reverse Clutch Slipping

When operating the reverse clutch, if
the value calculated by the signal of
transmission
intermediate
shaft
sensor is different from the actual
value of travel speed sensor, TCU
determines that the clutch slipping
occurs.

Reverse clutch pressure is low.

Main clutch pressure is low.
Faulty transmission intermediate shaft sensor
Faulty travel speed sensor
Sensor mounting space error
Faulty clutch

5700-0

Overheating Transmission Oil

TCU detects higher oil temperature
than allowable value.
Clogged Engine Oil Filter
Oil filter contamination
TCU detects pressure difference Broken the harness and connector, or faulty connection to
beyond allowable range.
power circuit from the harness and connector
Faulty transmission oil filter restriction switch

5730-0

5745-15

Overrunning
TCU detects transmission output
speed beyond the specified value.

5755-15

Over-Transmission Input Torque

TCU detects transmission output
torque beyond the specified value.

Cause

T5-5-52

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,
operate again. Then, machine can travel at first or
second speed stage.
If other clutch is abnormal, TCU is fixed to neutral.

Check fast forward clutch pressure

Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor

Check the sensor gap in travel speed sensor

Check the signal of transmission intermediate shaft

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,

operate again. Then, machine can travel at first or
second speed stage.
If other clutch is abnormal, TCU is fixed to neutral.

Turn TCU to neutral.

After returning the forward/reverse lever to neutral,

operate again. Then, machine can travel at first or
second speed stage.
If other clutch is abnormal, TCU is fixed to neutral.

sensor
Check the signal of travel speed sensor
Replace the clutch
Check slow forward clutch pressure
Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor
Replace the clutch
Check reverse clutch pressure
Check main system pressure
Check the sensor gap in transmission intermediate
shaft sensor
Check the sensor gap in travel speed sensor
Check the signal of transmission intermediate shaft
sensor
Check the signal of travel speed sensor
Replace the clutch
Machine cooling
Check oil level
Check the sensor
Check the transmission oil filter
Check the harness between TCU and restriction switch
Check the restriction switch (resistance measurement)

TCU may be fixed to neutral.

T5-5-53

TROUBLESHOOTING/ Troubleshooting A

Fault Code
5770-4

5770-3

5770-5

5810-3

5810-4

Trouble

Cause

Abnormal Forward/Reverse Switch Grounding to vehicle machine because of faulty harness

Enable Signal Circuit Low Voltage
Internal fault in the monitor unit
Grounding the connector pin to vehicle frame
Abnormal Forward/Reverse Switch Short in power circuit because of faulty harness
Enable Signal Circuit High Voltage
Internal fault in the monitor unit
Short in power circuit by the connector pin
Open Circuit in Forward/Reverse Faulty connection of harness and TCU
Switch Enable Signal Circuit
Internal fault in the monitor unit
Faulty connection of connector and TCU
Abnormal Sensor Power Source
High Voltage
6 V or more at terminal #3 (for 5 V
sensor) in TCU

5820-4

Abnormal Sensor Power Source Low

Voltage
4 V or less at terminal #3 (for 5 V
sensor) in TCU
Power Source Voltage Decrease
Measurement voltage at the power source is 18 V or less.

5820-3

Power Source Voltage Increase

Measurement voltage at the power source is 32.5 V or

more.

5830-2

Proportional Solenoid Valve Power

Source Error
While power from CPU in TCU is
supplied to terminals #12 and #13,
measuring CPU detects low voltage,
or while power from CPU in TCU is
not supplied to terminals #12 and
#13, measuring CPU detects voltage.

Short in harness or connector and power circuit

Grounding the harness and connector to vehicle frame
No power from fuse #3 in the fuse box
Internal failure in TCU

T5-5-54

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Check the harness between TCU and monitor unit

Check the harness between monitor unit and TCU
Faulty monitor unit
Check the harness between TCU and monitor unit
Check the harness between monitor unit and TCU
Faulty monitor unit
Check the harness between TCU and monitor unit
Check the harness between monitor unit and TCU
Faulty monitor unit
Check the harness and connector from terminal #3 in
TCU
Check the power at terminal #3 in TCU (5V)
Replace TCU

Check the harness and connector from terminal #3 in

Fixed to neutral

Fixed to neutral

Fixed to neutral

TCU
Check the power at terminal #3 in TCU (5V)
Replace TCU
Check fuse #7 in fuse box A and fuse #3 in fuse box B
Check the harness and connector between fuse #7 in
fuse box A, fuse #3 in fuse box B and TCU
Check fuse #7 in fuse box A and fuse #3 in fuse box B
Check the harness and connector between fuse #7 in
fuse box A, fuse #3 in fuse box B and TCU
Check fuse #3 in fuse box B
Check the harness between transmission control valve
and TCU
Check the connector between transmission control
valve and TCU
Replace TCU

T5-5-55

TROUBLESHOOTING/ Troubleshooting A

Fault Code

Trouble

5890-2

Broken EPROM
TCU cannot make out the memory.
Broken Program
Transmission control is disabled.
Application Error
Application is defective.
Learning Failure in Transmission
Learning Control Program
No Correcting Data of Transmission
Learning Control Program and
Clutch Cut Control Pressure

5900-13
5910-13
5930-7
5930-13

Cause

Faulty TCU
Failure in data save
Install new TCU or the used one for other machine
One of the learning values in transmission learning control
program is beyond normal range.
Failure in data save to the memory
New TCU

T5-5-56

TROUBLESHOOTING/ Troubleshooting A

Behavior of TCU

Repair Procedure

Replace TCU
Fixed to neutral.

Replace TCU

Fixed to neutral.

Replace TCU

Fixed to neutral.

Check the clutch

Clutch cut control is disabled.

Execute transmission learning control program

Re-install transmission learning control program

T5-5-57

TROUBLESHOOTING/ Troubleshooting A
ICF FAULT CODE LIST
Fault Code
14000-2
14001-2

Trouble

Cause

Abnormal CAN Communication

Data cannot be received due to the noise on the CAN bus

line.
ICF: Flash Memory: Read / Write In case the internal memory is abnormal when the key is
Error
turned ON

14002-2

ICF: External RAM: Read / Write In case the internal memory is abnormal when the key is
Error
turned ON

14003-2

ICF: EPROM: Sum Check Error

14006-2

14008-2

In case the internal memory is abnormal when the key is

turned ON
ICF:
Satellite
Communication In case communication to the satellite terminal cannot be
Terminal: Communication Error
done over 30 seconds.

ICF: Abnormal Internal RAM

In case the internal memory is abnormal when the key is

turned ON

T5-5-58

TROUBLESHOOTING/ Troubleshooting A

Remedy
If trouble is not resolved after retrial B, check for CAN communication bus line.
After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
If the error code is displayed after re-try, ICF may be broken.
Replace ICF.
NOTE: When initializing the information C/U, all stored data is deleted.
After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
If the error code is displayed after re-try, ICF may be broken.
Replace ICF.
NOTE: When initializing the information C/U, all stored data is deleted.
If trouble is not resolved after retrial B, ICF may be broken. Replace ICF.
Check for the items below.
1. Retrial B.
2. Check if the communication line is abnormal.
3. Check if the electrical power source of communication terminal is abnormal.
Electrical power source
Fuses
3. Check if the satellite terminal is broken.
Re-try in the troubleshooting by using Dr.ZX.
If the error code is displayed after re-try, ICF may be broken. Replace ICF.

T5-5-59

TROUBLESHOOTING/ Troubleshooting A
SATELLITE TERMINAL FAULT CODE LIST
Fault Code
14100-2
14101-2
14102-2

Trouble

Cause

Satellite Communication Terminal: In case internal memory is abnormal

Abnormal EPROM
Satellite Communication Terminal: In case internal memory is abnormal
Abnormal IB/OB Queue
Satellite Communication Terminal: In case data cannot be received from the satellite terminal
Abnormal Local Loup Back

14103-2

Satellite Communication Terminal: In case the satellite terminal cannot be acquired

The satellite is not found.

14104-2

Satellite Communication Terminal:

Fail 1 of Remote Loup Back
Satellite Communication Terminal:
Fail 2 of Remote Loup Back
Satellite Communication Terminal:
Sending and receiving data are
unmatched.

14105-2
14106-2

In case communication to the satellite terminal base cannot

be done
In case communication to the satellite terminal base cannot
be done
In case sending and receiving data are unmatched

T5-5-60

TROUBLESHOOTING/ Troubleshooting A

Remedy
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Check the communication aerial.
Replace the ICF controller.
Retrial B.
Check the communication aerial.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.
Retrial B.
Replace the ICF controller.

T5-5-61

TROUBLESHOOTING/ Troubleshooting A
MONITOR UNIT FAULT CODE LIST
Fault Code

Trouble

Cause

13306-2
13308-2
13312-2

Abnormal EPROM
Abnormal CAN Communication
Abnormal
Transmission
Oil
Temperature Sensor
Service Brake Pressure Sensor High
Voltage
Service Brake Pressure Sensor Low
Voltage

When failure reading EPROM occurs

Bus off occurs beyond five times
Shorted ground circuit in the transmission oil temperature
sensor
Voltage at the signal line in service brake pressure sensor:
4.75 V or higher
Voltage at the signal line in service brake pressure sensor:
0.25 or less

13314-3
13314-4

T5-5-62

TROUBLESHOOTING / Troubleshooting A
CONTROLLER HARDWARE FAILURE
MC FAULT CODES 11000 to 11002
Fault Code
11000-2
11001-2
11002-2

Trouble
Abnormal EPROM
Abnormal RAM
Abnormal A/D Converter

Cause
Faulty MC
Faulty MC
Faulty MC

YES

Influenced Control
All Control
All Control
All Control

*Normal.

Check if operation of machine

is normal.
Faulty MC.
NO

* When the fault code is displayed in the result of

retrial and If operation of engine or machine is
normal, the machine can be used.

T5-5-63

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
Fault Code
11003-3

Trouble
Abnormal Sensor Voltage

Cause
Shorted circuit in harness
Faulty sensor
Faulty MC

Influenced Control
All Control

YES
Disconnect connectors of
all sensors corresponding
to the displayed fault code
and connector monitor-1B
in monitor unit. Retry.
Check if fault code
11003-3 disappears.
NO

Faulty any sensors.

Disconnect all connectors at
MC end.
Check for continuity
between terminals #1 and
#3 of harness end
connector of each sensor to
MC, terminal #1 and vehicle
frame.
Check for continuity
between terminals #27 and
#32 of connector
monitor-1B in monitor unit,
each terminal #27, #28,
#29, #30 or #31 and vehicle
frame.

YES

Shorted circuit in harness with

continuity.

Faulty MC or faulty monitor

unit.

NO

Key switch: OFF

Connector (Harness end of connector viewed from the

open end side)

Parking Brake Pressure Sensor

Pump Delivery Pressure Sensor

Implement Pressure Sensor

Monitor Unit
Connector Monitor-1B
(Harness end)
#27
#28

T4GB-05-05-002

#32 #31 #30 #29

T5-5-64

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Fault Code
11004-2

Trouble
Cause
Abnormal
CAN Shorted harness
Communication
Faulty MC

Influenced Control
All Pump Control
All Transmission Control
All Engine Control
Hydraulic Drive Fan Cooling Control
Ride Control
CAN Cycle Data Communication

GPS
Monitor Unit

Dr-ZX
ICF
TCU

ECM

CAN Harness

MC

T5-5-65

TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
Check the wiring connections first.

NO
YES Check for continuity in
CAN harness between
MC and ECM.

YES

Key switch: OFF

Refer to CAN
Harness Continuity
Check on T5-5-70.

Check for continuity in

CAN harness between
MC and ICF.
Key switch: OFF
Refer to CAN
Harness Continuity
Check on T5-5-71.

Retry by using Dr. ZX.

Check if fault code
11004-2 is displayed.

NO

Open circuit in CAN

harness between MC and
ECM.

Check for continuity

in CAN harness
YES between MC and
monitor unit.
Key Switch: OFF
Refer to CAN
Harness Continuity
Check on T5-5-72.
Open circuit in CAN
harness between MC and
ICF.

Normal.
NO

IMPORTANT: If the CAN harness is completely

opened in circuit, the controller
name not displayed on the
diagnosing screen on Dr. ZX (refer to
T5-2-4).

T5-5-66

TROUBLESHOOTING / Troubleshooting A

Shorted circuit in CAN

harness between ground
circuit and CAN circuit.

YES
Disconnect all
connectors in MC,
ICF, ECM, TCU and
monitor unit.
YES Check for continuity
between CAN circuit
and ground circuit in
MC, ICF, ECM, TCU
and monitor unit.

Check for continuity

YES in CAN harness
between MC and
TCU.

Key switch: OFF

Refer to Discontinuity
Check between CAN
Circuit and Ground
Circuit on T5-5-74 to
79.

Key switch: OFF

Refer to CAN
Harness Continuity
Check on T5-5-73.

To A

NO

Open circuit in CAN

harness between MC and
TCU.

NO

Open circuit in CAN

harness between MC and
monitor unit.

NO

Shorted circuit in CAN

harness between power
circuit and CAN circuit.

YES

Check for continuity

between CAN circuit
and power circuit in
MC, ICF, ECM, TCU
and monitor unit.
Key switch: OFF
Refer to Discontinuity
Check between CAN
Circuit and Power
Circuit on T5-5-80 to
84.

NO

T5-5-67

Check for continuity

between CAN circuit
and key signal circuit
in MC, ICF, ECM,
TCU and monitor
unit.

YES Shorted circuit in CAN

harness between key signal
circuit and CAN circuit.

NO
Key switch: OFF
Refer to Discontinuity
Check between CAN
Circuit and Key Signal
Circuit on T5-5-85 to
88.

Check for continuity

between High side
and Low side in CAN
harness.
Key switch: OFF
Refer to
Discontinuity Check
in CAN Harness on
T5-5-89.

To B

TROUBLESHOOTING / Troubleshooting A

Shorted circuit in
CAN harness.

YES

Connect connector
YES in MC.
Check if fault code
11004-2 is
displayed.

Connect all
connectors except
connector MC-C in
MC.
Check if resistance
between terminals
#C4 and #C15 of
NO harness end of
connector MC-C is
within 6010 .

Key switch: ON

Key switch: OFF

NO

Connect connector in
MC. Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .

Faulty MC.
YES

YES

NO

MC
Connector MC-C
(Harness end)
#C4

NO

Check the
connection of ICF
and connector.
Faulty ICF.

YES

Connect connector in
ICF.
Disconnect
connector in ECM.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector is within
12010 .

YES

Key switch: OFF

NO

Connect connector
in ECM. Check if
fault code 11004-2
is displayed.
Key switch: ON

#C15
C10

C1

C23

Connect connector
in ICF.
Check if fault code
11004-2 is
displayed.
Key switch: ON

Key switch: OFF

Connector

Check the
connection of MC
and connector.

NO

C31

Connect connector in
ECM.
Disconnect
connector monitor-2B
in monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF

ICF
Connector ICF-C
(Harness end)
#C5

#C11
ECM
Connector
(Harness end)

T1V1-05-04-002

Monitor Unit
Connector Monitor-2B
(Harness end)
#18

#37

T1GR-05-04-002

T5-5-68

T4GB-05-05-002

#34

#33

TROUBLESHOOTING / Troubleshooting A

Check the connection of

ECM and connector.

NO

Faulty ECM.
YES

YES

Faulty monitor unit.

YES

Key switch: ON

NO

Check the connection of

monitor unit and
connector.

NO

Connect connector in
monitor unit.
Check if fault code
11004-2 is displayed.

Connect connector in
monitor unit.
Disconnect connector
in TCU.
Check if resistance
between terminals #25
and #26 of harness
end of connector is
within 12010 .

Connect connector in
YES TCU.
Check if fault code
11004-2 is displayed.

NO

Check the connection of

TCU and connector.
Faulty TCU.

YES

Failure in any controller

of MC, ICF, ECM, TCU
and monitor unit.

NO

#25
#26

T4GB-05-05-001

T5-5-69

TROUBLESHOOTING / Troubleshooting A
Continuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.

Between MC and ECM

CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #18 of harness end of connector in ECM.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #37 of harness end of connector in ECM.
Connector
MC
Connector MC-C
(Harness end)
#C4
C1

C23

#C15
C10

C31

ECM
Connector
(Harness end)
#18

#37

T1GR-05-04-002

T5-5-70

TROUBLESHOOTING / Troubleshooting A
Between MC and ICF
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #C5 of harness end of connector ICF-C
in ICF.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #C11 of harness end of connector ICF-C
in ICF.

Connector
MC
Connector MC-C
(Harness end)
#C4

#C15
C10

C1

C23

C31

ICF
Connector ICF-C
(Harness end)
#C5

#C11

T1V1-05-04-002

T5-5-71

TROUBLESHOOTING / Troubleshooting A
Between MC and Monitor Unit
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #B33 of harness end of connector
monitor-2B in the monitor unit.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #B34 of harness end of connector
monitor-2B in the monitor unit.

Connector
MC
Connector MC-C
(Harness end)
#C4

#C15
C10

C1

C23

C31

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#B34

#B33

T5-5-72

TROUBLESHOOTING / Troubleshooting A
Between MC and TCU
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #25 of harness end of connector in TCU.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #26 of harness end of connector in TCU.

Connector
MC
Connector MC-C
(Harness end)
#C4
C1

C23

#C15
C10

C31

TCU
Connector
(Harness end)

#25
#26

T4GB-05-05-001

T5-5-73

TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit
between CAN circuit and ground
circuit is shorted.
In case of discontinuity, the circuit is
normal.

Connector
Connector MC-C
(Harness end)
#C4
C10

C1

C23

MC
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.

C31

Connector MC-A
(Harness end)
#A2

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal
#A13 of harness end of connector in MC-A.
#A13

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal #B8
of harness end of connector in MC-B.

T183-05-04-008

Connector MC-B
(Harness end)

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal
#B18 of harness end of connector in MC-B.

#B8

#B18
T183-05-04-021

T5-5-74

TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Ground
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.

Connector

Check for continuity between terminal #C15 of

harness end of connector MC-C and terminal
#A13 of harness end of connector in MC-A.
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #B8
of harness end of connector in MC-B.
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal
#B18 of harness end of connector in MC-B.

Connector MC-C
(Harness end)
#C15
C10

C1

C23

C31

Connector MC-A
(Harness end)
#A2

#A13
T183-05-04-008

Connector MC-B
(Harness end)
#B8

#B18
T183-05-04-021

T5-5-75

TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminals #18 and
#1 of harness end of connector.

ECM
Connector
(Harness end)
#18

#43

Check for continuity between terminals #18 and

#3 of harness end of connector.

#4
#3

Check for continuity between terminals #18 and

#4 of harness end of connector.
#62

Check for continuity between terminals #18 and

#43 of harness end of connector.

#1

T1GR-05-04-002

#81

Check for continuity between terminals #18 and

#62 of harness end of connector.
Check for continuity between terminals #18 and
#81 of harness end of connector.

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminals #37 and
#1 of harness end of connector.

ECM
Connector
(Harness end)

#37

#43
#4

Check for continuity between terminals #37 and

#3 of harness end of connector.
Check for continuity between terminals #37 and
#4 of harness end of connector.
Check for continuity between terminals #37 and
#43 of harness end of connector.
Check for continuity between terminals #37 and
#62 of harness end of connector.
Check for continuity between terminals #37 and
#81 of harness end of connector.

T5-5-76

#3

#62
#81

#1

T1GR-05-04-002

TROUBLESHOOTING / Troubleshooting A
ICF
Between CAN Circuit (High Side) and Ground
Circuit

ICF
Connector ICF-C
(Harness end)

Check for continuity between terminals #C5 and

#C9 of harness end of connector ICF-C.

#C5

Check for continuity between terminals #C5 and

#C14 of harness end of connector ICF-C.
Check for continuity between terminals #C5 and
#C15 of harness end of connector ICF-C.

Between CAN Circuit (Low Side) and Ground

Circuit

#C14

#C15

Check for continuity between terminals #C11 and

#C15 of harness end of connector ICF-C.

T5-5-77

T1V1-05-04-002

ICF
Connector ICF-C
(Harness end)
#C9

Check for continuity between terminals #C11 and

#C9 of harness end of connector ICF-C.
Check for continuity between terminals #C11 and
#C14 of harness end of connector ICF-C.

#C9

#C14

#C15

#C11

T1V1-05-04-002

TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #33 of
harness end of connector monitor-2B and terminal
#19 of harness end of connector monitor-2A in the
monitor unit.
Check for continuity between terminal #33 of
harness end of connector monitor-2B and terminal
#4 of harness end of connector monitor-1A in the
monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#33
Monitor Unit
Connector Monitor-2A
(Harness end)

T183-05-04-013

#19
Monitor Unit
Connector Monitor-1A
(Harness end)

#4

T183-05-04-013

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminal #34 of
harness end of connector monitor-2B and terminal
#19 of harness end of connector monitor-2A in the
monitor unit.
Check for continuity between terminal #34 of
harness end of connector monitor-2B and terminal
#4 of harness end of connector monitor-1A in the
monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#34
Monitor Unit
Connector Monitor-2A
(Harness end)

T183-05-04-013

#19
Monitor Unit
Connector Monitor-1A
(Harness end)

#4

T183-05-04-013

T5-5-78

TROUBLESHOOTING / Troubleshooting A
TCU

#1

Between CAN Circuit (High Side) and Ground

Circuit
Check for continuity between terminals #25 and
#1 of harness end of connector in TCU.
Check for continuity between terminals #25 and
#2 of harness end of connector in TCU.

#2

#25

T4GB-05-05-001

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminals #26 and
#1 of harness end of connector in TCU.
Check for continuity between terminals #26 and
#2 of harness end of connector in TCU.

#1

#2

#26

T4GB-05-05-001

T5-5-79

TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit

Connector

IMPORTANT: Before continuity check, turn the key

switch OFF.
In case of continuity, the circuit
between CAN circuit and power
circuit is shorted.
In case of discontinuity, the circuit is
normal.

Connector MC-C
(Harness end)
#C4
C1

C23

C10

C31

MC
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A1
of harness end connector MC-A.

#A1

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal
#A12 of harness end connector MC-A.

#A12

Connector MC-A
(Harness end)

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal #B7
of harness end connector MC-B.

T183-05-04-008

Connector MC-B
(Harness end)
#B7

Check for continuity between terminal #C4 of

harness end of connector MC-C and terminal
#B17 of harness end connector MC-B.
#B17
T183-05-04-021

T5-5-80

TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Power
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2
of harness end connector MC-A.

Connector
Connector MC-C
(Harness end)

Check for continuity between terminal #C15 of

harness end of connector MC-C and terminal
#A12 of harness end connector MC-A.

C1

Check for continuity between terminal #C15 of

harness end of connector MC-C and terminal #B7
of harness end connector MC-B.
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal
#B17 of harness end connector MC-B.

C23

#C15

C10

C31

Connector MC-A
(Harness end)

#A1

#A12
T183-05-04-008

Connector MC-B
(Harness end)
#B7

#B17
T183-05-04-021

T5-5-81

TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #18 and
#2 of harness end of connector.

ECM
Connector
(Harness end)
#18

#5

Check for continuity between terminals #18 and

#5 of harness end of connector.

T1GR-05-04-002

#2

Between CAN Circuit (Low Side) and Power

Circuit
Check for continuity between terminals #37 and
#2 of harness end of connector.

ECM
Connector
(Harness end)

#37

#5

Check for continuity between terminals #37 and

#5 of harness end of connector.
#2

ICF
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #C5 and
#C1 of harness end of connector ICF-C.

ICF
Connector ICF-C
(Harness end)

Check for continuity between terminals #C5 and

#C2 of harness end of connector ICF-C.

#C1

#C2

T1GR-05-04-002

#C5

T1V1-05-04-002

Between CAN Circuit (Low Side) and Power

Circuit
Check for continuity between terminals #C11 and
#C1 of harness end of connector ICF-C.

ICF
Connector ICF-C
(Harness end)
#C2

Check for continuity between terminals #C11 and

#C2 of harness end of connector ICF-C.

#C1

#C11

T5-5-82

T1V1-05-04-002

TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and
Circuit
Check for continuity between terminal
harness end of connector monitor2B
monitor unit and terminal #1 of harness
connector monitor1A in the monitor unit.

Power
#33 of
in the
end of

Monitor Unit
Connector Monitor-2B
(Harness end)

#33

T4GB-05-05-002

Monitor Unit
Connector Monitor-1A
(Harness end)
#1

T183-05-04-013

Between CAN Circuit (Low Side) and Power

Circuit
Check for continuity between terminal #34 of
harness end of connector monitor2B in the
monitor unit and terminal #1 of harness end of
connector monitor1A in the monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

#34

T4GB-05-05-002

Monitor Unit
Connector Monitor-1A
(Harness end)
#1

T183-05-04-013

T5-5-83

TROUBLESHOOTING / Troubleshooting A
TCU
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #25 and
#23 of harness end of connector in TCU.
#25

Check for continuity between terminals #25 and

#68 of harness end of connector in TCU.

#23
#68
T4GB-05-05-001

Between CAN Circuit (Low Side) and Power

Circuit
Check for continuity between terminals #26 and
#23 of harness end of connector in TCU.
Check for continuity between terminals #26 and
#68 of harness end of connector in TCU.

#26

#23
#68
T4GB-05-05-001

T5-5-84

TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit

Connector

IMPORTANT: Before continuity check, turn the key

switch OFF.
In case of continuity, the circuit
between CAN circuit and key signal
circuit is shorted.
In case of discontinuity, the circuit is
normal.

Connector MC-C
(Harness end)
#C4
C10

C1

C23

MC
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal
#B16 of harness end of connector MC-B.

C31

Connector MC-B
(Harness end)
#B16

T183-05-04-021

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal
#B16 of harness end of connector MC-B.

Connector
Connector MC-C
(Harness end)
#C15
C1

C23

C10

C31

Connector MC-B
(Harness end)
#B16

T183-05-04-021

T5-5-85

TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #18 and
#24 of harness end of connector.

ECM
Connector
(Harness end)
#18

#24

T1GR-05-04-002

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminals #37 and
#24 of harness end of connector.

ECM
Connector
(Harness end)
#37

#24

T1GR-05-04-002

ICF
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #C5 and
#C7 of harness end of connector ICF-C.

ICF
Connector ICF-C
(Harness end)
#C5
#C7

T1V1-05-04-002

Between CAN Circuit (Low Side) and Key Signal

Circuit

ICF
Connector ICF-C
(Harness end)

Check for continuity between terminals #C11

and #C7 of harness end of connector ICF-C.

#C7

#C11

T5-5-86

T1V1-05-04-002

TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminal #33 of
harness end of connector monitor2B in the
monitor unit and terminal #2 of harness end of
connector monitor1A in the monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#33
Monitor Unit
Connector Monitor-1A
(Harness end)

#2

T183-05-04-013

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminal #34 of
harness end of connector monitor2B in the
monitor unit and terminal #2 of harness end of
connector monitor1A in the monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#34
Monitor Unit
Connector Monitor-1A
(Harness end)
#2

T183-05-04-013

T5-5-87

TROUBLESHOOTING / Troubleshooting A
TCU
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #25 and
#45 of harness end of connector in TCU.
#25

T4GB-05-05-001

#45

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminals #26 and
#45 of harness end of connector in TCU.

#26

T4GB-05-05-001

#45

T5-5-88

TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit
between CAN (high side) circuit and
CAN (low side) circuit is shorted.
In case of discontinuity, the circuit is
normal.

Connector MC-C
Check for continuity between terminals #C4 and
#C15 of harness end of connector MC-C in MC.

MC
Connector MC-C
(Harness end)
#C4
C1

C23

#C15
C10

C31

Connector ECM
Check for continuity between terminals #18 and
#37 of harness end of connector in ECM.

ECM
Connector
(Harness end)
#18

#37

T1GR-05-04-002

T5-5-89

TROUBLESHOOTING / Troubleshooting A
Connector ICF-C
Check for continuity between terminals #C5 and
#C11 of harness end of connector ICF-C in ICF.

ICF
Connector ICF-C
(Harness end)

#C5

T1V1-05-04-002

#C11

Connector Monitor-2B in Monitor Unit

Check for continuity between terminals #B33 and
#B34 of harness end of connector monitor-2B in
the monitor unit.

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#B34 #B33

Connector TCU
Check for continuity between terminals #25 and
#26 of harness end of connector TCU.

#25
#26

T4GB-05-05-001

T5-5-90

TROUBLESHOOTING / Troubleshooting A
ENGINE FAILURE
MC FAULT CODE 11103
Fault Code
Trouble
Cause
11103-3 Abnormal Accelerator Pedal Voltage: 4.75 V or higher
High Voltage

11103-4

Abnormal Accelerator Pedal Voltage: Less than 0.25 V

Low Voltage

Influenced Control
Pump
Torque
Decrease
Control
Engine Accelerator Pedal
Control
Pump
Torque
Decrease
Control
Engine Accelerator Pedal
Control
Open circuit in
harness between MC
and accelerator pedal
sensor (terminal #1).

NO
Disconnect connector
MC-C in MC.
Check for continuity
between terminal #C13
YES of harness end of
connector and terminal
#1 of harness end of
connector in
accelerator pedal
sensor.

Check if voltage between

terminals #2 and #6 of
harness end of connector
in accelerator pedal sensor
is 50.5 V.

Check if voltage
between terminal #2 of
harness end of
connector in
NO accelerator pedal
sensor and vehicle
frame is specigication.

Key switch: ON

With connector of
accelerator pedal sensor
connected, insert a tester YES Faulty MC.
probe into rear of
connector of terminal #1.
Operate accelerator
YES pedal.
Faulty accelerator
Check if voltage reaches
pedal sensor.
specification.
NO
Key switch: ON
Open circuit in
YES
Specification: Refer to
harness between MC
the table below.
and accelerator pedal
sensor (terminal #6).

Key switch: ON
Specification: 50.5 V

Specification of Accelerator Pedal Sensor

Slow Idle
0.5 to 0.65 V
Fast Idle
4.35 to 4.5 V
Connector (Harness end of connector viewed from the
open end side)
MC
Connector MC-C
#C13
C10

C1

C23
C31
Accelerator Pedal Sensor Connector
#2

#1

5
#6

T5-5-91

NO

Open circuit in
harness between MC
and accelerator pedal
sensor (terminal #2).

TROUBLESHOOTING / Troubleshooting A
PUMP FAILURE
MC FAULT CODE 11204
Fault Code
11204-3
11204-4

Trouble
Abnormal
Pump
Delivery
Pressure Sensor High Voltage
Abnormal
Pump
Delivery
Pressure Sensor Low Voltage

Switch pump delivery

pressure sensor with
normal pressure sensor
and retry.
Check if fault code
disappears.

Cause
Influenced Control
Output voltage: 4.75 V or Pump
Torque
Decrease
higher
Control: Disabled
Output voltage: Less than 0.25 Pump
Torque
Decrease
V
Control: Disabled
Disconnect connector
MC-C in MC. Check for
continuity between
terminal #C2 of
YES harness end of
connector and terminal
#2 of harness end of
connector in pump
delivery pressure
sensor.

Disconnect connector
of pump delivery
pressure sensor.
Check if voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.

Check if voltage
between terminal #1 of
harness end of
connector in pump
delivery pressure
sensor and vehicle
frame is specification.
Key switch: ON
Specification: 50.5 V.

NO

Connector (Harness end of connector viewed from

the open end side)
Pump Delivery
Pressure Sensor

#C2
C1

C10
3

C23

Open circuit in harnees

between MC and pump
delivery pressure sensor
(terminal #2).
Faulty MC.

YES
YES Open circuit in harness
between MC and pump
delivery pressure sensor
(terminal #3).

NO

Open circuit in harness

between MC and pump
delivery pressure sensor
(terminal #1).
Faulty pump delivery
pressure sensor.

YES

MC
Connector MC-C

NO

C31

T5-5-92

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11209
Fault Code
11209-3
11209-4

Trouble
Cause
Influenced Control
Abnormal Implement Pressure Output voltage: 4.75 V or Pump
Torque
Decrease
Sensor High Voltage
higher
Control: Disabled
Abnormal Implement Pressure Output voltage: Less than 0.25 Pump
Torque
Decrease
Sensor Low Voltage
V
Control: Disabled

Disconnect connector
MC-C in MC.
Check for continuity
YES between terminal #C12
of harness end of
connector and terminal
#2 of harness end of
connector in implement
pressure sensor.

Disconnect connector
of implement pressure
sensor.
Check if voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Switch implement
pressure sensor with
normal pressure sensor
and retry.
Check if fault code
disappears.

Key switch: ON

NO

Check if voltage
between terminal #1 of
harness end of
connector in implement
pressure sensor and
vehicle frame is
specification.
Key switch: ON
Specification: 50.5 V

Connector (Harness end of connector viewed from the

open end side)
Implement
Pressure Connector

#C12
C1

C10
3

C23

Open circuit in harnees

between MC and
implement pressure
sensor (terminal #2).
Faulty MC.

YES
YES Open circuit in harness
between MC and
implement pressure
sensor (terminal #3).

NO

Open circuit in harness

between MC and
implement pressure
sensor (terminal #1).
Faulty implement
pressure sensor.

YES

MC
Connector MC-C

NO

C31

T5-5-93

TROUBLESHOOTING / Troubleshooting A
PILOT FAILURE
MC FAULT CODE 11313
Fault Code
11313-3
11313-4

Trouble
Abnormal
Parking
Brake
Pressure Sensor High Voltage
Abnormal
Parking
Brake
Pressure Sensor Low Voltage

Cause
Influenced Control
Output voltage: 4.75 V or Parking Brake Indicator Control
higher
Output voltage: Less than 0.25 Parking Brake Indicator Control
V

Disconnect connector
MC-C in MC.
Check for continuity
YES between terminal #C23
of harness end of
connector and terminal
#2 of harness end of
connector in pressure
sensor.

Disconnect connector
of pressure sensor.
Check if voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Key switch: ON

Check if voltage
between terminal #1
of harness end of
NO connector in pressure
sensor and vehicle
frame is specification.
Key switch: ON
Specification: 50.5 V

Switch pressure sensor

with normal pressure
sensor and retry.
Check if fault code
disappears.

NO

Open circuit in harnees

between MC and
pressure sensor (terminal
#2).
Faulty MC.

YES

Open circuit in harness

YES between MC and
pressure sensor (terminal
#3).
Open circuit in harness
between MC and
NO pressure sensor (terminal
#1).
Faulty pressure sensor.

YES

Connector (Harness end of connector viewed from the

open end side)
Parking Brake Pressure
Sensor Connector

MC
Connector MC-C
C10

C1

C23

C31
#C23

T5-5-94

TROUBLESHOOTING / Troubleshooting A
PROPORTIONAL SOLENOID VALVE FAILURE
MC FAULT CODE 11412
Fault Code
11412-2

11412-3

11412-4

Trouble
Abnormal Feedback of Hydraulic
Drive Fan Flow Rate Control
Solenoid Valve
Abnormal
Feedback
High
Current of Hydraulic Drive Fan
Flow Rate Control Solenoid
Valve
Abnormal
Feedback
Low
Current of Hydraulic Drive Fan
Flow Rate Control Solenoid
Valve

YES

Check for continuity in

harness between MC
and hydraulic drive fan
flow rate control
solenoid valve.
Between terminal #A32
of connector MC-A in
MC and terminal #1 of
connector in hydraulic
drive fan flow rate
control solenoid valve
Between terminal #A29
of connector MC-A in
MC and terminal #2 of
connector in hydraulic
drive fan flow rate
control solenoid valve

Cause
Influenced Control
The feedback current to MC Hydraulic Drive Fan Cooling
becomes the uncertain value. Control
The feedback current to MC is Hydraulic Drive Fan Cooling
beyond the upper limit.
Control

While the command from MC Hydraulic Drive Fan Cooling

is output, the feedback current Control
to MC is 56 mA or less.

Switch connectors of
hydraulic drive fan flow
rate control solenoid
valve and normal
solenoid valve.
Retry.
Check if fault code
disappears.

NO

Faulty hydraulic drive fan

flow rate control solenoid
valve.
Faulty MC.

YES

Open circuit in harness.

NO

Connector (Harness end of connector viewed from the

open end side)
MC
Connector MC-A

#A32

#A29

T183-05-04-008

Hydraulic Drive Fan Flow Rate

Control Solenoid Valve Connector

T5-5-95

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11413
Fault Code
11413-2
11413-3

11413-4

Trouble
Abnormal Feedback of Pump
Torque Control Solenoid Valve
Abnormal Feedback High
Current of Pump Torque
Control Solenoid Valve
Abnormal
Feedback
Low
Current of Pump Torque
Control Solenoid Valve

YES

Check for continuity in

harness between MC
and pump torque
control solenoid valve.
Between terminal #A31
of connector MC-A in
MC and terminal #1 of
connector in pump
torque control solenoid
valve
Between terminal #A5
of connector MC-A in
MC and terminal #2 of
connector in pump
torque control solenoid
valve

Cause
Influenced Control
The feedback current to MC Pump Standard Torque Control
becomes the uncertain value.
The feedback current to MC is Pump Standard Torque Control
beyond the upper limit.
While the command from MC Pump Standard Torque Control
is output, the feedback current
to MC is 56 mA or less.

Switch connectors of
pump torque control
solenoid valve and normal
solenoid valve.
Retry.
Check if fault code
disappears.

Faulty pump torque

control solenoid valve.

Faulty MC.
YES

Open circuit in harness.

NO

Connector (Harness end of connector viewed from the

open end side)
MC
Connector MC-A
#A5

#A31

T183-05-04-008

Pump Torque Control Solenoid Valve

NO

T5-5-96

TROUBLESHOOTING / Troubleshooting A
CAN DATA RECEPTION FAILURE
MC FAULT CODES 11910, 11920
Fault Code
11910-2

11920-2

Trouble
Actual Engine Speed Receive
Error
Received from ECM
Fuel Flow Rate Receive Error
Received from ECM

Cause
Faulty Harness
Faulty ECM

Influenced Control

Pump Torque Decrease Control

Hydraulic Drive Fan Cooling
Control

Faulty Harness
Faulty ECM

Engine

Speed

Decrease

Control

GPS
Monitor Unit

Dr. ZX
ICF
TCU

ECM

CAN Harness

MC

T5-5-97

CAN Harness

TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
MC FAULT CODES 11910, 11920
Check the wiring connections first.

Disconnect all
connectors of MC, ICF,
ECM, TCU and
monitor unit.
YES Check for continuity
between ground circuit
(MC, ICF, ECM, TCU,
monitor unit) and CAN
circuit.

Check for continuity in

YES CAN harness between
MC and ECM.

Key switch: OFF

Refer to
Discontinuity Check
between CAN Circuit
and Ground Circuit
on T5-5-74 to 79.

Key switch: OFF

Refer to Continuity
Check in CAN
Harness on T5-5-70.

Retry by using Dr. ZX.

Check if fault code
11004-2 is displayed.

NO

YES

Shorted circuit in CAN

harness between ground
circuit and CAN circuit.

Check for continuity

between power
To A
circuit MC, ICF,
NO ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to Discontinuity
Check between CAN
Circuit and Power Circuit
on T5-5-80 to 84.
Open circuit in CAN
harness between MC and
ECM.

Normal.
NO

Shorted circuit in CAN

harness between power
circuit and CAN circuit.

YES

Shorted circuit in CAN

harness between key
signal circuit and CAN
circuit.

YES

A
Check for continuity
between key signal
circuit in MC, ICF,
NO ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to
Discontinuity
Check between
CAN Circuit and
Key Signal Circuit
on T5-5-85 to 88.

YES

NO

Check for continuity

between High side
and Low side in CAN
harness.
Key switch: OFF
Refer to
Discontinuity Check
in CAN Harness on
T5-5-89.

Shorted circuit in CAN

harness.

Connect all connectors

YES
except connector
MC-C in MC.
Check if resistance
Disconnect
between terminals #C4
connector in MC.
NO and #C15 of harness
Connect connector of
end of connector
harness end.
MC-C is within 6010
NO Check if resistance
.
between terminals
#18 and #37 of
Key switch: OFF
connector in ECM is
within 12010 .
Key switch: OFF

T5-5-98

To B

To C

TROUBLESHOOTING / Troubleshooting A

Connect connector
in MC.
Check if fault code
11004-2 is
displayed.

Key switch: ON

Connect connector
in MC.
YES Check if fault code
11004-2 is
displayed.

NO

Check the connections of

MC and connector.
Faulty MC.

YES

Check the connections of

ECM and connector.

NO

Faulty ECM.

YES

Key switch: ON
C
Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
NO between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
Key switch: OFF

Connect connector
in ICF.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON

NO

Check the connection of

ICF and connector.
Faulty ICF.

YES

YES

NO

Connect connector in
ICF.
Disconnect
connector monitor-2B
in monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF

Connect connector
in monitor unit.
Check if fault code
11004-2 is
displayed.
Key switch: ON

NO

Check the connections of

monitor unit and
connector.
Faulty monitor unit.

YES

To D

NO

Connector
ECM
Connector
(Harness end)

MC
Connector MC-C
(Harness end)
#C4
C1

C23

#18

#C15

#37

C10

C31

T1GR-05-04-002

T5-5-99

TROUBLESHOOTING / Troubleshooting A

Connect connector in
monitor unit.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .

Connect connector
YES in TCU.
Check if fault code
11004-2 is
displayed.

NO

Check the
connections of TCU
and connector.
Faulty TCU.

YES

Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.

NO

Connector
ICF
Connector ICF-C
(Harness end)

#C5

#25
#26

#C11

T1V1-05-04-002

Monitor Unit
Connector Monitor-2B
(Harness end)

T4GB-05-05-002

#34 #33

T4GB-05-05-001

T5-5-100

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11914
Fault Code
11914-2

Trouble
Cause
Radiator
Coolant Faulty Harness
Temperature Receive Error Faulty Monitor Unit
Received from Monitor Unit

Influenced Control

Hydraulic Drive Fan Cooling Control

GPS
Monitor Unit

Dr. ZX
ICF
TCU

ECM

CAN Harness

MC

T5-5-101

TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
FAULT CODE 11914
Check the wiring connections first.

Disconnect all
connectors of MC, ICF,
ECM, TCU and
YES monitor unit. Check for
continuity between
ground circuit MC, ICF,
ECM, TCU, monitor
unit and CAN circuit.
Check for continuity in
YES CAN harness between
MC and monitor unit.

Key switch: OFF

Refer to
Discontinuity Check
between CAN Circuit
and Ground Circuit
on T5-5-74 to 79.

Key switch: OFF

Refer to Continuity
Check in CAN
Harness on T5-5-72.

Retry by using Dr. ZX.

Check if fault code
11004-2 is displayed.

YES Open circuit in CAN

harness between ground
circuit and CAN circuit.

NO

Check for continuity

between power
circuit MC, ICF,
To A
ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to
Discontinuity Check
between CAN Circuit
and Power Circuit on
T5-5-80 to 84.
Open circuit in CAN
harness between MC and
monitor unit.

NO

Normal.
NO

Shorted circuit in CAN

harness between power
circuit and CAN circuit.

YES

Shorted circuit in CAN

harness between key
signal circuit and CAN
circuit.

YES
A
Check for continuity
between key signal
circuit in MC, ICF,
NO ECM, TCU, monitor
unit and CAN circuit.
Key switch: OFF
Refer to
Discontinuity
Check between
CAN Circuit and
Key Signal Circuit
on T5-5-85 to 88.

YES

NO

Check for continuity

between High side
and Low side in CAN
harness.
Key switch: OFF
Refer to
Discontinuity Check
in CAN Harness on
T5-5-89.

NO

Shorted circuit in CAN

harness.
Connect all
connectors except
connector MC-C in
MC.
Check if resistance
between terminals
#C4 and #C15 of
harness end of
connector MC-C is
within 6010 .
Key switch: OFF

YES

NO

To B
Connect connector in
MC.
Disconnect
connector monitor-2B
in the monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF

T5-5-102

To C

TROUBLESHOOTING / Troubleshooting A

NO

Check the connections of

MC and connector.

Connect connector
in MC. Check if fault
code 11004-2 is
displayed.

Faulty MC.

Key witch: ON

YES

Connect connector
in the monitor unit.
YES Check if fault code
11004-2 is
displayed.

NO

Check the connections of

monitor unit and
connector.
Faulty monitor unit.

YES

Key witch: ON

C
Connect connector in
monitor unit.
Disconnect
connector ECM.
Check if resistance
between terminals
#18 and #37 of
NO harness end of
connector is within
12010 .

Connect connector
in ECM.
YES Check if fault code
11004-2 is
displayed.
Key witch: ON

Key witch: OFF

NO

Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .

NO

Check the connections of

ICF and connector.
Faulty ICF.

YES

YES

Connect connector
in ICF.
Check if fault code
11004-2 is
displayed.
Key witch: ON

NO Check the connections of

ICF and connector.
Faulty ICF.
YES

To D

NO

Key witch: OFF

Connector
MC
Connector MC-C
(Harness end)
#C4
C1

C23

Monitor Unit
Connector Monitor-2B
(Harness end)
#C15
C10

C31

T4GB-05-05-002

#34

T5-5-103

#33

TROUBLESHOOTING / Troubleshooting A

NO
Connect connector
YES in TCU. Check if
fault code 11004-2
is displayed.

Connect connector in
ICF.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .

Check the
connections of TCU
and connector.
Faulty TCU.

YES

Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.

NO

Connector
ICF
Connector ICF-C
(Harness end)

#C5

#C11

T1V1-05-04-002

ECM
Connector
(Harness end)

#25
#26
#18

#37

T1GR-05-04-002

T4GB-05-05-001

T5-5-104

TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11912, 11913,11916, 11917
Fault Code
Trouble
11912-2 Torque Converter Rotation or
Transmission Rotation Receive
Error
11913-2 Forward/Reverse Switch Enable
Signal Receive Error
11916-2
11917-2

Cause
Faulty Harness
Faulty TCU

Influenced Control
Pump Torque Decrease Control

Faulty Harness
Faulty TCU

Engine Accelerator Pedal Control

(only when the forward/reverse
switch is used)
Engine Speed Decrease Control

Selected
Speed
Position Faulty Harness
Receive Error
Faulty TCU
Actual Speed Position Receive Faulty Harness
Error
Faulty TCU

Engine Speed Decrease Control

GPS
Monitor Unit

Dr. ZX
ICF
TCU

ECM

CAN Harness

MC

T5-5-105

TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
FAULT CODES 11912, 11913, 11916, 11917
Check the wiring connections first.

Disconnect all
connectors of MC, ICF,
ECM, TCU and
YES monitor unit. Check for
continuity between
ground circuit MC, ICF,
ECM, TCU, monitor
unit and CAN circuit.

Retry by using Dr. ZX.

Check if fault code
11004-2 is displayed.

NO

Check for continuity

between power
circuit MC, ICF,
ECM, TCU, monitor
unit and CAN circuit.

To A

Key switch: OFF

Refer to Discontinuity
Check between CAN
Circuit and Power
Circuit on T5-5-80 to
84

Key switch: OFF

Refer to Discontinuity
Check between CAN
Circuit and Ground
Circuit on T5-5-74 to
79.

YES Check for continuity in

CAN harness between
MC and TCU.
Key switch: OFF
Refer to Continuity
Check in CAN
Harness on
T5-5-73.

YES Open circuit in CAN

harness between ground
circuit and CAN circuit.

Open circuit in CAN

harness between MC and
TCU.

NO

Normal.
NO
Shorted circuit in CAN
harness between ground
circuit and CAN circuit.

YES

Shorted circuit in CAN

harness between key
signal circuit and CAN
circuit.

YES

A
Check for continuity
between key signal
circuit (MC, ICF,
NO ECM, TCU, monitor
unit) and CAN circuit.
Key switch: OFF
Refer to
Discontinuity Check
between CAN Circuit
and Key Signal
Circuit T5-5-85 to
88

YES

NO

Check for continuity

between High side
and Low side in CAN
harness.
Key switch: OFF
Refer to
Discontinuity Check
in CAN Harness on
T5-5-89

NO

Shorted circuit in CAN

harness.
Connect all
connectors except
connector MC-C in
MC.
Check if resistance
between terminals
#C4 and #C15 of
harness end of
connector MC-C is
within 6010 .
Key switch: OFF

YES

NO

To B
Connect connector in
MC.
Disconnect
connector monitor-2B
in the monitor unit.
Check if resistance
between terminals
#33 and #34 of
harness end of
connector is within
12010 .
Key switch: OFF

T5-5-106

To C

TROUBLESHOOTING / Troubleshooting A

Connect connector
in MC.
Check if fault code
11004-2 is
displayed.

Key switch: ON

Connect connector
in monitor unit.
YES
Check if fault code
11004-2 is
displayed.

Check the
connections of MC
and connector.

NO

Faulty MC.
YES

Check the
connections of
monitor unit and

NO

Faulty monitor unit.

YES

Key switch: ON
C

NO

Connect connector in
monitor unit.
Disconnect
connector ECM.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector is within
12010 .

Connect connector
in ECM.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON

Key switch: OFF

NO

Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .

Check the
connections of ICF
and connector.

NO

Faulty ICF.
YES

YES

Connect connector
in ICF.
Check if fault code
11004-2 is
displayed

NO

Check the
connections of ICF
Faulty ICF.

YES

Key switch: ON

NO

To D

Key switch: OFF

Connector

Monitor Unit
Connector Monitor-2B
(Harness end)

ICF
Connector ICF-C
(Harness end)
#C4
C1

C23

#C15
C10

C31

T4GB-05-05-002

#34 #33

T5-5-107

TROUBLESHOOTING / Troubleshooting A

NO

Connect connector in
ICF.
Disconnect
connector in TCU.
Check if resistance
between terminals
#25 and #26 of
harness end of
connector is within
12010 .

Connect connector
YES in TCU. Check if
fault code 11004-2
is displayed.

Check the
connections of TCU
and connector.
Faulty TCU.

YES

Failure in any
controller in MC, ICF,
ECM, TCU or
monitor unit.

NO

Connector
ICF
Connector ICF-C
(Harness end)
#C5

#C11

T1V1-05-04-002

ECM
Connector
(Harness end)

#25
#18

#26

#37

T1GR-05-04-002

T4GB-05-05-001

T5-5-108

TROUBLESHOOTING / Troubleshooting A
OTHER FAILURES
MC FAULT CODE 11901
Fault Code
Trouble
Cause
11901-3 Hydraulic
Oil
Temperature Voltage: 4.52 V or higher
Sensor High Voltage
11901-4

Hydraulic
Oil
Temperature Voltage: Less than 0.23 V
Sensor Low Voltage

Disconnect connector of
hydraulic oil temperature
sensor.
Check if resistance at
sensor end connector is
specification.
Specification: Refer to
the table below.

Connect terminals #1
and #2 of harness end
of connector in
hydraulic oil
temperature sensor by
YES using a clip.
Disconnect connector
MC-D from MC.
Check for continuity
between terminals #D8
and #D6 of harness
end of connector
MC-D.

Influenced Control

Auto Warning-up Control

Hydraulic Drive Fan Cooling
Control
Auto Warning-up Control
Hydraulic Drive Fan Cooling
Control

Faulty MC.

YES

NO

Connect terminal #D6

of harness end of
connector MC-D in
MC to vehicle frame.
Check for continuity
between terminals #2
of harness end of
connector in hydraulic
oil temperature
sensor and vehicle
frame.

NO

Open circuit in harness

between MC and
hydraulic oil temperature
sensor (terminal #2).
Faulty hydraulic oil
temperature sensor.

NO

Specification of Hydraulic Oil Temperature Sensor

Hydraulic Oil Temperature
Resistance
(C, F)
(k)
-20, -4
16.21.6
0, 32
(5.88)
20, 68
2.450.24
40, 104
(1.14)
60, 140
(0.534)
80, 176
0.322

NOTE: If fault code 11901-4 is not displayed and

hydraulic oil temperature -30C is
displayed on the monitor by using Dr.ZX,
the circuit in hydraulic oil temperature
sensor may be opened.

Connector (Harness end of connector viewed from the

open end side)
MC
Connector MC-D

Hydraulic Oil Temperature

Sensor Connector
#D8
1

#D6

Open circuit in harness

YES between MC and
hydraulic oil temperature
sensor (terminal #1).

T183-05-04-009

T5-5-109

TROUBLESHOOTING / Troubleshooting A
PROPORTIONAL
TROUBLE CHECK

SOLENOID

VALVE

When the harness in proportional solenoid valve is

faulty, the fault code may be not detected. If the trouble
is related to the proportional solenoid valve,
disconnect the connectors in MC and proportional
solenoid valve. Then check for continuity.

Circuit Condition in Trouble

A

MC

Proportional
Solenoid Valve

C
T1V1-05-06-008

: Fault code can be detected.

: Fault code can be detected according to trouble.
: Fault code cannot be detected.

Trouble

Fault Code

Open circuit in A-B

Damaged Parts in MC
None

T1V1-05-06-006

None

Open circuit in A-B

Harness in side B is shorted to
the ground.

T1V1-05-06-007

FET

Open circuit in A-B

Harness in side A is shorted to

the ground.

T1V1-05-06-009

Shorted circuit in A-B

FET

T1V1-05-06-010

Open circuit in C-D

None

T1V1-05-06-011

None

Open circuit in C-D

Harness in side C is shorted to
the ground.

T1V1-05-06-012

None

Open circuit in C-D

Harness in side D is shorted to

the ground.

T1V1-05-06-013

Shorted circuit in C-D

None

T1V1-05-06-014

T5-5-110

TROUBLESHOOTING / Troubleshooting A
MC

Proportional
Solenoid Valve

C
T1V1-05-06-008

: Fault code can be detected.

: Fault code can be detected according to trouble.
: Fault code cannot be detected.
Circuit Condition in Trouble
A

Trouble

Fault Code

Shorted circuit in harness

Damaged Parts in MC
Resistance

between A-B and C-D

D

C
T1V1-05-06-015

Open circuit in A- B
Harness in side A is shorted to
the power source.

None

T1V1-05-06-016

Open circuit in A- B
Harness in side B is shorted to

None

the power source.

T1V1-05-06-017

Harness in A-B is shorted to the

power source.

None

T1V1-05-06-018

Open circuit in C-D

Resistance

Harness in side D is shorted to

the power source.

T1V1-05-06-019

Open circuit in C-D

None

Harness in side C is shorted to

the power source.

T1V1-05-06-020

Harness in C-D is shorted to the

power source.

Resistance

T1V1-05-06-021

CAUTION: These are available to only the

proportional solenoid valve connected to MC.

T5-5-111

TROUBLESHOOTING / Troubleshooting A
(Blank)

T5-5-112

TROUBLESHOOTING / Troubleshooting A
ECM, SENSOR SYSTEM
ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172

P0522

Reference Page on
4HK1/6HK1 Engine
Manual Troubleshooting
1E-403

P0523

1E-409

P0237

1E-341

P0238

1E-348

Abnormal Boost Temperature Sensor (Abnormal P1113

High Voltage)
Abnormal Boost Temperature Sensor (Abnormal P1112
Low Voltage)
Abnormal
Atmospheric
Pressure
Sensor P0107
(Abnormal Low Voltage)

1E-460

108-4

Abnormal
Atmospheric
(Abnormal High Voltage)

Pressure

Sensor P0108

1E-238

110-3

Abnormal
Coolant
Temperature
(Abnormal High Voltage)
Abnormal
Coolant
Temperature
(Abnormal Low Voltage)

Sensor P0118

1E-266

Sensor P0117

1E-259

Abnormal Common Rail Pressure

(Abnormal High Voltage)
Abnormal Common Rail Pressure
(Abnormal Low Voltage)
Abnormal
Intake-Air
Temperature
(Abnormal High Voltage)
Abnormal
Intake-Air
Temperature
(Abnormal Low Voltage)

Sensor P0193

1E-294

Sensor P0192

1E-288

Sensor P0113

1E-251

Sensor P0112

1E-245

Fault
Code
100-3
100-4
102-3
102-4
105-3
105-4
108-3

110-4

157-3
157-4
172-3
172-4

Trouble

Fault Code (Tech 2)

Abnormal Engine Oil Pressure Sensor (Abnormal

Low Voltage)
Abnormal Engine Oil Pressure Sensor (Abnormal
High Voltage)
Abnormal Boost Pressure Sensor (Abnormal Low
Voltage)
Abnormal Boost Pressure Sensor (Abnormal
High Voltage)

T5-5-113

1E-452
1E-231

TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 174, 636, 723, 10001

Fault
Code
174-3
174-4
636-2
636-2
636-7

723-2
723-2
10001-3

Trouble

Fault Code (Tech 2)

Abnormal Fuel Temperature Sensor (Abnormal P0183

High Voltage)
Abnormal Fuel Temperature Sensor (Abnormal P0182
Low Voltage)
Abnormal Cam Angle Sensor (No Signal)
P0340
Abnormal Cam Angle Sensor (Abnormal P0341
Signal)
Phase Mismatch of Cam Angle Sensor
P1345

Abnormal Crank Speed Sensor (No Signal)

P0335
Abnormal Crank Speed Sensor (Abnormal P0336
Signal)
Abnormal EGR Position (Brushless spec.)
P0487

IMPORTANT: When fault code 723-2 (abnormal

crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.

T5-5-114

Reference Page on
4HK1/6HK1 Engine
Manual Troubleshooting
1E-280
1E-274
1E-368
1E-375
1E-524

1E-355
1E-362
1E-391

TROUBLESHOOTING / Troubleshooting A
ECM, EXTERNAL DEVICE SYSTEM
ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002
Fault Code

Trouble

651-3

Open Circuit in Injection Nozzle #1

Drive System
Open Circuit in Injection Nozzle #2
Drive System
Open Circuit in Injection Nozzle #3
Drive System
Open Circuit in Injection Nozzle #4
Drive System
Open Circuit in Injection Nozzle #5
Drive System
Open Circuit in Injection Nozzle #6
Drive System
Open Circuit in Suction Control Valve
Drive System, Shorted Circuit in + B or
GND
Abnormal EGR Valve Control

652-3
653-3
654-3
655-3
656-3
1347-0

10002-2

P0201

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-301

P0202

1E-308

P0203

1E-315

P0204

1E-322

P0205

1E-329

P0206

1E-334

P0090

1E-225

P0488

1E-397

Fault Code (Tech 2)

T5-5-115

TROUBLESHOOTING / Troubleshooting A
ECM, FUEL SYSTEM
ECM FAULT CODES 157, 633, 1239, 1240
Fault Code

Trouble

157-0

Abnormal Common Rail Pressure

(First Stage)
Abnormal Common Rail Pressure
(Second Stage)
Abnormal Common Rail Pressure
(Pump Over-Pressure)
Pressure Limiter Open
No Pressure to Pump (Fuel Leakage)

157-0
157-2
633-7
1239-1

P0088

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-215

P0088

1E-215

P0089

1E-220

P1095
P0087
P1093

1E-443
1E-207
1E-434

Fault Code (Tech 2)

T5-5-116

TROUBLESHOOTING / Troubleshooting A
ECM, ENGINE PROTECTION
ECM FAULT CODES 110, 190
Fault Code
110-0
190-0

Trouble
Overheating
Overrunning

Fault Code (Tech 2)

P1173
P0219

T5-5-117

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-466
1E-339

TROUBLESHOOTING / Troubleshooting A
ECM, EXTERNAL CIRCUIT SYSTEM
ECM FAULT CODES 987, 1485
Fault Code
987-3
1485-2

Trouble
Abnormal Check Engine Lamp
Abnormal Main Relay System (None)

Fault Code (Tech 2)

P0650
P1625

T5-5-118

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-429
1E-529

TROUBLESHOOTING / Troubleshooting A
ECM, INTERNAL CIRCUIT SYSTEM
ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005
Fault Code

Trouble

628-2
1077-2
1079-2
1080-2
10003-2

Abnormal ROM
Abnormal IC for CPU Watching
Abnormal 5 V Power Source 1 Voltage
Abnormal 5 V Power Source 2 Voltage
Abnormal Injection Nozzle Common 1
Drive System
Abnormal Injection Nozzle Common 2
Drive System
Abnormal Charge Circuit (Bank 1)

10004-2
10005-1

P0601
P0606
P1631
P1632
P1261

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-417
1E-421
1E-538
1E-541
1E-476

P1262

1E-487

P0611

1E-423

Fault Code (Tech 2)

T5-5-119

TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013
Fault Code

Trouble

Fault Code (Tech 2)

10006-1
10007-2
10008-2
10009-2
10010-2
10011-2
10013-2

Abnormal Charge Circuit (Bank 2)

Abnormal CPU
Abnormal A/D Converter
Abnormal 5 V Power Source 3 Voltage
Abnormal 5 V Power Source 4 Voltage
Abnormal 5 V Power Source 5 Voltage
Abnormal EPROM

P0612
P0606
P1630
P1633
P1634
P1635
P0603

T5-5-120

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-426
1E-421
1E-536
1E-544
1E-547
1E-550
1E-419

TROUBLESHOOTING / Troubleshooting A
ECM, COMMUNICATION SYSTEM
ECM FAULT CODE 639
Fault Code
639-2
639-3

Trouble
Abnormal CAN Bus Line
Abnormal CAN Time Out

Fault Code (Tech 2)

U2104
U2106

T5-5-121

Reference Page on
4HK1/6HK1 Engine Manual
Troubleshooting
1E-553
1E-558

TROUBLESHOOTING / Troubleshooting A
ROLE AND CONNECTION OF EACH TERMINAL IN TCU
68 Pin Connector
Signal
Terminal
Direction
Role
Connected to
No.
for TCU
1
Ground
Ground
2
Ground
Ground
3
Output
Wiring terminal #396 in torque converter input
Power source in torque converter input shaft sensor
shaft sensor, output shaft sensor, Wiring terminal #397 in output shaft sensor
transmission middle shaft sensor
Wiring terminal #398 in transmission middle shaft
sensor
4
Output
Travel speed sensor ground
Wiring terminal #403 in travel speed sensor
5
Input
Ground
circuit
formation
for
Terminal #34 of connector 1B in monitor controller
forward/reverse switch mode enable
(wiring terminal #94)
signal light
6
Input
Terminal #18 of connector 1A in monitor controller
Starter operating signal receive
(wiring terminal #452)
7
Input
Ground circuit formation for reverse relay
Wiring terminal #109 in reverse relay
exciting
9
Output
Slow forward clutch proportional solenoid Wiring terminal #392 in slow forward clutch
valve operating signal sending
proportional solenoid valve
10
Output
Reverse clutch proportional solenoid Wiring terminal #389 in reverse clutch proportional
valve operating signal sending
solenoid valve
12
Ground for each clutch solenoid valve
Wiring terminal #386 in each clutch solenoid valve
13
Ground for each clutch solenoid valve
Terminal #12 in TCU (wiring terminal #386)
(backup)
15
Output/ ZF self diagnosing tool connection
ZF self diagnosing tool
Input
terminal
17
Input
Feedback current receive in transmission Wiring terminal #735 in transmission filter
filter restriction switch
restriction switch
18
Output/ ZF self diagnosing tool connection
ZF self diagnosing tool
Input
terminal
19
Input
Feedback current receive in torque Wiring terminal #399 in torque converter input shaft
converter input shaft sensor
sensor
20
Input
Forward/reverse relay neutral signal
Wiring terminal #358 in forward/reverse relay
receive
NOTE: The terminal without No. is not used.

T5-5-122

TROUBLESHOOTING / Troubleshooting A
Signal
Terminal
Direction
No.
for TCU
21
Input
22

Input

23

Input

24
25

28

Output
Output/
Input
Output/
Input
Output/
Input
-

29
30

Input
Input

31

Input

32

Output

37
38

Input

39

Input

41

Input

42

Input

43

Input

44

Input

45
46

Input
Output

49

Input

26
27

Role

Connected to

Brake pressure sensor power source

Wiring terminal #26 of connector 1B in monitor

controller (wiring terminal #440)
Wiring terminal #106 in down-shift switch
Wiring terminal #101 in up-shift/down-shift switch
Wiring terminal #14 in fuse box B (wiring terminal
#3)
Wiring terminal #209 in brake pressure sensor

CAN high line

CAN

CAN low line

CAN

CAN low line (backup)

CAN

Parking brake release signal receive

Down-shift switch signal receive
TCU power source input

CAN wiring radio interference protection

cover
Up-shift switch signal receive
Wiring terminal #102 in up-shift/down-shift switch
Forward/reverse selector switch signal Wiring terminal #92 in forward/reverse selector
receive
switch
Forward/reverse switch reverse signal
Wiring terminal #355 in forward/reverse switch
receive
First stage clutch proportional solenoid Wiring terminal #390 in first stage clutch
valve operating signal sending
proportional solenoid valve
Brake pressure sensor ground
Wiring terminal #208 in brake pressure sensor
Feedback signal receive in brake
Wiring terminal #207 in brake pressure sensor
pressure sensor
Feedback signal receive in transmission Wiring terminal #394 in transmission control valve
control valve temperature sensor
temperature sensor
Feedback signal receive in torque Wiring terminal #400 in torque converter output
converter output shaft sensor
shaft sensor
Feedback signal receive in transmission Wiring terminal #401 in transmission intermediate
intermediate shaft sensor
shaft sensor
Forward/reverse lever forward signal Wiring terminal #83 in forward/reverse lever
receive
connector
Forward/reverse switch forward signal Wiring terminal #354 in forward/reverse switch
receive
connector
TCU power source input
Terminal #7 in fuse box A (wiring terminal #464)
Wiring terminal #734 in torque converter
Power source in torque converter temperature sensor
temperature sensor, transmission filter Wiring terminal #736 in transmission filter
restriction switch, transmission control restriction switch
valve temperature sensor
Wiring terminal #395 in transmission control valve
temperature sensor
Feedback current receive in torque Wiring terminal #733 in torque converter
converter temperature sensor
temperature sensor

NOTE: The terminal without No. is not used.

T5-5-123

TROUBLESHOOTING / Troubleshooting A
Signal
Terminal
Direction
Role
Connected to
No.
for TCU
51
Output
Second stage clutch proportional solenoid Wiring terminal #393 in second stage clutch
valve operating signal sending
proportional solenoid valve
52
Output
Terminal #15 of connector 1A in monitor controller
Transmission failure signal sending
(wiring terminal #458)
55
Output
Third stage clutch proportional solenoid Wiring terminal #391 in third stage clutch
valve operating signal sending
proportional solenoid valve
56
Output
Fast forward clutch proportional solenoid Wiring terminal #388 in fast forward clutch
valve operating signal sending
proportional solenoid valve
62
Input
Feedback signal receive in travel speed
Wiring terminal #404 in travel speed sensor
sensor
63
Input
Shift switch signal A
Wiring terminal #89 in shift switch
64
Input
Forward/reverse lever reverse signal
Wiring terminal #84 in forward/reverse lever
receive
65
Input
Shift switch signal B
Wiring terminal #90 in shift switch
66
Input
Hold switch signal receive
Wiring terminal #104 in hold switch
67
Input
Forward/reverse lever neutral signal
Wiring terminal #82 in forward/reverse lever
receive
68
Input
TCU power source input
Terminal #14 in fuse box B (wiring terminal #3)
NOTE: The terminal without No. is not used.

1
46

49
51
52

55
56

24
25
26
27
28
29
30
31
32

2
3
4
5
6
7
9
10
12
13

37
38 15
62 39 17
63
18
64 41 19
65 42 20
66 43 21
67 44 22
68 45
23
T4GB-05-05-001

T5-5-124

TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003
Fault Code
Trouble
14000-2 Abnormal CAN Communication

14001-2
14002-2
14003-2

ICF: Flash Memory

Read / Write Error
ICF: External RAM
Read Error
ICF: EPROM
Sum Check Error

Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Check the CAN communication line (harness).
Execute retry B in self-diagnosing and execute the following
item.
Execute Information C/U: Initialize.
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Execute Control Data: Initialize.
Execute Enter Model and Serial No..
Then, execute self-diagnosing and execute retry B.

T5-5-125

TROUBLESHOOTING / Troubleshooting A
Information C/U: Initialize

Push
and select the selection
screen of ICF controller.
Push ICF Controller.

After starting Dr. ZX, push Select

Controller.

Push OK.

Select failure-diagnosis
controller

Select Function
+

Self-Diagnostic Result

Select Controller

ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY

ICF Controller

To the
lower

Is it correct?

ESC

ESC

OK

ESC

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Start.

Push Information
Setup.

Push Information C/U: Initialize.

C/U:

Various

Select Item

Password

Information C/U: Various

Setup

+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd

Select Item

Data Download

Information C/U: Initialize

Enter Model and Serial

No.

Save Data Check

Enter Date and Time

Control Data: Initialize

Op. Manual
Start

Back

ESC

Title Screen

Main Menu Screen

Push Init and the controller control

data is initialized.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

Information C/U: Initialize

Init

Initialization has been

completed.
Initialization has been
completed.

ESC

ESC

Information C/U: Various Setup

Screen

Push ESC and return to Main

Menu Screen.
Select Item

Is operation data erased?

Init

ESC

OK

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: initialize

ESC

Information C/U: Initialize Screen

Information C/U: Various Setup

Screen

T5-5-126

To the
lower

TROUBLESHOOTING / Troubleshooting A
Control Data: Initialize

Push
and select the selection
screen of ICF controller.
Push ICF Controller.

After starting Dr. ZX, push Select

Controller.

Push OK.

Select failure-diagnosis
controller

Select Function
+

Self-Diagnostic Result

Select Controller

ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY

ICF Controller

To the
lower

Is it correct?

ESC

ESC

OK

ESC

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Start.

Push Information
Setup.

Push Control Data: Initialize.

C/U:

Various

Select Item

Password

Information C/U: Various

Setup

+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd

Select Item

Data Download

Information C/U: Initialize

Enter Model and Serial

No.

Save Data Check

Enter Date and Time

Control Data: Initialize

Op. Manual
Start

Back

ESC

Title Screen

Main Menu Screen

Push Init and the controller

operating data is initialized.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Push OK and return to Information

C/U: Various Setup Screen.

ESC
Information C/U: Various Setup
Screen

Push ESC and return to Main

Menu Screen.
Select Item

Control Data: Initialize

+ Information C/U: Initialize

Is control data initialized?
Init

Initialization has been

completed.
Initialization has been
completed.

ESC

Init

ESC

+ Enter Model and Serial

No.
+ Enter Date and Time
+ Control Data: Initialize

OK

ESC

Control Data: Initialize Screen

Information C/U: Various Setup

Screen

T5-5-127

To the
lower

TROUBLESHOOTING / Troubleshooting A
Enter Model and Serial No.
Push
and select the selection
screen of ICF controller.
Push ICF Controller.

After starting Dr. ZX, push Select

Controller.

Push OK.

Select failure-diagnosis
controller

Select Function
+

Self-Diagnostic Result

Select Controller

ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY

ICF Controller

To the
lower

Is it correct?

ESC

ESC

OK

ESC

Function Selection Screen

Controller Selection Screen

ICF Controller Screen

Push Start.

Push Information
Setup.

Push Enter Model and Serial No.

C/U:

Various

Select Item

Password

+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd

+
+

Select Item

Information C/U: Various

Setup
Data Download

Information C/U: Initialize

Enter Model and Serial

No.

Save Data Check

Enter Date and Time

Control Data: Initialize

Op. Manual
Start

Back

ESC
Main Menu Screen

Title Screen

Enter Model and Serial No.

Push ESC and return to Main

Menu Screen.

Enter Model and Serial No.

04GB

Select Item

Model |
Exec

Serial No. 000001

Exec

Information C/U: Various Setup

Screen

After inputting model and serial No.,

push OK and return to Enter Model
and Serial No. Screen.
Push ESC and return to Information
C/U: Various Setup Screen.

Push Exec, and model and serial

No. can be input.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.

Model

ESC

ESC

ESC

Ex. Mach.No.(HCM4GB00P00
0001) Model(04GB)

Serial No.
Ex. Mach.No.(HCM4GB00P00
0001) Serial No.(000001)

OK

ESC

Enter Model and Serial No.

ESC
OK

Information C/U: Initialize

Enter Model and Serial

No.

Enter Date and Time

Control Data: Initialize

ESC
Information C/U: Various Setup
Screen

T5-5-128

To the
lower

TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106
Fault Code
Trouble
Remedy
14006-2 ICF:
Satellite
Communication Execute retry B in self-diagnosing.
Terminal Communication Error
If this error code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.

14008-2

ICF: Abnormal Internal RAM

Then, execute self-diagnosing and execute retry B.

Execute retry B in self-diagnosing.
If this error code is displayed after re-try, replace the
controller.

14100-2

Satellite Communication Terminal:

Abnormal EPROM
14101-2 Satellite Communication Terminal:
Abnormal IB/OB Queue
14102-2 Satellite Communication Terminal: Check the communication aerial of satellite terminal. (Refer
to T5-5-130.)
Abnormal Local Loup Back
14103-2 Satellite Communication Terminal:
The satellite is not found.
14104-2 Satellite Communication Terminal: Execute retry B in self-diagnosing.
Fail 1 of Remote Loup Back
If this error code is displayed after re-try, replace the
14105-2 Satellite Communication Terminal: controller.
Fail 2 of Remote Loup Back
14106-2 Satellite Communication Terminal:
Sending and receiving data are
mismatched.
Fault Code 14006-2
Check the communication line
Connector (Harness end of connector viewed from the
1. Check for continuity between terminal #A8 of
open end side)
harness end of connector ICF-A in ICF and
terminal #10 of harness end of connector A in
satellite terminal.
ICF
2. Check for continuity between terminal #A9 of
Connector ICF-A
harness end of connector ICF-A in ICF and
#A8
terminal #20 of harness end of connector A in
#A9
satellite terminal.
3. Check for continuity between terminal #A31 of
#A31
harness end of connector ICF-A in ICF and
Satellite Terminal
terminal #2 of harness end of connector B in
Connector A
satellite terminal.
Check the power source line of satellite terminal
10 9 8 7 6 5 4 3 2 1
1. Check the battery power
20 19 18 17 16 15 14 13 12 11
Check if voltage between terminal #2 of harness
end of connector A in satellite terminal and vehicle
frame is 24 V.
Satellite Terminal
Connector B
2. Check the main power
With the key switch ON, check if voltage between
terminal #1 of harness end of connector A in
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
satellite terminal and vehicle frame is 24 V.
3. Check the ground circuit
Check for continuity between terminals #11 and
#12 of harness end of connector A in satellite
terminal.

T5-5-129

TROUBLESHOOTING / Troubleshooting A
Fault Codes 14102-2, 14103-2
GPS Aerial

Communication
Aerial

T4GB-05-07-002

Satellite Terminal

Communication
Aerial

GPS Aerial

T1V1-05-06-004

T5-5-130

TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306, 13308

Fault Code

Trouble

13306-2

Abnormal EPROM

13308-2

Abnormal CAN Communication

Remedy
If this error code is displayed after re-try, replace the monitor
unit.
Refer to Check CAN Harness (T5-5-70).

T5-5-131

TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13312
Fault Code
13312-2

Trouble

Remedy

Abnormal
Transmission
Temperature Sensor

YES

Check if sensor resistance

is specification.

Oil Execute re-try.

Check the transmission oil temperature sensor and harness.

With sensor connector

disconnected, check for
continuity between terminal
#A5 of harness end of
connector 2-A in monitor unit
and vehicle frame.

Shorted circuit in harness

between monitor unit and
sensor.
Faulty monitor unit.

NO

Faulty transmission oil

temperature sensor.

NO

Transmission Oil Temperature Sensor

Coolant Temperature
Resistance
(C, F)
(k)
25, 77
7.60.76
40, 104
4.00.35
50, 122
2.70.22
80, 176
0.920.07
95, 203
0.560.04
105, 221
0.420.03
120, 248
0.280.01
Connector (Harness end of connector viewed from the
open end side)
Monitor Unit
Connector 2-A

YES

#A5

T183-05-04-013

T5-5-132

TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13314
Fault Code

Trouble

13314-3

Service Brake Pressure Sensor High

Voltage
Service Brake Pressure Sensor Low
Voltage

13314-4

Remedy
Execute re-try.
Check the service brake pressure sensor and harness.
Execute re-try.
Check the service brake pressure sensor and harness.

Disconnect connector
of pressure sensor.
Check if voltage
NO between termnals #1
and #3 of harness end
connector is 50.5 V.
Key switch: ON

Check if haness
between terminal #6 of
hanress end of
YES connector 2-A in
monitor unit and
terminal #2 in pressure
sensor is open or
shorted.

Check if voltage
between termnal #1
of harness end
connector in pressure
NO
sensor and vehicle
frame is 50.5 V.

Replace pressure
sensors and retry.
Check if fault code
disappears.

Key switch: ON

YES

Faulty harness
between monitor unit
and pressure sensor.

Faulty monitor unit.

NO

Open circuit in
YES harness between MC
and pressure sensor
(terminal #3).
Open circuit in
harness between MC
NO and pressure sensor
(terminal #1).
Faulty service brake
pressure sensor.

YES

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-A

Service Brake Pressure Sensor Connector

#6
1

T183-05-04-013

T5-5-133

TROUBLESHOOTING / Troubleshooting A
(Blank)

T5-5-134

TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the service mode (built-in diagnosing
system) in monitor and Dr.ZX although the machine
operation is abnormal.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.

How to Read the Troubleshoting Flow Charts

YES(OK)

(2)

After checking or measuring item (1), select either YES (OK) or

NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(1)
NO(NOT OK)

(3)

Special instructions or reference item are indicated in the spaces under the box.

Key switch: ON

Incorrect measuring or checking methods will render troubleshooting impossible,

and may damage components as well.

Use the service mode in monitor and the diagnosing system/controller diagnosing

Causes are stated in a thick-line box. Scanning through thick-line boxes, possible

system in Dr.ZX.

causes can be seen without going through the flow chart.

T5-6-1

TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP
BETWEEN
MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Symptoms in control
system when trouble occurs.

Function

Parts
Forward/Reverse Lever

Shift Switch

Parking Brake Switch

Sends the command signal

on forward/reverse to TCU.
Sends the signal on Forward/Reverse to the neutral
relay.

Sends the command signal

on speed gear to TCU.

Releases/applies the parking

brake.

Keeps TCU in neutral when

traveling.

Symptoms in machine
operation when trouble
occurs.

Particular speed gear only

can be operated according to
condition of the shorted or
open circuit.

The parking brake cannot be

released or applied.

Travel
Switch

Mode

Work Mode
Switch

Selector

Selector

Down-Shift Switch
Down-Shift/Up-Shift
Switch

Hold Switch

When the travel mode switch

is manually operated, the
machine can travel at particular speed gear only.
When the travel mode switch
is automatically operated,
speed can be shifted to particular speed gear only.
Although the parking brake
switch is OFF, the machine
cannot operate in the forward
or reverse direction.
Although the parking brake
switch is ON on the slope,
the machine moves.

Sends the command signal

on travel mode to MC.
MC sends the command
signal to TCU through the
CAN circuit.

TCU makes only the travel

mode in manual gear shifting
operable.

When the automatic gear

shifting is selected, the machine can travel in the travel
mode in manual gear shifting
only.

Sends the command signal

on work mode to MC.

MC keeps the work mode

selector switch in Normal
mode.

Although mode L has been

used, fuel consumption suddenly increases after certain
week or month.
Machine operation may be
normal according to the
switch by which engine output is controlled to low at low
speed gear.

Clutch Cut-Off Position

Switch

Although the forward/reverse

lever is operated, the machine does not travel.
Although the forward/reverse
lever is in Reverse, the backlight and back buzzer are not
operated.

Sends the command signal

on clutch cut-off to MC.
MC sends the command
signal to TCU through the
CAN circuit.

Sends the command signal

on down-shift/up-shift switch
to TCU. (The circuit in
down-shift switch is
connected to that at
down-shift side in
down-shift/up-shift switch.)

Sends the command signal

on hold switch to TCU.

If MC does not receive the

signal, MC makes the clutch
cut-off mode disabled.
If the CAN circuit is open,
TCU makes the clutch cut-off
mode disabled.

Although mode S,N or D in

the clutch cut-off mode
switch is selected and the
brake pedal is depressed,
the clutch cut-off is not operated.

TCU makes
down-shift/up-shift switch
control disabled.

Although the
down-shift/up-shift switch is
pushed, down-shift/up-shift is
not operated.
Although the down-shift
switch is pushed, down-shift
is not operated.

TCU makes hold switch

control disabled.

T5-6-2

Although the auto spped gear

shifting is selected and the
hold switch is pushed, travel
speed gear is not fixed.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault Code

TCU: 5010

Evaluation by Monitor
Function

NOTE

T2-1, T2-4

TCU Monitor Item: FNR

switch, Selected speed
gear, Actual speed gear

TCU: 5000

T2-1, T2-4

TCU
Monitor
Item:
Selected
speed
gear,
Actual speed gear, Speed
gear

The parking brake is the spool regulated

pump control circtuit (The parking brake
is released with the parking brake switch
OFF).
If the parking brake pressure sensor is
faulty, the parking brake indicator does
not light with the parking brake switch
ON.

T2-1

T2-1

MC Monitor Item: Clutch

cut-off
switch,
Clutch
cut-off mode

TCU Monitor Item: DSS

switch, USS switch

Although other levers and switches

corresponding to travel are operated
and the down-shift/up-shift switch
control is disabled, this contition is
normal.

T2-1

Although other levers and switches

corresponding to travel are operated
and the hold switch control is disabled,
this contition is normal.

T2-1

T2-1, T2-3, T2-4

T2-1

MC
Monitor
Item:
Auto/manual
selection,
auto speed gear shifting
mode
MC Monitor Item: Engine
torque
control,
Pump
torque control

Descriptions of Control
(Operational Principle
Section in T/M)

TCU Monitor Item: Hold

switch, Hold mode

T5-6-3

TROUBLESHOOTING / Troubleshooting B

Parts

Symptoms in control
system when trouble occurs.

Function

Forward/Reverse Switch

Forward/Reverse Selec-
tor Switch

Fan Reversing Switch

Sends the command signal

on forward/reverse to TCU.
When the machine travels
forward, the signal on
forward is sent to the neutral
relay in forward/reverse
switch.

Sends the command signal

that the forward/reverse
switch is enabled during the
work to TCU.

Sends the command signal

that the fan motor rotates
reverse to MC.

TCU makes forward/reverse

switch control disabled
during the work.

Symptoms in machine
operation when trouble
occurs.

The machine cannot travel

forward/reverse by using the
forward/reverse switch.

The hydraulic drive fan

cleaning control cannot be
selected or released.

Ride Control Switch

Sends the command signal

on ride control to MC.

Ride control cannot be

stopped or operated.

Emergency
Check Switch

Steering

Lift Arm Auto Leveler Set

Switch (Optional)

Sends the operating

command signal on
emergency steering pump
unit to the monitor unit.

Sends the operating

command signal on lift arm
auto level to MC.
Sends the setting signal on
lift arm stop position to MC.

The command signal is not

sent to the monitor unit.
The command signal
continues to be sent to the
monitor unit.

The lift arm auto level cannot

be operated or stopped.
The lift arm stop position
cannot be set randomly.

T5-6-4

The machine cannot travel

forward/reverse by using the
forward/reverse switch during
the work.
Although the forward/reverse
selector switch is turned ON
and the forward/reverse
switch indicator on monitor
lights during the work, the
machine does not travel
forward/reverse.
The machine cannot travel
forward/reverse by using the
forward/reverse switch during
the work.
Although the forward/reverse
selector switch is turned ON,
the forward/reverse switch
indicator on monitor does not
light during the work.
Although the switch is turned
ON, the cooling fan does not
rotate reverse.
Although the switch is turned
OFF, the cooling fan does not
rotate forward.
If the switch is turned OFF
and the forward/reverse
switch is operated, engine
speed does not increase.
Although the ride control
switch is turned ON, ride
control is not operated.
(Travel speed: 7 km/h or
faster)
Although the ride control
switch is turned OFF, ride
control is not stopped.
Emergency steering check
operation cannot be
operated.
Whenever the engine strats,
the emergency steering
pump unit is operated for 30
seconds.
Although the switch is turned
ON, the lift arm does not stop
at the set position.
Although the switch is turned
OFF, the lift arm stops at the
set position.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code
TCU: 5040

Evaluation by Monitor
Function

NOTE

Descriptions of Control
(Operational Principle
Section in T/M)

TCU
Monitor
Item:
Optional
FNR
switch,
Selected
speed
gear,
Actual
speed
gear,
Optional FNR mode

Although the forward/reverse lever is

operated and the forward/reverse switch
operation is disabled during the work,
this contition is normal.

T2-1

TCU
Monitor
Item:
Optional
FNR
selector
switch,
Optional
FNR
mode

Although the forward/reverse lever is

operated and the command signal from
forward/reverse selector switch is
disabled during the work, this contition is
normal.

T2-1

MC Monitor Item: Fan reversing switch

If the switch is turned ON under the

certaion conditions, the fan reversing
control cannot be operated.
If the key switch is turned OFF and the
fan reversing switch is turned OFF, turn
the key ON in 10 seconds. If not, the fan
reversing control is operated on the
logic in MC. When the switches
cprresponding to travel are operated,
engine speed is fixed to the idling
speed. This condition is normal.

T2-1, T2-3

If the travel speed sensor is faulty, ride

control is disabled.

T2-1T2-3

Ride

Monitor Unit Monitor Item:

Emergency steering operation check switch

When the engine starts, the emergency

steering pump unit is operated for 2
seconds. This condition is normal.

T2-1T2-4

MC Monitor Item: Boom

height
kickout
switch,
Boom height kickout setup
switch,
Ground
stop
switch, Ground stop setup
switch

The lift arm auto leveler upward set

switch and lift arm auto leveler
downward set switch are installed.
Each lift arm auto leveler set switch
consists of the auto leveler ON/OFF
switch and lift arm stop position setup
switch.
The lift arm stop position cannot be set
without learning the angle sensor. (Refer
to T4-6.)

T2-1

MC Monitor Item:
control switch
-

T5-6-5

TROUBLESHOOTING / Troubleshooting B

Parts
Accelerator Pedal Sensor

Coolant
Sensor

Temperature

Hydraulic Oil Level Sen-

sor
Air
Filter
Switch

Symptoms in control
system when trouble occurs.

Function

Restriction

Fuel Level Sensor

Hydraulic Oil Tempera-

ture Sensor

Sends the command signal

on accelerator depressing to
MC.

MC fixes engine speed to

-1
1000 min .

As the accelerator pedal is

depressed and engine speed
does not increase, the
machine moves slowly.

Sends the signal on coolant

temperature to the monitor
unit.

Coolant temperature cannot

be detected.

Auto warming-up control is

operated abnormally.
The coolant temperature
gauge is operated
abnormally.

Sends the signal on hydrauli

oil level to the monitor unit.

Hydraulic oil level cannot be

detected.

The brake oil indicator is

operated abnormally.

Sends the signal on air filter

in-take pressure to the
monitor unit.
Sends the signal on fuel level
to the monitor unit.

Air filter in-take pressure

cannot be detected.

Fuel level cannot be

detected.

The air filter restriction

indicator is operated
abnormally.
The fuel gauge is operated
abnormally.

Sends the signal on hydraulic

oil temperature to MC.

Hydraulic oil temperature

cannot be detected.
MC fixes the cooling fan to
the maximum speed.
Engine auto warming-up
control cannot be operated.
Although outside air
temperature is high, auto
warming-up control is
operated.

Hydraulic drive fan cooling

control cannot be operated.
(Cooling fan: Maximum
speed)
The hydraulic oil temperature
indicator is operated
abnormally.

Uses for bucket auto leveler

control.
ON: While the bar is passed
in front, OFF: When the bar
is out of front

The bar cannot be detected.

The bucket auto leveler

cannot be used.

Uses for lift arm height

kickout control.
ON: While the plate is
passed in front, OFF: When
the plate is out of front

The plate cannot be

detected.

The lift arm height kickout

cannot be used.

Lift Arm Angle Sensor

(Optional)

Uses for lift arm auto leveler

control (optional).
Sends the signal on lift arm
operating angle to MC.

Lift arm operating angle

cannot be detected.

The lift arm auto leveler

control (optional) cannot be
used.

Torque Converter Oil

Temperature
Sensor
(Torque Converter Cooler
Piping Upper)

Sends the signal on torque

converter oil temperature to
the monitor unit.

Torque converter oil

temperature cannot be
detected.

Hydraulic drive fan cooling

control cannot be operated.
(Cooling fan: Maximum
speed)
The transmission oil
temperature gauge is
operated abnormally.

Outside Air Temperature

Sensor (for Air Conditioner)

Sends the signal on air

temperature to the air
conditioner controller.

Bucket Proximity Switch

Symptoms in machine
operation when trouble
occurs.

Lift Arm Proximity Switch

Auto temperature control in

the air conditioner cannot be
operated.

T5-6-6

The cab inside becomes cold

or hot rapidly.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code

Evaluation by Monitor
Function

NOTE

Descriptions of Control
(Operational Principle
Section in T/M)

MC: 11103

MC Monitor Item: Required

engine speed deviation,
Engine speed deviation,
Accelerator pedal,
ECM Monitor Item: Actual
engine
speed,
Target
engine speed

If MC malfunctions, ECM set engine

speed to 1000min-1. In this case, if the
accelerator dedal wiring is connected to
ECM directly, engine speed control
becomes possible.

T2-1

ECM: 110

The harnesses from same sensors are

connected to ECM and the monitor unit
respectively. If both temperature
displays are abnormal, the sensor may
be faulty. If one temperature display is
abnormal, the controller including the
abnormal harness may be faulty.

T2-1

ECM Monitor Item: Coolant

temperature
Monitor Unit Monitor Item:
Radiator
coolant
temperature (possible to
be displayed by using the
service mode on monitor)
MC Monitor Item: Service
brake oil level switch

Monitor Unit Monitor Item:

Air filter restriction

Monitor Unit Monitor Item:

Fuel level

If the circuit is opened or shorted, the

fuel gauge pointes to E.

MC Monitor Item: Hydraulic

oil temperature (possible to
be displayed by using the
service mode on monitor)

MC: 11901

T2-1, T2-3

T2-1
-

T2-1
-

If the angle sensor learning is not

completed, the lift arm stop position
cannot be set. (Refer to T4-6.)

T2-1

MC Monitor Item: Boom

angle,
Angle
sensor
learning status
Monitor Unit Monitor Item:
T/M Torque converter oil
temperature (possible to
be displayed by using the
service mode on monitor)

If the circuit is shorted, overheating (red

zone) is displayed.

T2-1, T2-3, T3-12

Monitor Unit: 13312

T5-6-7

TROUBLESHOOTING / Troubleshooting B

Parts

Symptoms in control
system when trouble occurs.

Function

Symptoms in machine
operation when trouble
occurs.

Outside Air Temperature

Sensor (for MC)

Sends the signal

temperature to MC.

air

Air temperature cannot be

detected.

Just after the engine starts,

the air conditioning is weak
with the air conditioner switch
ON. (No cooled wind blows.)

Torque Converter Input

Speed Sensor

Sends the signal on torque

converter inlet speed to TCU.

Torque converter inlet speed

cannot be detected.

As torque decrese control

cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.

Torque Converter Output

Speed Sensor

Sends the signal on torque

converter outlet speed to
TCU.

Torque
converter
outlet
speed cannot be detected.

As torque decrese control

cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.

Control

Is
installed
to
the
transmission.
Decreases oil presssure from
the drive unit pump and
supplies clutch connection
pressure.
The spool moves according
to
the
transmission
proportional solenoid valve
and
clutch
connection
pressure is supplied to the
certain clutch pack.

Speed gear cannot be shifted

normally.

Transmission
Propor-
tional Solenoid Valve

Is
installed
to
the
transmission control valve.
Consists of 6 solenoid valves
for slow forward, fast forward,
reverse, first gear, second
gear and third gear. Is
operated by the command
signal from TCU and shifts
the spool in transmission
control valve.

The following troubles may

occur
according
to
malfunction. As the serious
accident
including
the
transmission break occurs,
judge the trouble carefully.
Although the forward/reverse
lever is in Neutral, the
machine moves.
Although the accelerator
pedal is depressed, the
machine moves slowly or
does not move at all. At this
time, although engine speed
increases, the engine has a
heavy load.
Big shock occurs when
speed gear is shifted.
Certain speed gear can be
used.

Tem-

Is
installed
to
the
transmission control valve.
Sends the signal on oil
temperature to TCU.

Transmission
Valve

Transmission Oil
perature Sensor

on

Speed gear cannot be shifted

normally.
Travel speed is fixed to first
gear or second gear due to
the abnormal proportional
solenoid valve.

Transmission oil temperature

cannot be detected.

T5-6-8

Transmission oil temperature

is not displayed on Dr.ZX and
the monitor.
Transmission learning cannot
be performed.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code

Evaluation by Monitor
Function
MC Monitor Item: Outside
air temperature

NOTE

The cooling fan rotates slowly just after

the engine starts. At this time, if the air
conditoner switch is turned ON, the air
conditioning becomes weak. When air
temperature is high and hydraulic oil
and coolant temeprature are low, if the
air conditoner switch is turned ON, MC
increases target fan speed.

MC Monitor Item: Actual

engine
speed,
Engine
speed deviation, Torque
converter speed ratio
TCU Monitor Item: Actual
engine speed
(possible to be displayed
by using the service mode
on monitor)

TCU: 5140

T2-1, T3-9

TCU Monitor Item: Torque

converter output speed,
Torque converter speed
ratio

TCU: 5150

Descriptions of Control
(Operational Principle
Section in T/M)

T2-1, T3-9
-

T3-9

TCU: 5480, 5490, 5500,

5510, 5520, 5530, 5830

If the travel mode siwtch is in Auto, only

speed gear which is selected by using
the shift switch can be operated. This
condition is normal.

T2-1, T3-9

TCU: 5110, 5770

TCU Monitor Item: Transmission oil temperature

T3-9
-

T5-6-9

TROUBLESHOOTING / Troubleshooting B

Parts

Symptoms in control
system when trouble occurs.

Function

Symptoms in machine
operation when trouble
occurs.

Middle

Sends
the
signal
on
trasmission middle shaft
speed to TCU.

Transmission middle shaft

speed cannot be detected.

If the travel speed sensor

malfunctions, travel speed is
not displayed on the monitor.

Sends
the
signal
on
trasmission
output
shaft
speed to TCU.

Travel speed in TCU cannot

be calculated.

Travel speed
second gear.

Oil

Is installed between torque

converter
and
torque
converter oil cooler pipng
upper in order to protect the
oil cooler.

If the valve is kept open,

torque converter oil returns to
the tank without flowing
through the torque converter
oil cooler.
If the valve is kept closed,
the torque converter oil
cooler check valve which is
installed to the drive unit is
operated.

If the valve is kept open,

transmission oil temperature
becomes high and the
transmission indicator may
light easily.
If the valve is kept closed,
there is no efficiency.

Is installed to the axle upper.

Sends the signal on axle oil
temperature to the monitor
unit.

Axle oil temperature cannot

be detected.

Service Brake Pressure

Sensor

Is installed to the service

brake pressure outlet port in
front axle.
Sends the signal on pressure
to TCU.

MC makes clutch
control disabled.

cut-off

Although S, N or D in the
clutch cut-off mode switch is
selected, clutch cut-off is not
operated when the brake
pedal is depressed.

(Main

Divides main pump delivery

pressure oil into the steering
valve and the control valve
effectively.

Division of main pump

delievery
pressure
oil
becomes less efficient.

The
steering
or
front
attahment is operated slowy
according to malfunction.

Main
Pump
Delivery
Pressure Sensor

Sends the signal on main

pump delivery pressure to
MC.

Main pump delivery pressure

cannot be detected.
MC makes torque decrease
control disabled.

Although
engine
torque
control cannot be operated
properly, clear malfunction
may not occur except bad
fuel consumption.
As torque decrease control
cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.

Transmission
Shaft Sensor

Travel Speed Sensor

Torque Converter
Cooler Check Valve

Axle Oil
Sensor

Temperature

Priority
Pump)

Valve

Steering Relief Valve

Is installed to the priority

valve (main pump) side on
main pump upper.
Is operated when steering
circuit pressure exceeds the
specification in order to
protect the steering circuit.

If the valve is kept open, the

priority valve (main pump) is
operated abnormally.

T5-6-10

is fixed to

Although axle oil temperature

is over 120 C, the service
indicator does not light.
Although axle oil temperature
is less than 120C, the
service indicator lights.

If the valve is kept open, the

priority valve (main pump)
spool stops and pressure oil
is supplied to the control
valve. Then, steering is
operated slowly.
If the valve is kept closed,
the steering circuit may be
damaged.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code

Evaluation by Monitor
Function

NOTE

TCU: 5160, 5660, 5665,

5670, 5675, 5680, 5685

MC Monitor Item: Travel

speed
TCU Monitor Item: Transmission
output
speed

TCU: 5170, 5180, 5660,

5665, 5670, 5675, 5680,
5685

Descriptions of Control
(Operational Principle
Section in T/M)
T2-1, T3-9

T2-1, T3-9

T3-12

Monitor Unit: 13318

Monitor Unit Monitor Item:

Axle oil temperature
-

TCU Monitor Item: Pedal

brake pressure

TCU: 5313

T2-1
-

T2-3, T3-1
-

MC Monitor Item: Pump

pressure

MC: 11204

T2-1, T2-3, T3-1

T2-3, T3-1

T5-6-11

TROUBLESHOOTING / Troubleshooting B

Parts
Implement
Sensor

Symptoms in control
system when trouble occurs.

Function
Pressure

Is installed to piping upper

between main pump and
control valve.
Sends the signal on pressure
to control valve from main
pump to MC.

Pressure cannot be detected.

MC makes torque decrease
control disabled.

Symptoms in machine
operation when trouble
occurs.

Negative Control Valve in

Control Valve

Supplies front/rear pressures

at the orifice in neutral circuit
in control valve to the main
pump regulator.
As
pressure
difference
becomes large with the front
attachment in neutral, the
main
pump
regulator
decreases
main
pump
delivery flow rate.

Bucket Flow Rate Control

Valve in Control Valve
(ZW220)

Controls pressure oil flow

rate to the bucket cylinder
during combined operation of
bucket and lift arm in order to
operate combined operation
smoothly.

Pressure oil flow rate to the

bucket cylinder cannot be
controlled properly.

Flow Rate Control Poppet

Valve in Control Valve
(ZW250)

Controls pressure oil flow

rate to the bucket cylinder
during combined operation of
bucket and lift arm in order to
operate combined operation
smoothly.

Pressure oil flow rate to the

bucket cylinder cannot be
controlled properly.

Flow Rate Control Se-

lector Valve in Control
Valve (ZW250)

Reduces pressure oil flow

rate to the bucket cylinder
during combined operation of
bucket and lift arm raise in
order to operate combined
operation smoothly.

Pressure oil flow rate to the

bucket cylinder cannot be
controlled properly.

Controls pressure oil flow

rate to the steering cylinder.

The steering cylinder cannot

be controlled.

Steering Valve

Main pump delivery flow rate

cannot be controlled properly.

Steering Accumulator

Absorbs pulsation
steering circuit.

the

Pulsation in the steering

circuit cannot be absorbed.

Stop Valve

Stops supplying pressure oil

to the steering valve from the
steering pilot valve when the
steering is operated to the
stroke end, comes in contact
with the frame and closes the
valve.

Pressure oil flow rate to the

steering valve from the
steering pilot valve cannot be
controlled.

in

T5-6-12

Although
engine
torque
control cannot be operated
properly, clear malfunction
may not occur except bad
fuel consumption.
As torque decrease control
cannot be operated, the
engine has a load during
combined operation of travel
and front attachment.
When travel load is heavy
and the front attachment is
operated, the engine may be
stalled.
If
pressure
difference
becomes small, there is no
efficiency to the machine
operation. In the long and
medium
terms,
fuel
consumption may become
bad.
If
pressure
difference
becomes large, the front
attachment and steering are
operated slowly.
Speed ratio during combined
operation of front attachment
changes.

Speed ratio during combined

operation of front attachment
changes.
Bucket single operation may
become slow.
Speed ratio during combined
operation of front attachment
changes.
Bucket single operation may
become slow.
According to malfunction, the
troubles may occur including
the steering is operated
slowly,
the
steering
is
operated without operating
the steering hadle, and so
on.
When
the
steering
is
operated, hunting may occur.
When
the
steering
is
operated, hunting occurs
easily.
When the valve is kept open,
although the steering is
operated to the stroke end,
the steering handle can be
operated.
When the valve is kept
closed, the steering handle is
operated hardly or cannot be
operated.

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code
MC: 11209

Evaluation by Monitor
Function
MC
Monitor
Implement pressure

NOTE

Descriptions of Control
(Operational Principle
Section in T/M)

Item:

If pressure becomes small, pump

delivery pressure becomes over 2 Mpa
2
(20kgf/cm ) when the engine speed is at
fast idle in neutral.
-

T2-3, T3-2

T2-3, T3-2
-

T2-3, T3-2
-

T2-3, T3-2
-

T2-3, T3-5

T2-3
T2-3

T5-6-13

TROUBLESHOOTING / Troubleshooting B

Parts

Symptoms in control
system when trouble occurs.

Function

Symptoms in machine
operation when trouble
occurs.

Steering Pilot Valve

Controls pilot pressure oil

flow rate and direction to the
steering valve spool end
according to steering handle
operating
speed
and
direction.

Pilot pressure oil flow rate

cannot be controlled properly.

Ride Control Valve

Supplies lift arm cylinder

bottom pressure to the
accumulator through the
chage cut-off spool with the
ride control switch OFF.
Closes the charge cut-off
spool and blocks the circuit
to lift arm cylinder bottom
side
when
accmulated
pressure in the accumulator
exceeds the specification.
Operates the solenoid valve
by the command signal from
MC, moves the main spool
and connects the circuits
between lift arm cylinder
bottom side and accumulator,
between lift arm rod side and
hydraulic oil tank when travel
speed reaches 7km/h or
faster with the ride control
switch ON.
Is installed to emergency
steering block in circuit upper
between main pump and
steering valve.
Sends the signal on steering
circuit pressure to the
monitor unit.
Is installed to between
emergency steering pump
and emergency steering
block.
When pressure oil beyond
specification
from
the
emergency steering pump is
supplied, the connection is
broken and the monitor unit
judges that the emergency
steering switch is operated
correctly.
Operates the flow rate
adjustment solenoid valve by
the command signal from
MC. Controls pressure oil
flow rate to the fan motor by
operating the flow rate
control valve. Increases or
decreases cooling fan speed.
Operates the reverse control
solenoid
valve
by
the
command signal from MC.
Shifts the outlet port for
pressure oil to the fan motor
by operating the reverse
control valve. Switches the
cooling fan in reverse
rotation.

Pressure
cannot
be
accumulated
in
the
accumulator.
The solenoid valve and main
spool cannot be controlled.

Steering circuit pressure

cannot be detected.

Although there is no trouble

in the steering circuit, the
emergency steering pump is
operated.

The
normal
signal
on
pressure occurrence is not
sent to the monitor unit.

Although the emergency

steering pump auto check
circuit is operated when the
engine starts, the emergency
steering
pump
indicator
blinks.

The flow rate control valve

cannot be controlled.
The reverse control valve
cannot be controlled.

Cooling fan speed cannot be

controlled.
Cooling fan reverse control
cannot be operated.

Emergency
Steering
Pressure Switch

Emergency
Steering
Pump Delivery Pressure
Switch

Hydraulic Fan Motor

T5-6-14

According to malfunction, the

troubles may occur including;
although the steering handle
is
operataed
fast,
the
steering is operated slowly,
although the steering handle
is operataed slowly, the
steering is operated fast, and
so on.
Ride control is not operated.
(Shock when traveling is
continued.)
Ride control does not stop.
(Shock when traveling is
always reduced.)

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code

Evaluation by Monitor
Function

NOTE

Descriptions of Control
(Operational Principle
Section in T/M)
T2-3, T3-4

MC Monitor Item: Ride

control proportional valve
output, Ride control proportional valve output FB

If the travel speed sensor malfunctions,

MC makes ride control disabled.

T2-1, T2-3, T3-8

Although the emergency steering pump

is operated for 2 seconds when the
engine starts, this condition is normal.

T2-3, T2-4, T3-12

Monitor Unit: 13313

Monitor Unit Monitor Item:

Steering pressure

T2-3, T2-4

Monitor Unit Monitor Item:

Emergency steering pump
pressure switch
-

MC: 11412

T2-1, T2-3, T3-3

MC Monitor Item: Hydraulic

fan target speed, Hydraulic
drive
fan
proportional
valve, Hydraulic drive fan
proportional
valve
FB,
Hydraulic drive fan reverse
valve
-

T5-6-15

TROUBLESHOOTING / Troubleshooting B

Parts

Symptoms in control
system when trouble occurs.

Function

Charging Block

Priority Valve (Charging

Block)

Primary Brake Pressure

Sensor

Service
Valve

Brake

Relief

Symptoms in machine
operation when trouble
occurs.

Divides pilot pump pressure

oil into the brake circuit and
the pilot circuit effectively.
Accumulates pressure at
outlets of brake circuit and
pilot circuit and supplies
stable pressure to both
circuits.

Is installed in the charging

block. Divides pilot pump
pressure oil into the brake
circuit and the pilot circuit
effectively.

Is installed in the charging

block. Monitors accumulated
pressure in the service brake
accumulator.

Is installed in the charging

block. Is operated when
accumulated pressure in the
service brake accumulator
exceeds the specification.
Supplies pilot pump delivery
oil to the pilot circuit after the
priority valve (charging block)
is open.

Is installed in the charging

block. Is operated by the
command signal from MC.
Supplies pilot pressure for
pump delivery flow rate
control to the main pump
regulator.

Pilot pressure to the main

pump regulator cannot be
controlled and supplied.

According to malfunction, the

troubles may occur including
the front attachment/steering
are operated slowly, the
engine
stalled
during
combined operation of front
attachment and travel or
engine idling, and so on.

Stable pressure cannot be

supplied to the brake circuit
or the pilot circuit.

Stable pressure cannot be

supplied to the brake circuit
or the pilot circuit.

Accumulated pressure in the

the
service
brake
accumulator
cannot
be
detected.

Accumulated pressure in the

the
service
brake
accumulator
cannot
be
controlled.

The brake oil pressure

indicator lights.
The parking brake cannot be
released.
The
front
attachment/
steering
cylinders
are
operated slowly.
The brake oil pressure
indicator lights.
The parking brake cannot be
released.
The brake oil pressure
indicator on monitor always
lights.
Although the trouble in the
service brake circuit due to
pressure decrease, the brake
oil pressure indicator on
monitor does not light.
According to malfunction, the
service
brake
efficinecy
becomes bad or the parts in
service brake circuit are
damaged.
According to malfunction, the
parking brake is completery
not released or the parts in
parking brake circuit are
damaged.

Pump Torque Control

Proportional
Solenoid
Valve

Parking Brake Solenoid

Valve

Controls that the parking

brake is applied or released.

The parking brake cannot be

controlled to apply or release.

According to malfunction, the

parking brake cannot be
applied or released.

Parking Brake Pressure

Sensor

Sends the signal on parking

brake circuit pressure to MC.

Parking
brake
circuit
pressure cannot be detected.
MC makes the parking brake
indicator go off forcibly.
MC makes forward/reverse
operation disabled when the
parking brake is applied.

The machine cannot travel

forwad/reverse.
The parking brake indicator
does not light with the
parking brake switch OFF.
Although the parking brake is
applied, the machine can
travel.

Electromagnet in Pilot
Valve

Fixes the control lever by the

magnetic force when the
electromagnet in pilot valve
is magnetized and the control
lever in pilot valve is moved
to the detent position.

The control lever in pilot

valve is not fixed in the
detent position.

Although the electromagnet

in pilot valve is magnetized,
the control lever is not fixed.

Brake Valve

Supplies
pilot
pressure
according to brake pedal
depression from the outlet
port and operates the service
brake.

Pilot pressure
controlled.

The service brake does not

function.

T5-6-16

cannot

be

TROUBLESHOOTING / Troubleshooting B

Evaluation by Fault
Code

Evaluation by Monitor
Function

NOTE

Descriptions of Control
(Operational Principle
Section in T/M)
T2-3, T3-7

T2-3, T3-7
-

Monitor Unit: 13314

Monitor Unit Monitor Item:

Service brake pressure

T2-3, T3-7

T2-3, T3-7

T2-1, T2-3, T3-7

MC Monitor Item: Pump

displacement proportional
valve output, Pump displacement
proportional
valve output FB

MC: 11413

T2-1, T2-3, T2-4, T3-12

-

MC Monitor Item: Parking

brake pressure
Monitor Unit Monitor Item:
Parking
brake
signal,
Parking brake pressure
switch

MC: 11313

The parking brake body circuit is

separated from the parking brake
operation monitoring circuit. Therefore,
although the parking brake operation
monitoring circuit malfunctions, if the
parking brake body circuit is normal, the
parking brake can be operated.

MC Monitor Item: Boom

height kickout, Ground
stop system

T2-1, T2-3, T2-4, T3-12

T2-1, T3-6
-

T2-1, T2-3, T3-11

-

T5-6-17

TROUBLESHOOTING / Troubleshooting B
CORRELATION
BETWEEN
TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.

z : 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.

Engine System Troubleshooting

Trouble
Symptom

E-1
Starter does not rotate.

E-2
Even if starter rotates, engine
does not start.

E-3
Engine is difficult to start at
low temperature.

Parts
Battery Relay

Glow Relay
Safety Relay
Neutral Relay
Main Relay for ECM
MC
ECM
Key Switch
Forward/Reverse Lever
Forward/Reverse Switch
Fan Reverse Switch
Accelerator Pedal Sensor
Main Pump Regulator
Fuel Pump
Pump Delivery Pressure Sensor
Implement Pressure Sensor

z
z
z
z
z

z
z
z

Pump Torque Control Proportional

Solenoid Valve
Engine Unit
Engine Electrical Equipment
Remarks

z
Check fuse and battery.

z
Check intake and fuel system.
(filter, piping)

T5-6-18

z
Check fuse and battery.

TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.

E-4
Even if accelerator pedal is depressed, engine speed remains
unchanged.

z
z

E-5
Even if key switch is turned
OFF, engine does not stop.

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.

E-6
Engine stalls during operation
under adverse condition such as
at high altitude.

z
z
{

z
z
z
z
z
z
z
z
Check wiring
pedal sensor.

{
z
of

accelerator

Check fuse and battery.

T5-6-19

TROUBLESHOOTING / Troubleshooting B

Front Attachment System Troubleshooting

F-1
Trouble
All front attachments does not
Symptom
move.
Parts

F-2
All front attachment operations are slow/ weak.

MC
ECM
TCU
Shift Switch
Work Mode Selector Switch
Accelerator Pedal Sensor
Lift Arm Proximity Switch
Torque Converter Input Speed Sensor

F-3
Certain front attachment is
slow/ weak.

z
{

Torque Converter Output Speed Sensor

Main Pump
Main Pump Regulator
Priority Valve (Main Pump)
Main Pump Delivery Pressure Sensor
Steering Relief Valve
Pilot Pump
Implement Pressure Sensor
Control Valve Spool
Main Relief Valve in Control Valve
Overload Relief Valve in Control Valve

z
{
z
z
z
z
{
{
{

z
{
z

Load Check Valve in Control Valve

Make-Up Valve in Control Valve

Restriction Valve in Control Valve

Bucket Flow Rate Control Valve in

Control Valve (ZW220)

Flow Rate Control Poppet Valve in

Control Valve (ZW250)

Flow Rate Control Selector Valve in

Control Valve (ZW250)

Cylinder

Steering Valve

Steering Pilot Valve

Charging Block

Priority Valve (Charging Block)

Service Brake Relief Valve

Pilot Relief Valve

z
{

Pump Torque Control Proportional Solenoid Valve

Pilot Valve

Electromagnet in Pilot Valve

Pilot Shut-Off Valve

Engine Unit

Engine Electrical Equipment

Remarks

Check fuse and battery.

T5-6-20

TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
F-4
Front attachment moves
with lever in neutral.

F-5
Front attachment drifts
remarkably.

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.

F-6
Bucket is slow during
combined operation.

F-7
Work mode is not effective.

F-8
Lift arm height kickout is
not operated.

z
z
{
z
z
z
z
z

z
z

z
z

z
z
z
z

{
z

z
z

When the engine stops.

z : 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.

T5-6-21

TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.

Trouble Symptom

F-9
Lift arm float is
not operated.

F-10
Bucket auto leveler
is not operated.

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.
F-11
Lift arm auto lever is
not operated. (optional)

F-12
Lift arm auto lever
stop position cannot be set. (optional)

F-13
Ride Control is not
effective.

Parts
MC
TCU

Ride Control Switch

Lift Arm Auto Leveler Set

Switch (Optional)
Bucket Proximity Switch

Lift Arm Angle Sensor (Optional)

Travel Speed Sensor
Control Valve Spool

z
{

Overload Relief Valve in Control Valve

Cylinder
Ride Control Valve
Charging Block
Priority Valve (Charging Block)
Service Brake Relief Valve
Pilot Relief Valve
Electromagnet in Pilot Valve

{
z
{
{
{
{
z

z
When the lift arm angle
sensor does not learn
and the stop position is
not set, lift arm auto
leveler is not operated.

Remarks

z : 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.

T5-6-22

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-23

TROUBLESHOOTING / Troubleshooting B

Travel System Troubleshooting

Trouble
Symptom

T-1
Machine does
travel
ward/reverse.

not
for-

T-2
Machine does not
travel forward or reverse.

T-3
Machine moves with
lever in neutral.

T-4
Even if travel speed is
turned up or down,
travel speed gear is
not changed.

Parts
MC (Main Controller)
TCU
Monitor Unit
Forward/Reverse Lever
Shift Switch
Travel Mode Selector Switch
Down-Shift Switch
Down-Shift/Up-Shift Switch
Hold Switch
Forward/Reverse Switch
Forward/Reverse Selector Switch
Drive Unit Charging Pump
Torque Converter
Transmission Control Valve
Transmission
Valve

Proportional

z
z
{
z

z
z
z
z
z

Solenoid

Transmission
Travel Speed Sensor
Axle
Service Brake
Service Brake Pressure Sensor
Propeller Shaft
Parking Brake Pressure Sensor
Brake Valve
Engine Unit
Engine Electrical Equipment

z
z

{
{
z
{
z
z
{
{

Remarks

T5-6-24

z
z

TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.

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.

T-5
T-6
T-7
Even if up-shift switch is Even if down-shift switch Even if hold switch is
pushed, travel speed gear is pushed, travel speed pushed, travel speed gear
is not turned up.
gear is not turned down.
is not fixed.

{
z

z
z

{
z

z : Related, required to check

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.

T5-6-25

TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.

Trouble
Symptom

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.

T-9
T-8
Travel mode is not Clutch cut-off is not
shifted.
operated.

Parts
MC (Main Controller)
TCU
Monitor Unit
Travel Mode Selector Switch
Clutch Cut-off Position Switch
Torque Converter Input Speed Sensor
Torque Converter Output Speed Sensor
Travel Speed Sensor
Service Brake Pressure Sensor

z
{
z
z

z
{
z
z

{
{
{
z

Remarks

z : 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.

T5-6-26

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-27

TROUBLESHOOTING / Troubleshooting B

Brake System Troubleshooting

Trouble
Symptom

B-1

B-2

B-3

Parking brake is not

released.

Parking brake is
not locked.

Service brake efficiency is bad or

low.

Parts
Parking Brake Relay 1
Parking Brake Relay 2
Monitor Unit
Parking Brake Relay Switch
Parking Brake
Service Brake
Pilot Pump
Charging Block
Priority Valve (Charging Block)
Service Brake Relief Valve
Pilot Relief Valve
Parking Brake Solenoid Valve
Brake Valve
Engine Electrical Equipment

z
z
z
z
z

z
z
z
z
{

{
{
{
{

z
z

z
z

Remarks

z : 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.

T5-6-28

NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-29

TROUBLESHOOTING / Troubleshooting B

Steering/Other System Troubleshooting

Trouble
Symptom
Steering
Parts
Main Pump
Main Pump Regulator
Priority Valve (Main Pump)
Steering Relief Valve
Pilot Pump
Cylinder
Steering Valve
Steering Overload Relief Valve
Stop Valve
Steering Pilot Valve
Charging Block
Priority Valve (Charging Block)
Pilot Relief Valve
Other Electrical Equipment

H-1

O-1

cylinder operation is slow or does

not move.

Air conditioner operation

malfunctions.

{
{
z
z
{
z
z
z
z
z
{
{
{
z
Check if the steering
shaft is normal.

Remarks

z : 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.

T5-6-30

NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-31

TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key

switch is not routed to safety relay with the forward/reverse lever

or forward/reverse switch in
Forward or Reverse position, the
starter does not rotate. (Refer to
Electrical System / SYSTEM.)

This trouble has nothing to do with the electronic

control system such as MC.

Check the wiring connections first.

YES
Switch neutral relay
YES with other general relay.
Check if starter rotates.
Key switch: START

Check if both voltages

YES at key switch terminals #5 and #6 are 24
V.

Faulty neutral relay.

Remove neutral relay.

Check if voltage at terminal #3 of harness end
NO of connector is 24 V.
Key switch: START

Key switch: ON

YES Faulty key switch.

Check if battery voltage

and electrolyte density is
normal, and fusible link
(100 A) is not blown.

NO

Voltage: 24 V or more
Density: 1.26 or more

Check for continuity

between battery positive terminal and key
switch terminal #1.
Key switch: ON

NO

Faulty fuse or harness

between battery and key
switch.

Faulty battery or faulty

fusible link.

NO

Battery Relay:

Key Switch:

Terminal A

#6

#1

#5
T178-05-04-001
T105-07-04-002

T5-6-32

TROUBLESHOOTING / Troubleshooting B

YES Check if voltage at

terminal A in battery
relay is 24 V.
Check if voltage at
YES terminal #1 of harness end of connector in neutral relay is 0 V.

Disconnect connector
of safety relay.
Connect terminal S of
harness end of connector to vehicle
YES frame.
Check for continuity
between terminal #4 of
harness end of connector in neutral relay
and vehicle frame.

Faulty battery relay.

NO

Key switch: ON
NO

Open circuit in harness

between key switch and
neutral relay.

NO

Connector (Harness end of connector viewed from the

open end side)
Neutral Relay

Safety Relay

E
#1

#3

Shorted circuit in harness

between neutral relay
and forward / reverse

Open circuit in harness

between neutral relay
and safety relay.

NO

#4

Faulty starter, or faulty

YES harness between starter
and battery relay.

T183-05-04-003

#S

T5-6-33

TROUBLESHOOTING / Troubleshooting B
E-2 Even if starter rotates, engine does not start.
Related MC Fault Code: None

Check the wiring connections first.

Check if fuel system malfunctions, the fuel filter is
clogged or the fuel pump is properly operated
with the key ON.

Faulty main relay.

YES

Switch main relay

with other general
relay.
Check if engine
starts.
Disconnect main relay
from connector.
Check if voltage beNO tween terminal #3 of
harness end of connector and vehicle
frame is specification.
Specification: 24V
Key switch: ON

Connect terminal #5 of
harness end of connector in main relay to vehicle frame.
YES Disconnect connector in
ECM.
Check for continuity
between terminals #2,
#5 of harness end of
connector and vehicle
frame.

Connect terminal #1 of
harness end of connector in main relay to
YES vehicle frame.
Check for continuity
between terminals #21,
#40 of harness end of
connector in ECM and
vehicle frame.

Open circuit in harness

between main relay and
NO ECM.
Open circuit in harness
between key switch and
main relay.

NO

Connector (Harness end of connector viewed from the

open end side)
Main Relay Connector

ECM Connector

#21

#24

#5

#1
#2

#5
#3
T183-05-04-003
T1GR-05-04-002

#40

T5-6-34

#2

TROUBLESHOOTING / Troubleshooting B

Check if voltage
YES between terminal
#24 of harness
Check for contiend of connector
nuity between
in ECM and vehiterminal #2 of
cle frame is
YES
harness end of
specification.
connector in main
Key switch: ON
relay and vehicle
Specification: 24
frame.
V

Disconnect con- YES

nector ICF-C in
ICF. Check if
voltage between
YES
Disconnect
terminal #C7 of
connector MC-B
harness end of
in MC.
connector and
Check if voltage
vehicle frame is
YES between terminal
specification.
NO
#B16 of harness

Key
switch:
ON
end of connector
Specification: 24
and vehicle
V
frame is specification.
Key switch: ON NO
Specification: 24
V

Open circuit in fuse or

harness between key
switch and monitor unit.

Open circuit in fuse or

harness between key
switch and ICF.

Open circuit in fuse or

harness between key
switch and MC.

Open circuit in fuse or

harness between key
switch and ECM.

NO

Faulty ground in main

relay.

NO

Open circuit in harness

between main relay and
ECM.

NO

Connector MC-B

Connector ICF-C
#B16

B1

B8

B19

B25

#C7

T5-6-35

T1V1-05-04-002

TROUBLESHOOTING / Troubleshooting B
E-3

Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does
not start even if pre-heated.)

Check if electricity is routed to the glow plugs.

Check the glow plugs for any abnormality.
Check the battery.
Check the wiring connections first.

NOTE: If there is no malfunction on the fol-

lowings and the engine is difficult to

start with the engine cold, the fuel
pump performance may become bad.

Faulty coolant temperature sensor.

YES

Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug
is 20 to 24 V.

Faulty ECM.

YES

Key switch: ON
NO

Connect terminal #10 in

ECM to vehicle frame.
Check if problem is corrected.
Connect to machine from
the back of connector by
using a clip with the connector connected.

Measurement of Glow Plug Voltage and Resistance

NO

Measure each glow plug

resistance.
Key switch: OFF
Before measuring, remove copper plates
connecting each glow
plug.

Voltage Check

Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
T105-07-04-006

Specification: Below 10

T105-07-04-007

T5-6-36

TROUBLESHOOTING / Troubleshooting B

10 or higher

Faulty glow plug.

NO

YES

Connect connector in
glow relay.
Connect terminal #4 of
harness end of connector
to vehicle frame.
Check if voltage at glow
plug is 20 to 24 V.
Key switch: ON

YES

Faulty glow relay, or

faulty harness between
glow relay and glow plug.

Open circuit in harness

between glow relay and
ECM.

Disconnect connector in
glow relay.
Check if voltages at terLess than 10 minals #1 and #3 of harness end of connector in
glow relay are 20 to 24 V.
Key switch: ON

If terminal #1 is 0 V, open
circuit in 100A fuse or
harness between glow
relay and battery. If terminal #3 is 0 V, open
circuit in fuse or harness
between glow relay and
terminal M in key switch.

NO

Connector (Harness end of connector viewed from the

open end side)
ECM Connector

Glow Relay Connector

#10

#1

#4

#3

T1GR-05-04-002
T183-05-04-003

T5-6-37

TROUBLESHOOTING / Troubleshooting B
E-4 Even if accelerator pedal is depressed, engine speed remains unchanged.
Related MC Fault Code: 11004-2, 11101-3, 11101-4

Check the wiring connections first.

Turn the key switch OFF with the fan reversing
switch ON. Turn the fan reversing switch OFF
within 10 seconds and start the engine. When the
machine travels, engine speed is fixed to idling
speed. This condition is normal. Although the fan
reversing switch is OFF, if the same trouble occurs, harness to the fan reversing switch or MC
may be shorted.

Faulty accelerator pedal,

or open circuit in harness
between accelerator
pedal and MC.

YES
Check if fault code 11101-3 or
11101-4 is displayed.
Monitor accelerator pedal
(standard voltage) by using
Dr. ZX.
Check if voltage is normal.
Key switch: ON
Standard voltage
Slow idle position: 0.3 to 1 V
Fast idle position: 4.0 to 4.7 V

YES

NO

Faulty CAN between MC

and ECM.

Check if fault code 11004-2 is

displayed at the same time.
Key switch: ON
Faulty MC.
NO

T5-6-38

TROUBLESHOOTING / Troubleshooting B
E-5 Even if key switch is turned OFF, engine
does not stop.

Check the wiring connections first.

The trouble that even if accelerator pedal is
depressed, engine speed remains unchanged may occur. Execute the troubleshooting procedures on this trouble.

YES

Faulty key switch.

Check if voltage at
terminal #5 in key
switch is 24 V.

NO

Key switch: OFF

NO

Disconnect connector
in ECM.
Check if voltage between terminal #24 of
harness end of connector and vehicle
frame is 0 V.

Faulty ECM.

Key switch: OFF

Key Switch:

Shorted circuit in
harness between
key switch and ECM.

YES

Connector (Harness end of connector viewed from the

open end side)
ECM
Connector (Harness end)

#24

T1GR-05-04-002

#5
T105-07-04-002

T5-6-39

TROUBLESHOOTING / Troubleshooting B
E-6 Engine stalls during operation under adverse condition such as at high altitude.
Related MC Fault Code: 11004-2, 11910-2, 11209-3,
11209-4,11413-2, 11413-3,11413-4

Check the wiring connections first.

Check if fuel system malfunctions, the fuel filter is
clogged or the fuel pump is properly operated
with the key ON.
Faulty pump delivery
pressure sensor, implement pressure
sensor or pump
torque control solenoid valve.

YES

Check if fault code

NO 11204-3, 11204-4,
11209-3, 11209-4,
11413-2, 11413-3 or
11413-4 is displayed.

Monitor pump torque

control solenoid valve
output. Install a pressure gauge to output
port.
Check pressure values
on Dr. ZX and pressure gauge.
Check if pressure increases or decreases
with both pressure in
equal.

Engine: Running

NO

Monitor actual engine

speed.
Check if abnormal engine speed is detected.

Faulty pump torque

NO control solenoid
valve, or open circuit
in harness to MC.

Disassemble and
check main pump
YES regulator.

Engine: Running
MC monitor item: Pump
displacement proportional
valve output
Refer to Operational Performance Test section.

Engine: Running
MC monitor item: Actual
engine speed

Refer to fault code

11004-2 in Troubleshooting A.

YES

Check if fault code

YES 11004-2 is displayed.

YES Refer to Engine Troubleshooting Manual.

Engine: Running
Check if fault code
NO 11910-2 is displayed.
Engine: Running

Faulty MC.
NO

T5-6-40

TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 All front attachments do not move.

YES

Faulty pilot shut-off

valve.

Check if pressure
at port P in pilot
shut-off valve is
within specification.

YES

Specification:
3.7+0.503 Mpa (38+53
kgf/cm2)
NO

Normal.

Disassemble and
clean pilot valve.
Check if machine
operation is normal.
Faulty pilot pump.
NO

T5-6-41

TROUBLESHOOTING / Troubleshooting B
F-2 All front attachment operations are slow /
weak.

When the service brake valve is kept closed, trouble

may occur. In this case, as the pilot hose or pilot filter is
damaged, this is not included here.
Internal leakage in
steering pilot valve.

YES
Remove hose connected to port P in
steering pilot valve.
NO Install a plug.
Check if front cylinder operating time
is within specification.

While raising lift

arm cylinder, turn
YES
steering handle.
Check if lift arm
speed decreases.

Check if travel performance is within

specification.
Engine: Running
Refer to Operational Performance Test section.

Engine: Running
Refer to Operational Performance Test section.

Remove hose
connected to port
LS in priority valve
Clogging between port
(main pump). In- YES
LS and drain port in
stall a plug. Install
steering valve.
drain hose to port
LS. Put oil into oil
NO pan. Check if lift
arm cylinder operating time is
Stuck spool in priority
within specificaNO valve (main pump).
tion.

Engine: Running
Refer to Operational PerformYES
To A
ance Test section.
Engine: Running
Check if pressure
YES at port A4 in pilot
shut-off valve is
within specification.
Faulty pilot shut-off
valve.
Engine: Running
NO
Pilot shut-off lever:
Check if pressure at
ON
port P in pilot
Specification:
shut-off valve is
3.7+0.503 Mpa
YES within specification.
Stuck check valve or
(38+53 kgf/cm2)
priority valve in charg Engine: Running
YES ing block, faulty pilot
Pilot shut-off lever:
pump or clogged pilot
ON
Disassemble,
filter.
Specification:
+0.5
clean
and
adjust
3.7 03 Mpa
pilot relief valve.
(38+53 kgf/cm2)
NO Check if trouble
occurs.
End

Engine: Running
NO

Refer to Engine Troubleshooting Manual.

YES
Operate accelerator pedal.
NO Check if engine
speed changes.

Refer to E-4 Even if

accelerator pedal is
depressed, engine
speed remains unchanged in this group.

Engine: Running
NO

T5-6-42

TROUBLESHOOTING / Troubleshooting B

YES

Check if main relief

pressure is within
specification.

Monitor pump displacement proportional solenoid valve

output of MC monitor
item by using Dr. ZX.
Check if output is 1
MPa (10 kg/cm2) or
less.
Accelerator pedal:
Fully depressed
Front attachment:
Operated

Engine: Running
Refer to Operational Performance Test section.

YES

NO

Faulty MC.

Check if pressure at
port ST in main pump
regulator is 2 MPa (20
kg/cm2) or more.
Accelerator pedal:
Fully depressed
Front attachment:
Operated
Faulty main relief
valve.

NO

Open circuit in harness in pump torque

control solenoid valve
or stuck spool.

YES

B
YES

End.

Disassemble and
clean main pump
regulator.
NO Check if front attachment operation is
normal.

Faulty main pump.

NO

T5-6-43

To B

TROUBLESHOOTING / Troubleshooting B
F-3 Certain front attachment is slow / weak.

If the lift arm or the bucket is normal, the pilot

pump (primary pilot pressure) should be normal.

If there is malfunction in the pilot poppet valve in

main relief valve, operating speed with light load
may be normal.

YES
Check if bucket opYES eration is worse only
during combined
operation of lift arm
raise and bucket.

YES

NO

Check if overload
relief valve pressure
is normal.

Stuck spool in control

valve or faulty cylinder
(faulty seal kit).
In case of lift arm, load
check valve may be
stuck.

Refer to Operational
Performance Test
section.

Check if secondary
pilot pressure in pilot
circuit which trouble
occurs is normal.

Clogged or stuck
bucket flow rate control valve (check, orifice, spool).

NO

Faulty overload relief

valve or make-up
valve.

Engine: Running
Secondary pilot pressure: Refer to operational Performance
Test section.
Faulty pilot valve.
NO
In case of lift arm, restriction valve may be
stuck.

T5-6-44

TROUBLESHOOTING / Troubleshooting B
F-4 Front attachment moves with lever in neutral.

Although the lever is released just after the lift

arm is operated, the lift arm is kept moving. In
this case, the restriction valve may be clogged.

YES

Faulty pilot valve.

NO

Stuck spool in control

valve.

Turn pilot shut-off

valve to LOCK position.
Check if lift arm stops.
Engine: Running

T5-6-45

TROUBLESHOOTING / Troubleshooting B
F-5 Front attachment drifts remarkably.

YES

Check if cylinder drift

in each front attachment is within specification.
Engine: Running
Refer to Operational
Performance Test
section.

Normal.

NO

NO

Lock pilot shut-off

valve.
Check if symptom
disappears.

Replace with other

overload relief valve
temporarily.
Check if symptom
disappears.
Engine: Running

Engine: Running

Faulty pilot valve.

YES

Lift Arm Cylinder Internal Leakage Check

1. With the bucket cylinder slightly extended from
the fully retracted position, lower the bucket tooth
tips onto the ground.
2. Remove the hoses from the lift arm cylinder rod
side. Drain oil from the hoses and cylinders.
(Plug the remove hose ends.)
3. Retract the bucket cylinder rod and lift the bucket
off the ground. If oil flows out of the hose removed pipe ends and the lift arm cylinders are
retracted at this time, oil leaks in the lift arm cylinders. In case no oil flows out of the hose removed pipe ends but the lift arm cylinders are retracted, oil leaks in the control valve.

T5-6-46

T4GB-05-04-001

TROUBLESHOOTING / Troubleshooting B

NO

Scored control valve

spool, broken spring, or
loose spool end.

NO Check if oil leaks

in cylinders.
Refer to the followings.

YES

YES

Faulty cylinder. (Replace

seal kit.)

Faulty overload relief

valve.

T5-6-47

TROUBLESHOOTING / Troubleshooting B
F-6 Bucket is slow during combined operation.

YES

NO

Check if each cylinder

speed in front attachment is normal.
Engine: Running
Refer to Operational
Performance Test
section.

As for ZW250, check if

bucket operation is
slow during combined
operation of lift arm
raise and bucket.

Faulty flow rate control

selector valve in control
valve.
ZW250 only

NO

ZW220: Faulty bucket

flow rate control valve in
control valve.
ZW250: Faulty bucket
flow rate control poppet
valve in control valve.

Refer to F-3 Certain

front attachment is slow/
weak in this group.

YES

T5-6-48

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-49

TROUBLESHOOTING / Troubleshooting B
F-7 Work mode is not effective.

Check the corresponding wiring and connectors

in electrical parts.

When the work mode switch malfunctions, the

remarkable trouble does not occur. As fuel consumption becomes bad, this trouble may come
out.
When the work mode selector switch is shifted,
engine torque control (refer to the Control System group/SYSTEM.) is executed. If the parts
corresponding to this control malfunction, the
fault code is displayed. Execute the remedy according to troubleshooting A.
Although the fault code is not displayed and fuel
consumption becomes bad, refer to Engine Troubleshooting Manual and inspect the engine.

T5-6-50

TROUBLESHOOTING / Troubleshooting B
F-8 Lift arm height kickout is not operated.

Check the wiring connections first.

Connect terminal #2 of
harness end connector YES
in electromagnet at lift
arm raise side to vehicle frame.
Raise and lower lift
arm.
YES
While plate is located
in front of proximity
switch, check if there is
continuity.
Or while plate is away
from proximity switch,
check if there is disNO
continuity.

Disconnect connector
in electromagnet at lift
arm raise side in pilot
valve. Ground terminal #1 of harness end
connector to vehicle
frame. Check if voltage is 24 V.

Engine: Running
If one is YES, go to NO.

Faulty electromagnet
at lift arm raise side.

Disconnect connector in lift arm proximity switch.

Check for continuity
in same procedures
as former ones.
Check if results are
same to former ones.
Engine: Running

YES

NO

Shorted or open circuit

in harness between lift
arm proximity switch
and electromagnet at
lift arm raise side, or
open circuit in harness
between lift arm
proximity switch and
ground.

Faulty lift arm proximity switch.

Engine: Running
Faulty fuse or faulty
harness between fuse
box B and electromagnet at lift arm
raise side.

NO

Connector (Harness end of connector viewed from the

open end side)
Electromagnet Connector at
Lift Arm Raise Side
#1

#2
1

T5-6-51

TROUBLESHOOTING / Troubleshooting B
F-9 Lift arm float is not operated.

Check the wiring connections first.

YES

YES
Disconnect connector in electromagnet
at lift arm lower side
in pilot valve.
Connect terminal #2
of harness end connector to vehicle
frame.
Check for continuity.

Connect terminal #1 of
harness end connector
in electromagnet at lift
arm lower side to vehicle frame.
Check if voltage is 24 V.
Engine: Running
NO

NO

Connector (Harness end of connector viewed from the

open end side)
Electromagnet Connector at Lift
Arm Lower Side
#2
1

Faulty fuse or faulty

harness between fuse
box B and electromagnet at lift arm
lower side.

Open ground circuit in

electromagnet at lift
arm lower side.

Engine: Running

#1

Faulty electromagnet
at lift arm lower side.

T5-6-52

TROUBLESHOOTING / Troubleshooting B
F-10 Bucket auto leveler is not operated.

Check the wiring connections first.

Disconnect connector in
electromagnet at bucket
tilt side in pilot valve.
Ground terminal #1 of
harness end connector
to vehicle frame.
Check if voltage is 24 V.

Connect terminal #2
of harness end connector in electromagnet at bucket tilt
side to vehicle frame.
Operate bucket.
While bar is located
YES in front of proximity
switch, check if there
is continuity.
Or while bar is away
from proximity
switch, check if there
is discontinuity.
Engine: Running
If one is YES, go to
NO.

YES

NO

Faulty electromagnet
at bucket tilt side.

Disconnect connector in bucket proximity switch.

Check for continuity
in same procedures
as former ones.
Check if results are
same to former ones.
Engine: Running

YES

NO

Shorted or open circuit

in harness between
bucket proximity
switch and electromagnet at bucket tilt
side, or open circuit in
harness between
bucket proximity
switch and ground.

Faulty bucket proximity switch.

Engine: Running
Faulty fuse or faulty
harness between fuse
box B and electromagnet at bucket tilt
side.

NO

Connector (Harness end of connector viewed from the

open end side)
Electromagnet Connector at
Bucket Tilt Side
#1

#2
1

T5-6-53

TROUBLESHOOTING / Troubleshooting B
F-11 Lift arm auto leveler is not operated. (Optional)

Check the wiring connections first.

YES
Check if boom angle of
MC monitor item by
using Dr. ZX is
3.780.5 V with lift arm
at highest position.

YES

Check if success is
displayed on angle
sensor learning status
of MC monitor item by
using Dr. ZX.

YES

Put the matching

mark on lift and shaft
by using a white pen.
Operate the lift arm
several times in order
to check.

To B

NO

Engine: Running
Lift arm auto leveler
switch: ON (2 used)

Raise and lower lift

arm.
Check arm angle
sensor shaft rotates
according to link.

To A

Execute lift arm angle

sensor learning.

NO

Refer to the Operational

Performance Test

Tighten link bolt.

NO
Rotate the shaft where
boom angle of MC
monitor item by using
Dr. ZX is 3.780.5 V
with lift arm at the highest position. Then,
tighten link bolt.

Connector (Harness end of connector viewed from the

open end side)
Lift Arm Auto Leveler
Switch Connector
#2

MC
Connector B

Lift Arm Angle Sensor

Connector

MC
Connector D

Lift Arm Solenoid

Valve Connector

#B3
#1

#2

3
1

#1

#B20
T183-05-04-021

T5-6-54

#2

#3
#10
T183-05-04-009

TROUBLESHOOTING / Troubleshooting B

Disconnect abnormal connector in lift

arm auto leveler
switch.
Ground terminal #2
of harness end of
connector.
Check if lift arm auto
leveler is operated
properly.

Faulty lift arm auto

leveler switch.

YES

NO

Connect terminal #2 of
harness end of connector in lift arm auto
leveler switch to vehicle frame.
Disconnect connector
MC-B in MC.
Connect terminal #B20
(upward) or B3 (downward) of harness end
to vehicle frame.
Check for continuity.

NO

YES

Open circuit in harness between lift arm

auto leveler switch
and MC.

To C

Key switch: OFF

Check if voltage between terminals #1

and #3 of harness
end of connector in
lift arm angle sensor
is 50.5 V.

Disconnect connector
MC-D in MC.
Check for continuity
YES between terminal
#D10 of harness end
of connector and terminal #2 of harness
end of connector in lift
arm angle sensor.

NO

YES

YES

Key switch: ON

Disconnect abnormal connector in lift

arm solenoid valve
in pilot valve. Check
if voltage at terminal
#1 of harness end of
connector is 24 V.

NO

Check if voltage between terminal #1 of

harness end of connector in lift arm angle
sensor and vehicle
frame is 50.5 V.
Key switch: ON

NO

Connect connector in
lift arm solenoid valve
in pilot valve.
YES Connect terminal #2 of
connector to vehicle
frame.
Turn lift arm raise lever
to detent position.
Check if lever is held.

YES

NO

Open circuit in harness between MC

and lift arm angle
sensor.

To C

Open circuit in harness between MC

and lift arm angle
sensor (terminal #3).
Open circuit in harness between MC
and lift arm angle
sensor (terminal #1).

Open circuit in harness between lift arm

electromagnet and
MC, or faulty MC.

Faulty lift arm electromagnet.

Faulty fuse or faulty

harness between
fuse box B and lift
arm solenoid valve.

Engine: Running
NO

T5-6-55

TROUBLESHOOTING / Troubleshooting B
F-12 Lift arm auto leveler stop position cannot
be set. (Optional)

If the lift arm auto leveler stop position cannot be

set as for both upward and downward, lift arm
angle sensor learning has not been completed or
lift arm angle sensor, MC or harness may malfunction.
If the lift arm auto leveler stop position cannot be
set as for either upward or downward, lift arm
auto leveler set switch, MC or harness may malfunction.
Refer to F-11 Lift arm auto leveler is not operated and execute the remedy.

T5-6-56

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-57

TROUBLESHOOTING / Troubleshooting B
F-13 Ride control is not effective.

Check the wiring connections first.

When there is trouble with main circuit system
and system pilot oil in the lift arm cylinder, this
trouble may occur. As the front attachment operation malfunction together, refer to the related
pages and execute the remedy.
Ground terminal #7 of
harness end of connector in ride control
switch to vehicle frame.
YES Disconnect connector
MC-C.
Ground terminal #C21
to vehicle frame. Check
for continuity.

Disconnect connector
in ride control switch.
YES Check for continuity
between terminals #6
and #7 of switch end.

YES

Faulty MC.

NO

Open circuit in harness between ride

control switch and

Key switch: OFF

Ride control switch: ON

Monitor ride control
switch of MC monitor
item on Dr. ZX.
If ride control switch is
turned ON/OFF,
check if monitor display is shifted.

Faulty ride control

switch.

NO

YES
YES

Key switch: ON

NO

Monitor travel speed of

MC monitor item on
Dr. ZX.
Check if travel speed is
7 km/h or faster.
Travel: Forward

Normal.

When travel speed is 7

km/h or faster during
forward travel operation, check if ride control is effective.
Ride control switch: ON

To B

NO

To A

NO

Connector (Harness end of connector viewed from the

open end side)

Ride Control Switch Connector

Connector MC-C

Connector MC-A

C10

C1
4

10

#A23
C23

#7

#6

#A7

C31
#C21
T183-05-04-008

T5-6-58

TROUBLESHOOTING / Troubleshooting B

Monitor transmission output speed of

TCU monitor item
on Dr. ZX.
Check if speed below is displayed on
Dr. ZX screen when
traveling at 10 km/h.

ZX220: 880 min-1

ZX250: 910 min-1

YES

Faulty TCU.

NO

Faulty CAN circuit

between TCU and
MC.

YES Check if there is trouble with CAN harness

between TCU and MC.
Refer to CAN Harness Check Method
in Troubleshooting A.

YES

NO

Faulty travel speed

sensor.

If travel speed increases or decreases

at former section, display on Dr. ZX is
shifted.

Faulty travel speed

sensor, or faulty
harness between
travel speed sensor
and MC.

NO

NO

Check if ride control

accumulator gas
pressure is 3 MPa
(31 kgf/cm2).

Replace ride control

proportional solenoid
YES valve with normal one.
Check if ride control is
operated properly.

Between terminals
#A23 (#A7) of connector MC-A in MC and #1
(#2) in ride control
proportional solenoid
valve
YES

Proportional Solenoid
Valve Connector
#1

YES Faulty ride control

valve.

NO

Faulty harness between MC and ride

control proportional
solenoid valve.

Faulty ride control

proportional solenoid
valve.
Replace ride control
accumulator.

NO

#2

Check for continuity in

harness between MC
and ride control proportional solenoid
valve.

T5-6-59

TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Machine does not travel forward/ reverse.
Machine can travel only when the following con-

Check the wiring connections first.

If the followings are normal, the transmission and

ditions are present.

Forward/Reverse Lever: F or R
Parking Brake Switch: OFF

axles (front, rear) may be faulty. Check for abnormal sound at each part.

If the front attachment operation is normal, the

engine system and the pilot oil supply system
may be normal.

NO

Engine: Running
Refer to the Operational Performance
Test section.

Operate brake pedal.

NO Check if brake pedal is
operated heavily with
work brake applied.
Engine: Running

Check if trouble occurs;

although machine
YES cannot travel by using
forward/reverse switch,
machine can travel by
using forward/reverse
lever.

Monitor pedal brake

pressure of TCU monitor item on Dr. ZX.
Check if pressure is 0
MPa.

Check if front speed is

within specification.

Faulty service brake.

YES

YES

Faulty forward/reverse
switch or forward/reverse
lever, or faulty harness.

YES

Faulty brake valve.

Engine: Running

Check if port pressure at

brake pedal outlet or
NO brake pressure inlet in
axle exists.
Engine; Running
Tow the machine to level
ground and execute this
item. (Refer to the opera- NO
tional manual.)

T5-6-60

Faulty service brake

pressure sensor or
shorted circuit in harness
between TCU and brake
pressure sensor.

To A

TROUBLESHOOTING / Troubleshooting B

Monitor parking brake

pressure of MC moniYES tor item on Dr. ZX.
Check if pressure is
10.1 MPa (103
kgf/cm2) or more.
Engine: Running
Parking brake switch:
OFF

Check if parking brake

YES solenoid valve output
pressure is 10 MPa
(102 kgf/cm2) or more.

NO

YES

NO

NO

To B
Open circuit in harness in MC or between MC and monitor unit.
Between terminal
#B25 of connector
MC-B in MC and
terminal #A17 of
monitor unit connector 1-A in the monitor
unit
Faulty parking brake
pressure sensor.

Faulty pilot system

(Refer to the reference pages on Front
Attachment System
Troubleshooting in
this group.) or faulty
engine system (Refer
to Engine Troubleshooting Manual.).

NO

Engine: Running
Parking brake switch:
OFF

YES

Faulty parking brake

system. (Refer to the
reference pages on
Brake System Troubleshooting in this
group.)

Engine: Running
Parking brake switch:
OFF
A

Monitor parking brake

pressure switch of
monitor unit monitor
YES item on Dr. ZX.
Check if pressure is
displayed by using
outline characters on
a colored background.

To C

Monitor parking
brake signal output
of monitor unit monitor item on Dr. ZX.
Check if ON is displayed by using outline characters on a
colored background.

Faulty monitor unit.

Engine: Running
Parking brake switch:
OFF

NO

Monitor FNR switch

of TCU monitor item
on Dr. ZX.
Operate forward/reverse lever to
Forward or Reverse.
Check if F/R is displayed on Dr. ZX
according this lever
operation.

YES

Open circuit in harness in forward/reverse lever or

between forward/reverse lever
and TCU.

Open circuit in harness in TCU or between TCU and

monitor unit.

NO

Engine: Running
Parking brake switch:
OFF

Between terminal #26

of monitor unit connector 1-B in the
monitor unit and terminal #21 in TCU

T5-6-61

TROUBLESHOOTING / Troubleshooting B
T-2 Machine does not travel forward or reverse.

The transmission and axles (front, rear) may be

faulty. Check for abnormal sound at each part.

If other operations of front attachment and swing

are normal, the pilot pump, pilot filter and pilot relief valve may be normal.
Check the wiring connections first.
YES

Monitor selected travel

speed gear of TCU
monitor item on Dr. ZX.
Operate forward/reverse lever and
travel speed gear
switch.
Check if travel speed
gear according to combination of switch operations is displayed.
Engine: Running
Parking brake switch:
OFF

Monitor actual travel

speed gear of TCU monitor item on Dr. ZX.
Operate forward/reverse
YES lever and travel speed
gear switch.
Check if travel speed gear
according to combination
of switch operations is
displayed.
Engine: Running
Parking brake switch:
OFF

Replace transmission
control valve with norYES mal one.
Check if machine operation becomes normal.

Faulty transmission control valve.

Faulty transmission.
NO

Faulty TCU.
NO

YES
Check if machine can
travel forward/reverse by
NO using travel forward
lever.
Engine: Running
NO

T5-6-62

Faulty forward/reverse
switch or open circuit in
harness.

Faulty forward/reverse
lever or open circuit in
harness.

TROUBLESHOOTING / Troubleshooting B
T-3 Machine moves with lever in neutral.

YES
Monitor selected travel
speed gear of TCU
YES monitor item on Dr.
ZX.
Check if item except N
is displayed.

NO

Travel: Forward
Forward/reverse lever:
Neutral

Turn forward/reverse
switch ON.
Check if machine
moves.

Travel: Forward

Monitor actual travel

speed gear of TCU
monitor item on Dr.
ZX.
Check if item except N
is displayed.

Faulty forward/reverse
lever.

Faulty TCU.
NO

YES
Replace transmission
control valve with norNO mal one. Check if machine operation becomes normal.

Faulty transmission control valve.

Faulty transmission.
NO

Faulty TCU.
YES

T5-6-63

TROUBLESHOOTING / Troubleshooting B
T-4 Even if travel speed is turned up or down,
travel speed gear is not changed.

If the travel speed sensor malfunctions or if two

Check the wiring connections first.

Refer to T2-1-28 to 31 in the Control System

wirings in the shift switch are opened, travel

speed is fixed to second gear. When the travel
speed sensor malfunctions, the fault code is displayed on TCU.

group/ SYSTEM section.

NO

Execute troubleshooting of each controller

by using Dr. ZX.
Check if any fault
codes are displayed.

Monitor travel speed

gear of TCU monitor
item on Dr. ZX.
Operate shift switch
from first gear to fourth
gear.
Check if travel speed
gear is displayed on
screen according to
switch operation.
Key switch: ON

YES

Refer to Troubleshooting
A.

YES
Disconnect connector
in shift switch.
Check if voltage at
NO terminal #7 of harness
end of connector is 24
V.
Key switch: ON

Engine: Running

NO

Faulty fuse or open circuit

in harness.

Refer to Troubleshooting
A.

YES

Connector TCU

Connector (Harness end of connector viewed from the

open end side)
Shift Switch Connector

#7

#63
#65

T4GB-05-05-001

T5-6-64

TROUBLESHOOTING / Troubleshooting B

Connect connector in
shift switch.
Set travel speed to
fourth gear. Disconnect
connector in TCU.
Check for continuity
between terminals #63
and #65 of harness
end of connector.
Key switch: OFF

YES

Faulty TCU.

NO

Faulty shift switch or open

circuit in harness.

T5-6-65

TROUBLESHOOTING / Troubleshooting B
T-5 Even if up-shift switch is pushed, travel
speed gear is not turned up.

Refer to T2-1-34 to 35 in the Control System

group/ SYSTEM section.

Travel speed gear cannot be turned up by the

switch is selected, if the hold switch is pushed,

up-shift control is not operated.

up-shift switch beyond travel speed gear selected

by the shift switch.
Check the wiring connections first.

When auto L, N or H in the travel mode selector

YES
Monitor USS switch of
TCU monitor item on
Dr. ZX.
Turn up-shift switch
ON. Check if ON is displayed on screen.

NO

Key switch: ON

Execute troubleshooting of each controller

by using Dr. ZX.
Check if any fault
codes are displayed.
Engine: Running

Refer to Troubleshooting
A.

YES
Disconnect connector
in up-shift/down-shift
switch.
Check if voltage at
NO terminal #2 of harness
end of connector is 24
V.
Key switch: ON

NO

Faulty fuse or open circuit

in harness.

Refer to Troubleshooting
A.

YES

Connector (Harness end of connector viewed from the

open end side)

TCU Connector

Up-Shift/Down-Shift
Switch Connector

3
#29
#2

T4GB-05-05-001

T5-6-66

TROUBLESHOOTING / Troubleshooting B

Connect connector in
up-shift/down-shift
switch.
Disconnect connector
in TCU. Turn up-shift
switch ON.
Check for continuity
between terminal #29
of harness end of
connector and vehicle
frame.

YES

Faulty TCU.

NO

Faulty up-shift/down-shift
switch or open circuit in
harness.

Key switch: OFF

T5-6-67

TROUBLESHOOTING / Troubleshooting B
T-6 Even if down-shift switch is pushed, travel
speed gear is not turned down.

Refer to T2-1-32 to 33 in the Control System

When auto L, N or H in the travel mode selector

group/ SYSTEM section.

When machine travels at faster than travel speed
gear, which can decrease, although the
down-shift switch is pushed, travel speed gear
cannot be turned down.

switch is selected, if the hold switch is pushed,

down-shift control is not operated.
Check the wiring connections first.

YES

NO

Monitor DSS switch of

TCU monitor item on
Dr.ZX.
Turn down-shift switch
ON.
Check if ON is displayed on screen.
Key switch: ON

Execute troubleshooting of each controller

by using Dr. ZX.
Check if any fault
codes are displayed.
Key switch: ON

YES
Disconnect connector
in up-shift/down-shift
switch.
Check if voltage at
NO terminal #2 or #1 of
each harness end of
connector is 24 V.
Key switch: ON

Connector (Harness end of connector viewed from the

open end side)

TCU Connector

Down-Shift Connector

#2

NO

Faulty fuse or open circuit

in harness.

Refer to Troubleshooting
A.

YES

Up-Shift/Down-Shift
Switch Connector

Refer to Troubleshooting
A.

#1

#22

T4GB-05-05-001

T5-6-68

TROUBLESHOOTING / Troubleshooting B

Connect connector in
up-shift/down-shift
switch.
Disconnect connector
in TCU.
Turn down-shift side in
up-shift/down-shift
switch and down-shift
switch ON alternately.
Check for continuity
between terminal #22
of harness end of
connector and vehicle
frame.

YES

Faulty TCU.

NO

Faulty switch without continuity or open circuit in

harness.

Key switch: OFF

T5-6-69

TROUBLESHOOTING / Troubleshooting B
T-7 Even if hold switch is pushed, travel speed
gear is not fixed.

Refer to T2-1-38 to 39 in the Control System

Check the wiring connections first.

group/ SYSTEM section.

When auto L, N or H in the travel mode selector
switch is selected, hold control is not operated.

YES

NO

Execute troubleshooting of each controller

by using Dr. ZX.
Check if any fault
codes are displayed.

Monitor hold switch of

TCU monitor item on
Dr.ZX.
Turn hold switch ON.
Check if ON is displayed on screen.
Key switch: ON

Refer to Troubleshooting
A.

YES
Disconnect connector
in hold switch.
Check if voltage at
NO terminal #1 of harness
end of connector is 24
V.

Engine: Running

Key switch: ON

NO

Faulty fuse or open circuit

in harness.

Refer to Troubleshooting
A.

YES

TCU Connector

Connector (Harness end of connector viewed from the

open end side)

Hold Switch Connector

#1

#66

T4GB-05-05-001

T5-6-70

TROUBLESHOOTING / Troubleshooting B

Connect connector in
hold switch.
Disconnect connector
in TCU.
Turn hold switch ON.
Check for continuity
between terminal #66
of harness end of
connector and vehicle
frame.

YES

Faulty TCU.

NO

Faulty hold switch or open

circuit in harness.

Key switch: OFF

T5-6-71

TROUBLESHOOTING / Troubleshooting B
T-8 Travel mode is not shifted.

Check the wiring connections first.

Refer to T2-1-30 to 31 in the Control System
group/ SYSTEM section.

NO

Execute troubleshooting of each controller

by using Dr. ZX.
Check if any fault
codes are displayed.

Monitor auto gear shifting mode of MC monitor item on Dr. ZX.

Shift travel mode selector switch to auto L,
N and H in this order.
Check if Ld&Cry, Normal and Power are displayed on screen in this
order.
Key switch: ON

Engine: Running

YES

Refer to Troubleshooting
A.

Disconnect connector
in travel mode selector
switch.
Check if voltages at
terminals #2, #3, #4
NO and #5 of harness end
of connector are 1V,
2V, 3V and 4V respectively.

YES

Normal.

NO

Key switch: ON
Refer to Troubleshooting
A.

YES

Connector (Harness end of connector viewed from the

open end side)
Travel Mode Selector
Switch Connector
#2

#4

Monitor Unit Connector 1-B

#3

#B28

#5
#B31 #B30

#B29
T4GB-05-05-002

T5-6-72

TROUBLESHOOTING / Troubleshooting B

Connect connector in
travel mode selector
switch.
Disconnect monitor
unit connector 1-B in
monitor unit.
Check if voltages at
terminals #B28, #B29,
#B30 and #B31 of
harness end of connector are 4V, 3V, 2V
and 1V respectively.

Faulty travel mode selector switch or faulty harness.

YES

As for the harness in travel

mode selector switch, the
harness which correct current does not flow through
is faulty.
Faulty monitor unit.
NO

Key switch: ON

T5-6-73

TROUBLESHOOTING / Troubleshooting B
T-9 Clutch cut-off is not operated.

Check the wiring connections first.

Refer to T2-1-36 to 37 in the Control System
group/ SYSTEM section.

NO

Monitor clutch cut-off

mode of MC monitor
item on Dr. ZX.
Shift clutch cut-off position switch to S, N and
D in this order.
Check if Low, Medium
and High are displayed
on screen in this order.
Key switch: ON

Execute troubleshooting
of each controller by
using Dr. ZX. Check if
any fault codes are dis Engine: Running

YES

Refer to Troubleshooting
A.

Disconnect connector
in clutch cut-off position
switch.
Check if voltages at
terminals #2, #3, #4
NO and #5 of harness end
of connector are 1V,
2V, 3V and 4V respectively.

YES

Normal.

NO

Key switch: ON
Refer to Troubleshooting
A.

YES

Connector (Harness end of connector viewed from the

open end side)
Clutch Cut-Off Position
Switch Connector
#2

#4

Monitor Unit Connector 1-B

#3

#B28

#5
#B31 #B30

#B29
T4GB-05-05-002

T5-6-74

TROUBLESHOOTING / Troubleshooting B

Connect connector in
clutch cut-off position
switch.
Disconnect monitor
unit connector 1-B in
monitor unit.
Check if voltages at
terminals #B28, #B29,
#B30 and #B31 of
harness end of connector are 4V, 3V, 2V
and 1V respectively.

Faulty clutch cut-off position switch or faulty harness.

YES

As for the harness in

clutch cut-off position
switch, the harness which
correct current does not
flow through is faulty.
Faulty monitor unit.
NO

Key switch: ON

T5-6-75

TROUBLESHOOTING / Troubleshooting B
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is not released.
Check the wiring connections first.

NO

NO

Monitor service brake

pressure of monitor
unit monitor item on Dr.
ZX.
Check if pressure is
within specification.

To A

Replace parking brake

relays 1, 2 with other
YES
general relays.
Check if parking brake
is operated properly.
Faulty parking brake reYES lay 1 or 2.

Engine: Running

Engine: Running
Specification: 11.8 to 14.7
MPa (120 to 150 kgf/cm2)

Refer to F-1 and F-2 of

Front Attachment Troubleshooting in this group.

NO

Check if there is clearance between parking

brake disc and pad.
Engine: Running
Parking brake switch: OFF
Replace parking brake
pressure sensor with
normal one.
Check if parking brake
YES indicator goes off (brake
is released).

NO

Refer to Troubleshooting
C.

Engine: Running

End.
YES

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit Connector A

Parking Brake Relay 1

Connector

#A2

Parking Brake Relay 2

Connector
#2
#1

#3

#3

T183-05-04-013

#18
T183-05-04-003

T5-6-76

T183-05-04-003

TROUBLESHOOTING / Troubleshooting B

Remove parking
brake relay 1.
Check if voltages between terminals #1,
#3 of harness end
and vehicle frame are
24 V.

Install parking brake

relay 1.
Disconnect monitor
connector 2-A in
YES
monitor unit.
Check if voltage at
terminal #2 of harness
end of connector is 24
V.

Disconnect connector
in parking brake
switch.
Measure current at
YES connector of switch
end.
Check if all questions
are Yes.
Discontinuity between
terminals #6 and #7 with
switch in neutral
Discontinuity between
terminals #6 and #7 with
switch OFF
Continuity between terminals #3 and #8 with
switch OFF

Engine: Running

YES

NO

To B

Faulty parking brake

switch.

Faulty alternator or
faulty harness.

NO

Key switch: ON
Faulty fuse or faulty
harness.

NO

NO

NO

Check for continuity

between terminal #18
of harness end of
monitor connector 2-B
and vehicle frame.

Connect monitor connector 2-A.

Check for continuity
between terminal #7 of
harness end of parking
brake switch and vehicle frame.
Engine: Running

To C

Open circuit in harness between termiYES nal #2 and ground.

Faulty monitor unit.

YES
Shorted circuit in
harness between
terminal #7 of parking
brake switch connector, terminal #18 of
monitor connector 2-A
and terminal #2 of
parking brake relay
connector.

Key switch: OFF

YES

Parking Brake Switch Connector

#3
4

10

#8 #7

Disconnect parking
brake relay 2.
NO Check for continuity
between terminal #2 of
harness end and vehicle frame.

#6

T5-6-77

TROUBLESHOOTING / Troubleshooting B

Check if voltages at
terminal #3 of harness
end of parking brake
relay 2 and vehicle
frame, at terminal #8
of parking brake
switch and vehicle
frame are 24 V respectively.

Install all electric parts,

which are removed.
Remove parking brake
YES
solenoid valve.
Check for continuity at
terminal #2 of harness
end.

Hold parking brake

switch in OFF position.
Check if voltage at
YES terminals #1 and #2 of
harness end of parking
brake solenoid valve is
24 V.
Engine: Running

Key switch: OFF

NO

NO

Keep hand away from

parking brake switch.
Check if voltage at
terminals #1 and #2 of
harness end of connector in parking
brake solenoid valve
is 24 V.

Open circuit in harness between terminal #2 and ground.

End.

NO

Faulty parking brake

solenoid valve.

Disassemble, clean
and adjust parking
brake.
Check if parking brake
becomes normal.

Open circuit in harness between terminals #1 and #5 of

parking brake relay
2.

NO

Connector (Harness end of connector viewed from the

open end side)
Parking Brake Solenoid Valve Connector
#2
1

Open circuit in harness between terminal #1 of parking

brake relay 2 and
terminal #3 of parking brake switch.

YES

Engine: Running

#1

NO

To D

Open circuit in harness between terminal #8 of parking

brake switch or terminal #3 of parking
brake relay 2 and
terminal #4 of parking brake relay 1.

Engine: Running

YES

YES

T5-6-78

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-79

TROUBLESHOOTING / Troubleshooting B
B-2 Parking brake is not locked.

Check the wiring connections first.

NO
Replace parking brake
relay 2 with other general
YES relay.
Check if parking brake is
operated properly.
Engine: Running
Parking brake switch: ON
Monitor parking brake
pressure of MC monitor item on Dr. ZX.
Check if pressure is
within specification.

Disconnect connector in
parking brake switch.
Turn parking brake
switch ON.
Check for continuity
between terminals #7
and #6 of switch end.

NO

Faulty parking brake

switch.

Faulty parking brake relay 2.

YES

YES End.
Replace parking brake
pressure sensor with
YES normal one.
Check if parking brake
indicator lights.

Engine: Running
Parking brake switch: ON
Specification: 11.8 to 14.7
(120 to 150 kgf/cm2)

NO

Engine: Running

Check if parking brake

indicator does not light.

Connector (Harness end of connector viewed from the

open end side)
Parking Brake Switch Connector

Parking Brake Solenoid Valve Connector

#1

10

#2
1

#6

T5-6-80

Refer to Troubleshooting
NO C.

Stuck piston in parking

brake.

NO

#7

YES

TROUBLESHOOTING / Troubleshooting B

Disconnect connector in
parking brake solenoid
valve.
Check if voltage between
terminals #1 and #2 of
harness end is 24 V.
Engine: Running
Parking brake switch: ON

YES

Shorted power circuit.

NO

Stuck spool in parking

brake solenoid valve.

T5-6-81

TROUBLESHOOTING / Troubleshooting B
B-3 Service brake efficiency is bad or low.

NO

NO

Check if pressures at
ports BR1 and BR2 in
brake valve are within
specification.
Engine: Running
Brake pedal: Fully depressed
Specification: 4.18 0.85
2
YES
MPa (43 9 kgf/cm )

Monitor service brake

pressure of monitor
unit monitor item on Dr.
ZX. Check if pressure
is within specification.
Engine: Running
Specification: 11.8 to
14.7 MPa (120 to 150
2
kgf/cm )

Disassemble, clean and

NO adjust pilot relief valve.
Check if brake is operated properly.
Refer to the Operational
Performance Test section. YES

YES

Faulty pilot pump.

End.

Faulty brake valve or

faulty brake pedal.

Faulty service brake.

T5-6-82

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-83

TROUBLESHOOTING / Troubleshooting B
STEERING SYSTEM TROUBLESHOOTING
H-1 Steering cylinder operation is slow or does
not move.

Check if the steering shaft is deformed or stuck.

NO

Remove hoses from

ports Pa and Pb in
YES
steering valve.
Check if steering wheel
is operated properly.
Engine: Running
Put oil into hydraulic oil
pan from hose.

Install hoses to ports Pa

and Pb in steering
valve.
Remove hoses from
port A in right and left
stop valves.
Check if steering wheel
is operated properly.
Engine: Running
Put oil into hydraulic oil
pan from hose.

YES

NO

To A

Stuck spool in stop

valve.

Clogging in steering
valve pilot circuit.

YES

Check if steering handle

is operated to right and
left properly.
Engine: Running

YES

To B

Check if front attachYES ment operating speed is

within specification.
Engine: Running
Refer to the Operational
Performance Test section.

NO

Monitor pump pressure

of MC monitor item on
Dr. ZX.
Check if steering relief
pressure is within
specification.
NO

Engine: Running
Refer to the Operational
Performance Test section.

NO

T5-6-84

To C

Faulty steering relief

valve or faulty steering
overload relief valve.

TROUBLESHOOTING / Troubleshooting B

YES

Install hose to port A in

stop valve. Check if
pressure at port P in
steering pilot valve is 3.7
+0.5
+5
-0.3 KPa (38 -3
kgf/cm2).

Faulty steering pilot

valve.

YES

Engine: Running
NO

Disassemble, clean
and adjust pilot relief
valve.
Check if steering handle is operated properly.
NO

YES

Disassemble, clean and

adjust priority valve
(main pump).
Check if valve is operated properly.

Stuck check valve or

priority valve in charging
block, or clogged pilot
pump or pilot filter.

End.

YES

NO

End.

Disassemble, clean
and adjust steering
valve.
Check if valve is operated properly.

End.

Faulty steering cylinder.

NO

YES

End.

Disassemble, clean and

adjust main pump regulator.
Check if regulator is operated properly.
Faulty main pump.
NO

T5-6-85

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-86

TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Air conditioner malfunction
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display

Display Fault Code

1. Push the fan OFF switch and turn the fan OFF.
2. Push and hold both upper and lower sides of the
temperature control switch on the air conditioner
control panel at the same time for more than 3
seconds with the key switch ON.
NOTE: After operation has been performed, the
buzzer will sound.

Temperature
Control Switch

Fan OFF Switch

3. If any fault codes are found, the LCD displays the

fault codes as E{{.
NOTE: If more than one fault code is found, the
lower number fault code will be displayed
first.

LCD

M178-01-017

Fault Code List

Location in Trouble
Abnormal circulation
air sensor

Fault
Code
E11
E12

Abnormal fresh air

sensor

E13
E14

Abnormal coolant
temperature sensor

E15
E16

Abnormal air vent

sensor

E21
E22

Abnormal damper

E43
E44
E51

Abnormal refrigerant

Cause
Open circuit in air circulation
sensor
Shorted circuit in air circulation
sensor
Open circuit in fresh air sensor
Shorted circuit in fresh air sensor
Open circuit in coolant temperature sensor
Shorted circuit in coolant temperature sensor
Open circuit in air vent sensor
Shorted circuit in air vent sensor
Abnormal air vent damper
Abnormal air mix damper
Abnormal high/low refrigerant
pressure

T5-6-87

Symptom
Value Y (air flow-in temperature) in response to the set-temperature is fixed.

Operation is controlled under such circumstance as no fresh air sensor is provided.

Operation is controlled under such circumstance as the water temperature is
set to 60 C (140 F). (Warm-up control is
not performed.)
Operation is controlled under such circumstance as air flow-in temperature 0 C
(32 F).
Corresponding damper servo becomes
inoperable.
The compressor clutch is disengaged.
(The compressor stops.)

TROUBLESHOOTING / Troubleshooting B
Change Displayed Fault Code
1. When displaying more than one fault code, push
either upper or bottom side of the temperature
control switch. The following fault code is displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.

Temperature
Control Switch

LCD

Delete Fault Code

LCD

1. Push, and hold both the circulation air switch and

the fresh air vent switch for more than 3 seconds
at the same time and the fault code is deleted.
NOTE: After the fault code is deleted, the buzzer
sounds.
2. After the fault code has been deleted, the LCD
displays E{{.

M178-01-017

Circulation
Air Switch

Fresh Air vent

Switch

M178-01-017

Fan OFF Switch

End Fault Code Display

1. Push the fan OFF switch, and turn the fan ON.
The self-diagnostic mode is completed.

Fan Switch

T5-6-88

M178-01-017

TROUBLESHOOTING / Troubleshooting B
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machines air conditioning system.

< AIR CONDITIONER TROUBLE REPORT >

(1) What
Model

(Serial

File No.
Checked by:

No.
)
Operation Type
Manual
Semi-Auto
Full-Auto
Delivery Date
Year
Month
(2) When
Date
Year
Month
Day
Operating Hour (
h)
Time
Morning
Daytime
Evening
Night
Frequency
Every Day
Once a Week
Once a Month
Times per
(3) Where
Job Site Address
State
County
Town
Access Road Condition
Paved
Not Paved (Gravel
Sand
Soil)
(4) How (Operating Conditions)
Weather
Fine
Cloudy
Rain
Snow
Atmospheric Temperature
Very Hot
Hot
Cold
Very Cold
Operating Conditions
Parking
Traveling
Working
Temperature Control
Paint blanks equal to red indicators. / Fill in set-temperature
when full-auto operation
A/C
ON
OFF
Air Induction
Re-Circulation
Fresh Air Circulation
Control
AUTO
ON
OFF
Not Available
Panel
Fill following items when operated in manual mode or when manual control type unit is
used.
Vent Position
Front
Front / Rear
Foot
Front / Rear and Foot
Fan
First
Second
Third
Fourth
Fifth
Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not reproducible
Uncontrollable air temperature
(2) Pressure (To be measured at gauge maniSymptom
No cool air
fold)
No warm air
Low Pressure
Others
High Pressure
Uncontrollable air volume
(3) Which parts have been replaced ?
Symptom
Air flows in Hi mode only
1
No air flows
Small air volume
2
Others
Uncontrollable vent hole
Before replacing the control amplifier, be sure
Symptom
Vent hole isnt selected
to check that the connectors are correctly conOthers
nected while repeatedly disconnecting and reAbnormal panel indication
connecting connectors.
Faulty
Indi- Vent Hole
cator
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo

Hi)
Temperature Control
Symptom
Stays OFF
Stays ON
Blinks
Others

T5-6-89

TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure
in both high and
low-pressure sides is
low.

Bubbles can be seen in sight

glass.

No bubbles are seen in sight

glass.

Piping and/or parts are stained with oil,

respond to gas detector.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one season.

After cooling at fast speed continuously, cooling power is reduced. Air

flow volume remains unchanged.

Air flow volume is reduced.

Insufficient
Cooling
Power

Refrigerant pressure
in low-pressure side
is high.

Bubbles can be seen in sight

glass.

Compressor cylinder is extremely hot,

emitting a smell.

Refrigerant pressure in
high-pressure side is low.

Compressor cylinder is extremely hot,

emitting a smell.

Heater unit emits hot air.

Refrigerant pressure
in high-pressure side
is high.

Bubbles can be seen in sight

glass.

Refrigerant pressure in low-pressure

side is low.

Condenser is stained and clogged.

Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.

After cooling at fast speed continuously, cooling power is reduced. Air

flow volume is reduced.

Frost forms.

Thermistor does not cool.

Thermistor cools.

T5-6-90

TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts.

Re-tighten or replace parts.

Normal leakage of refrigerant from hoses.

Refill refrigerant.

Improper adjustment (excessive restriction) of expansion

valve.

Readjust or replace expansion valve.

Clogged expansion valve.

Remove clog, or replace receiver and/or expansion

valve.

Clogged low-pressure circuit and/or evaporator.

Remove clog, or replace parts.

Frozen expansion valve or water in circuit.

After evacuation, refill refrigerant and/or replace receiver dryer.

Gas leaks from case.

Seal gaps by using vinyl tape or packing compound.

Poor contact of expansion valve temperature sensing cylinder.

Make good contact. Replace temperature sensing

stay.

Improper adjustment (excessive open) of expansion valve.

Readjust or replace.

Insufficient compressor discharge (faulty gasket and/or valve).

Replace.

Improper water stop valve wire adjustment and/or faulty stop

valve.

Check and readjust or replace.

Poor airtight fitting of outside air damper (outside air induction

type).

Repair.

Clogged high-pressure circuit before receiver dryer.

Remove clog, or replace parts.

Clean Condenser.

Excessive refrigerant.

Remove excessive refrigerant to proper level.

Air is mixed in system.

After evacuation, refill refrigerant and/or replace receiver dryer.

Incorrect thermistor location.

Correct thermistor location.

Gas leaks from case.

Seal gaps by using vinyl tape or packing compound.

Faulty thermistor (stays ON).

Disconnected thermistor cord.

Even if function and performance are normal, when

air-conditioner is kept operated for a long time with thermistor
in max. cooling position and air flow in M or L mode, frost may
form.

Instruct user on correct air-conditioner operation.

(Reset thermistor to either minimum or middle cooling
position or increase air flow.)

T5-6-91

TROUBLESHOOTING / Troubleshooting B
Cooling Circuit

Case connection.

Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.

Noise

Brush friction noise, metal and/or thrust washer contact noise.

Gas blowing sound (roaring).

Gas vibration noise (compressor discharge and/or

suction gas noise).

Expansion valve connection, whistle

sound, gas blowing sound.

Abnormal noise from expansion valve (Expansion

valve is normally functioning.).

Faulty clutch bearing, and/or idle pulley bearing.

Clutch disengaging sound.
Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.

Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.

T5-6-92

TROUBLESHOOTING / Troubleshooting B

Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.
Replace if loud.

No functional problem exists.

Provide silencer if intolerable.

Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.

Replace.
Repair or replace clutch. Re-tighten screws.

Repair or replace.
Re-adjust drive belt.

Replace.
Clean.

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.

T5-6-93

TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor does not rotate.

Clutch terminal voltage is normal 24 V.

Inoperable
cooling
system.

Clutch terminal voltage is low.

Clutch terminal voltage is 0 V.

Bubbles exist even after refrigerant is refilled.
Both high and
low side
pressures are
low.
Both compressor and
blower motor rotate.

Check for oil and refrigerant leaks from parts other than
compressor and pipe joints by using gas detector.
Check for oil and refrigerant leaks from compressor (no
leaks from parts other than compressor) by using gas
detector.

(Refer to NOTE 1,
2 on page T5-6-97.)
Stain on exterior.

Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2
months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than
2 years.

Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.)

High pressure side is

slightly low and low pressure side is high.

No refrigerant returns in liquid form. High pressure side is low.

Bubbles can be seen through

sight glass.

Others

High pressure side is high.

Refer to the Cooling Circuit Troubleshooting

Table on page T5-6-90.

Temperature is not cooled when compressor is

operated at fast speed continuously.
Air flow from blower is insufficient.

T5-6-94

TROUBLESHOOTING / Troubleshooting B

Seized clutch.

Replace.

Improper gap between amature and rotor (improper air gap).

Replace.
Open or shorted circuit in core cable.
Shaft does not rotate (internally locked).

Replace.

Faulty Electrical System.

Faulty Electrical System.

Oil leaks from mechanical seal, gasket, and/or charge valve.
Replace.
Oil leaks from oil plug.

Oil and refrigerant leaks from front housing, and/or cylinder block joint.
Normal leaks from hoses.

Replace.
Charge
refrigerant.

No leaks (normal).

Refer to the Cooling Circuit Troubleshooting Table on page T5-6-90.

Broken valve (See NOTE 3 on page T5-6-97.)
Replace.
Blown gasket (See NOTE 3 on page T5-6-97.)

Check and adjust

oil level.

Excessive oil.

T5-6-95

TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor rotation is abnormally draggy.
Overheating
is susceptible
to occur.
Trouble other than compressor.

Noise is heard when clutch is OFF.

Abnormal
noise

Noise is heard when clutch is ON.

T5-6-96

Refer to the Cooling Circuit Troubleshooting Table on page T5-6-90.

TROUBLESHOOTING / Troubleshooting B

Broken clutch bearing due to overly tightened belt.

Replace.

Shaft does not rotate.

Replace.
Shaft rotates draggy.

Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit
Troubleshooting Table on
page T5-6-90.

Saggy belt.
Loose screws.

Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.

Replace.

Vibration due to saggy belt.

Refer to the Cooling Circuit

Troubleshooting Table on
page T5-6-90.

Loose screws.

NOTE:
1. Do not quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will disappear within about 10 seconds.

T5-6-97

TROUBLESHOOTING / Troubleshooting B
WORK AFTER REPLACING COMPONENTS
The following work is required after replacing
compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose and air
conditioner unit.
The same work is required when gas leakage is found.
1. Add compressor oil
Oil amount: 160 cm3 (0.17 qt)
2. Charge air conditioner with refrigerant
Purging
Charge air conditioner with refrigerant
Warm-up operation
Inspection

T5-6-98

TROUBLESHOOTING / Troubleshooting B
CHARGE
AIR
REFRIGERANT

CONDITIONER

WITH

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

Air

1. Pressure rise in the high pressure side:

If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied,
however, air cannot be liquefied and remains as a
gas in the condenser because the temperature at
which air liquefies is extremely low. That is,
liquidation of the refrigerant gas in the condenser
decreases by the amount of air in the circuit, and
the gas pressure in the high pressure side
increases accordingly.

Pressure increases if air

remains in the air
conditioner circuit.

W115-02-10-001

2. Metal corrosion:
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid
corrodes metals if
moisture exists.

Hydrochloric Acid

W115-02-10-002

Metal Corrosion

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.

Ice produced at the

expansion valve disturbs
refrigerant flow, lowering
cooling efficiency.

Plugged Refrigerant
Flow
W115-02-10-003

Low Cooling
Efficiency

T5-6-99

TROUBLESHOOTING / Troubleshooting B
Purging Procedure

Gauge Manifold

IMPORTANT: Never mistake the charge hose

connections.
1. Close the high and low pressure valves on the
gauge manifold (Parts Number 4360564).
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the
high-pressure-side charge valve (D marked) and
to the low-pressure-side charge valve (S
marked) located on the compressor, respectively.
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint
Number 4360566).

Adapter

Low Pressure
Valve
Low Pressure
Charge Hose

High Pressure
Valve
High Pressure
Charge Hose

Center Pressure
Charge Hose
Vacuum Pump

(Parts
W115-02-10-005

Low Pressure
Side
S
Compressor
D
High Pressure
Side
T142-02-05-018

Fully Open

2. Fully open the high pressure and low pressure

valves in the gauge manifold. Perform purging for
10 minutes or more by operating the vacuum
pump.

Fully Open

In Operation

W115-02-10-005

T5-6-100

TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again.

Close

3. When the low pressure gauge reading falls below

-100 kPa (-755 mmHg), stop the vacuum pump
and close the high and low pressure valves. Wait
for approximately five minutes and confirm that
the pointer does not return to 0.

Close

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves of

the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).

Refrigerant
Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the refrigerant
pressure.

Loosen

Open

W115-02-10-007

T5-6-101

TROUBLESHOOTING / Troubleshooting B
IMPORTANT: Always stop the engine when
charging the air conditioner with
refrigerant. Do not position the
refrigerant container upside down
during charging operation. When
changing the refrigerant container
during charging operation, purge air
from the charge hose, as shown in
step 10. Charge the low pressure
side hose first.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 C (104 F) or less to
warm the refrigerant container to aid in
charging operation.

High
Pressure
Gauge
Tighten

Open

Open

W115-02-10-007

W115-02-10-008

IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks by using leak tester (Parts Number
4360567).

T5-6-102

TROUBLESHOOTING / Troubleshooting B
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Open

IMPORTANT: Do not open the high pressure valve

in the gauge manifold.
9. Open the low pressure valve in the gauge
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear.
NOTE: The required refrigerant quantity is 1050 g
(2.31 lb).

Open

W115-02-10-007

Close

10. If the refrigerant container becomes empty during

the charging work, replace it with a new refrigerant
container as follows:
Close the high pressure and low pressure valves
on the manifold gauge.
Replace the empty container with a new one.
Tighten, then slightly loosen the refrigerant
container joint.
Slightly open the low pressure valve on the
manifold gauge.
When the refrigerant container joint starts to leak,
immediately tighten the refrigerant container joint
and close the low pressure valve on the manifold
gauge.
11. After charging, close the low pressure valve in the
gauge manifold and the refrigerant container valve.
Stop the engine.

T5-6-103

Close

W115-02-10-007

TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the air conditioner is operated with
very low refrigerant, a bad load will
be exerted on the compressor. If the
air conditioner is overcharged with
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner circuit,
causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver tank and
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

Sight Glass

Receiver Tank

W115-02-10-009

NOTE: As the bubbles in the sight glass vary

depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Checking procedures: Stop the air
conditioner and wait until refrigerant returns
to the balanced pressure. Then, start the air
conditioner again.

T5-6-104

TROUBLESHOOTING / Troubleshooting B
Relation between Refrigerant Quantity and Refrigerant
Flow in Sight Glass:
Refrigerant
Quantity

Refrigerant Flow in Sight Glass

(approx. 1 min. after air conditioner
switch is turned ON)
(immediately after)

(approx. 1 mm after)

Adequate

Explanation for Refrigerant Flow in Sight Glass

Immediately after the air conditioner is turned ON, few
bubbles are seen. Then the flow becomes transparent
and shows thin milk white color.

W115-02-10-016

No bubbles are seen after the air conditioner is turned

ON.

Overcharged
W115-02-10-017

Bubbles are seen continuously after the air conditioner is turned ON.

Not Enough
W115-02-10-018

W115-02-10-019

Bubbles exist: Bubbles are seen in refrigerant flow as

both liquid refrigerant and refrigerant gas exist, being
mixed.
W115-02-10-020

Transparent: Refrigerant flow is transparent as only

liquid refrigerant exists.

115-02-10-021

Milk white:
Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
CAUTION: Wait until the high-pressure-side
pressure drops to less than 980 kPa (10
kgf/cm2, 142 psi) before attempting to disconnect the high-pressure-side charge hose.
Otherwise, refrigerant and compressor oil
may spout.
13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
high-pressure-side charge hose.

T5-6-105

TROUBLESHOOTING / Troubleshooting B
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute in order to lubricate system
with compressor oil.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant
will
produce
poisonous material if exposed to heat of 1000
C (1800 F) or more. Never bring refrigerant
close to a fire.
1. Check the air conditioner for gas leaks by using a
leak tester.
Perform
checking
under
well-ventilated
conditions.
Thoroughly wipe off dust from the charge hose
connections of the compressor.
Pay special attention to check the line
connections.
If any gas leaks are found, retighten the line
connections.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Check each component for abnormalities.
Carry out ON-OFF check of the compressor
clutch.
Check compressor fan belt tension.
Check coolant level in the radiator.
Operate the air conditioner and check the
performance.

Leak Tester

W115-02-10-013

Retighten Line
Connection

W115-02-10-014

T5-6-106

TROUBLESHOOTING / Troubleshooting B
3. The checklist before the summer season is as
follows:
Check each air conditioner component for
abnormalities.
Check the line connections for oil leaks.
Check refrigerant quantity.
Check the engine cooling circuit.
Check V-belts for wear. Replace if necessary.
4. Off-Season Maintenance
During off-season, operate the idler pulley and
compressor at least once a month for a short time
in order to check for any abnormal sounds.
Do not remove the compressor belts during
off-season. Operate the compressor occasionally
at slow speed for 5 to 10 minutes with the belt
slightly loosened in order to lubricate the machine
parts.

T5-6-107

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-108

TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Many sensors used on this machine are identical.
Therefore, by using this switch-check method, faulty
part /component, and/or harness can be easily found.

(Main Pump)

Example: Abnormal pump delivery pressure sensor

high voltage (MC fault code: 11204-3)
Check Method:
1. Stop the engine. Release remained pressure

in the hydraulic oil tank. (Purge the hydraulic

oil tank if possible.)
2. Replace two pressure sensors as illustrated.
CAUTION: If the sensors are removed, hydraulic oil may gush out. Take a good care
and use the oil pan.

T4GB-05-06-010

(Parking Brake Solenoid

Valve Block)

3. Start the engine. Retry troubleshooting.

Result:
In case abnormal parking brake pressure sensor high
voltage is displayed (MC fault code 11313-3), the
pressure sensor is considered to be faulty.
In case abnormal pump delivery pressure sensor high
voltage is displayed (MC fault code 11204-3), the
pump delivery pressure sensor harness is considered
to be faulty.

T5-6-109

T4GB-01-02-011

TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
Fault Code
Trouble
11204-3
Abnormal Pump Delivery Pressure Sensor
High Voltage
11204-4
Abnormal Pump Delivery Pressure Sensor
Low Voltage
11209-3
Abnormal Implement Pressure Sensor High
Voltage
11209-4
Abnormal Implement Pressure Sensor Low
Voltage
11313-3
Abnormal Parking Brake Pressure Sensor
High Voltage
11313-4
Abnormal Parking Brake Pressure Sensor
Low Voltage
13314-3
Service Brake Pressure Switch High Voltage
13314-4
Service Brake Pressure Switch Low Voltage

T5-7-110

Applicability
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)
Applicable (Sensor only)

TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is contained in the brake, brake
efficiency is low so that the serious
accident may occur. When the brake
pipe is installed/ removed or hydraulic oil is replaced, release any
pressure in the brake. Until hydraulic oil (0.5 L) comes out from each
wheel (4 places) after bubbles stops,
continue to release any pressure.

1
1

NOTE: Two or more workers should do this work

at each wheel (4 places). Air bleed plug (1)
is located near the center of front/ rear axle
upper.
1. Turn the parking brake switch in front console to
P. Start the engine. Increase service brake oil
pressure.
2. Attach clear vinyl tube (2) onto end of air bleed
plug (1). Insert other of clear vinyl tube (2) into
clear container (3) filled with hydraulic oil.
3. Depress brake pedal (4) several times. Then,
depress and hold brake pedal (4) to the stroke
end.
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.

T4GB-05-04-004

T4GB-05-04-005

NOTE: When hydraulic oil (0.5 L) comes out, air

may be remained. In this case, repeat
steps 3 to 5.
7. Release any pressure at other 3 places in the
same procedures as steps 3 to 5.
IMPORTANT: After air bleeding work is completed
at 4 places, release any pressure at
4 places again. Release any pressure in the same procedures as
steps 3 to 5 twice and check if no
remained pressure inside.

T5-6-111

T4GB-05-04-006

TROUBLESHOOTING / Troubleshooting B
ONE PART OF DATA, DAILY REPORT
DATA, DISTRIBUTION DATA, TOTAL
OPERATING HOURS AND ALARM IS
NOT RECORDED
The required signal for data may not be sent to
ICF. As each signal is used for some data, check
the corresponding signal system according to the
table below.
Daily Report Data
Data

Input Signal

Date

Date of daily report data (Year/ Month/ Day)

Fuel level

Fuel level when the engine stops at last in one day

Fuel used amount

Fuel used amount in one day

Machine hour meter

Total hours of hour meter

Engine operating hours

Engine operating hours in one day

Travel operating distance

Traveling distance in one day

Manual gear shifting operating hours

Manual gear shifting operating hours in one day

Automatic gear shifting operating hours

Automatic gear shifting operating hours in one day

L mode operating hours

10

N mode operating hours

11

P mode operating hours

12

Radiator coolant temperature

L mode in work mode selector switch operating hours in one

day
N mode in work mode selector switch operating hours in
one day
P mode in work mode selector switch operating hours in
one day
Highest radiator coolant temperature in one day

13

Hydraulic oil temperature

Highest hydraulic oil temperature in one day

14

Intake-air temperature

Highest intake-air temperature in one day

15

Fuel temperature

Highest fuel temperature in one day

16

Torque converter oil temperature

Highest torque converter oil temperature in one day

17

Engine operating hours distribution

Engine operating hours distribution in one day

(Data is recorded only when alternator output signal is received for 10 minutes or longer.)

IMPORTANT: If the trouble occurs between each

controller and sensor, the data corresponding to this trouble is not
recorded in ICF.

T5-6-112

Although the machine is normal

(The fault code is not displayed as
for all controllers, the monitor display and the machine operation are
normal) and the required data is not
recorded in ICX, execute this inspection.

TROUBLESHOOTING / Troubleshooting B

Internal clock circuit in MC

Controller sending data

on CAN
ICF

Fuel level sensor

Monitor unit

Generated/Detected Data Position

Circuit calculating fuel used amount in ECM

ECM
Hour meter circuit in monitor unit
Monitor unit
Alternator

Alternator
ECM

Travel speed sensor

TCU

M mode in travel mode selector switch

MC

L mode in travel mode selector switch

N mode in travel mode selector switch
H mode in travel mode selector switch

MC

L mode in work mode selector switch

MC

N mode in work mode selector switch

MC

P mode in work mode selector switch

MC

Coolant temperature sensor

Monitor unit

Hydraulic oil temperature sensor

MC

Intake-air temperature sensor

ECM

Fuel temperature sensor

ECM

Torque converter oil temperature sensor

Monitor unit

Alternator

Alternator
ECM

Inspected Position
-

Communication line between monitor

unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Wiring between alternator and ICF
Communication line between ECM
and ICF (CAN line)
Communication line between TCU and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Wiring between alternator and ICF
Communication line between ECM
and ICF (CAN line)

As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.

T5-6-113

TROUBLESHOOTING / Troubleshooting B

Daily Report Data

Data

Input Signal
Replace ICF
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
3 Fuel used amount
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
4 Machine hour meter
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
5 Engine operating hours
Check terminal #8 of connector ICF-C in ICF, terminal L
in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
6 Travel operating distance
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #25, #26 of connector in TCU
7 Manual gear shifting operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
8 Automatic gear shifting operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
9 L mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
10 N mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
11 P mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
12 Radiator coolant temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
13 Hydraulic oil temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #4, #15 of connector MC-C in MC
14 Intake-air temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
15 Fuel temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
16 Torque converter oil temperature
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #33, #34 of connector monitor-2 in monitor unit
17 Engine operating hours distribution
Check terminal #8 of connector ICF-C in ICF, terminal L
in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF,
terminals #18, #37 of connector in ECM
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
1
2

Date
Fuel level

T5-6-114

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-115

TROUBLESHOOTING / Troubleshooting B
Distribution Data
Data

Input Signal

Fuel temperature distribution

Distribution of fuel temperature

Pump load distribution

Distribution of main pump delivery pressure

Travel load distribution

Distribution of travel torque

Radiator coolant temperature distribution

Distribution of coolant temperature

Hydraulic oil temperature distribution

Distribution of hydraulic oil temperature

Torque converter oil temperature distribution

Distribution of torque converter oil temperature

Radiator coolant temperature - Intake-air Distribution of temperature that intake-air temperature is

temperature distribution
taken from coolant temperature

Hydraulic oil temperature - Intake-air tem- Distribution of temperature that intake-air temperature is
perature distribution
taken from hydraulic oil temperature

Torque converter oil temperature - Intake-air Distribution of temperature that intake-air temperature is
temperature distribution
taken from torque converter oil temperature

10

Radiator coolant temperature / Intake-air Distribution of coolant temperature and intake-air temtemperature
perature

11

Hydraulic oil temperature / Intake-air tem- Distribution of hydraulic oil temperature and intake-air
perature
temperature

12

Torque converter oil temperature / Intake-air Distribution of torque converter oil temperature and intemperature
take-air temperature

13

Travel speed gear distribution during manual Distribution of travel speed gear during manual gear
gear shifting
shifting

14

Travel speed gear distribution during auto- Distribution of travel speed gear during automatic gear
matic gear shifting
shifting

15

Engine load rate

Distribution of engine speed and engine torque

IMPORTANT: If the trouble occurs between each

controller and sensor, the data corresponding to this trouble is not
recorded in ICF.
Although the machine is normal
(The fault code is not displayed as

T5-6-116

for all controllers, the monitor display and the machine operation are
normal) and the required data is not
recorded in ICX, execute this inspection.

TROUBLESHOOTING / Troubleshooting B

Fuel temperature sensor

Controller sending data

on CAN
ECM

Pump delivery pressure sensor

MC

Generated/Detected Data Position

Torque converter input shaft sensor

TCU
Torque converter output shaft sensor

Coolant temperature sensor

Monitor unit

Hydraulic oil temperature sensor

MC

Torque converter oil temperature sensor Monitor unit

Coolant temperature sensor

Intake-air temperature sensor

Monitor unit
ECM

Hydraulic oil temperature sensor

Intake-air temperature sensor

MC
ECM

Torque converter oil temperature sen- Monitor unit

sor
ECM
Intake-air temperature sensor
Coolant temperature sensor
Intake-air temperature sensor

Monitor unit
ECM

Hydraulic oil temperature sensor

Intake-air temperature sensor

MC
ECM

Torque converter oil temperature sen- Monitor unit

sor
ECM
Intake-air temperature sensor
M mode in travel mode selector switch MC
Shift switch
TCU
L mode in travel mode selector switch MC
N mode in travel mode selector switch
H mode in travel mode selector switch
Shift switch
Engine torque curve control circuit in ECM

Inspected Position
Communication line between ECM and
ICF (CAN line)
Communication line between MC and ICF
(CAN line)
Communication line between TCU and ICF
(CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between MC and ICF
(CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between monitor unit
and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between monitor
unit and ICF (CAN line)
Communication line between ECM and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between TCU and
ICF (CAN line)
Communication line between MC and ICF
(CAN line)

Communication line between ECM and

ECM
ICF (CAN line)
Engine speed sensor
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.

T5-6-117

TROUBLESHOOTING / Troubleshooting B
Distribution Data
Input Signal
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#18, #37 of connector in ECM
2
Pump load distribution
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#4, #15 of connector MC-C in MC
3
Travel load distribution
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#25, #26 of connector in TCU
4
Radiator coolant temperature distri- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
bution
#33, #34 of connector monitor-2 in monitor unit
5
Hydraulic oil temperature distribution Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#4, #15 of connector MC-C in MC
6
Torque converter oil temperature dis- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
tribution
#33, #34 of connector monitor-2 in monitor unit
7
Radiator coolant temperature In- Check terminal #8 of connector ICF-C in ICF, terminals #33,
take-air temperature distribution
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
8
Hydraulic oil temperature - Intake-air Check terminals #C5, #C11 of connector ICF-C in ICF, termitemperature distribution
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
9
Torque converter oil temperature - Check terminal #8 of connector ICF-C in ICF, terminals #33,
Intake-air temperature distribution
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
10 Radiator coolant temperature / In- Check terminal #8 of connector ICF-C in ICF, terminals #33,
take-air temperature
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
11 Hydraulic oil temperature /Intake-air Check terminals #C5, #C11 of connector ICF-C in ICF, termitemperature
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
12 Torque converter oil temperature / Check terminal #8 of connector ICF-C in ICF, terminals #33,
Intake-air temperature
#34 of connector monitor-2 in monitor unit
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37 of connector in ECM
13 Travel speed gear distribution during Check terminals #C5, #C11 of connector ICF-C in ICF, termimanual gear shifting
nals #4, #15 of connector MC-C in MC
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #25, #26 of connector in TCU
14 Travel speed gear distribution during Check terminals #C5, #C11 of connector ICF-C in ICF, termiautomatic gear shifting
nals #4, #15 of connector MC-C in MC
15 Engine load rate
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals
#18, #37 of connector in ECM
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
1

Data
Fuel temperature distribution

T5-6-118

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-119

TROUBLESHOOTING / Troubleshooting B
Total Operating Hours Data
Data

Input Signal

1
2

Hour meter (ICF)

Hour meter (monitor unit)

Hour meter value calculated in ICF

Hour meter value calculated in monitor unit

Engine operating hours

Total engine operating

Traveling distance

Total traveling distance

Manual gear shifting operating hours

Total manual gear shifting operating hours

Automatic gear shifting operating Total automatic gear shifting operating hours
hours

L mode operating hours

Total L mode in work mode selector switch operating hours

N mode operating hours

Total N mode in work mode selector switch operating hours

P mode operating hours

Total P mode in work mode selector switch operating hours

IMPORTANT: If the trouble occurs between each

controller and sensor, the data corresponding to this trouble is not
recorded in ICF.
Although the machine is normal
(The fault code is not displayed as
for all controllers, the monitor display and the machine operation are
normal) and the required data is not
recorded in ICX, execute this inspection.

T5-6-120

TROUBLESHOOTING / Troubleshooting B

Generated/Detected Data Position

Hour meter circuit in ICF
Hour meter circuit in monitor unit

Controller sending data

on CAN
ICF
Monitor unit

Alternator

Alternator
ECM

Travel speed sensor

TCU

M mode in travel mode selector switch

MC

L mode in travel mode selector switch

N mode in travel mode selector switch
H mode in travel mode selector switch

MC

L mode in work mode selector switch

MC

Inspected Position
Communication line between monitor
unit and ICF (CAN line)
Wiring between alternator and ICF
Communication line between ECM
and ICF (CAN line)
Communication line between TCU and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)
Communication line between MC and
ICF (CAN line)

Communication line between MC and

ICF (CAN line)
N mode in work mode selector switch
MC
Communication line between MC and
ICF (CAN line)
P mode in work mode selector switch
MC
Communication line between MC and
ICF (CAN line)
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.

T5-6-121

TROUBLESHOOTING / Troubleshooting B
Total Operating Hours Data
1
2
3

4
5

Data
Hour meter (ICF)
Hour meter (monitor
unit)
Engine operating hours

Input Signal
Replace ICF
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #33, #34
connector monitor-2 in monitor unit
Check terminal #8 of connector ICF-C in ICF, terminal L in alternator
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #18, #37
connector in ECM
Traveling distance
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #25, #26
connector in TCU
Manual gear shifting op- Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
erating hours
connector MC-C in MC

Automatic gear shifting Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
operating hours
connector MC-C in MC
7 L mode operating hours
Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
8 N mode operating hours Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
9 P mode operating hours Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #4, #15
connector MC-C in MC
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.

T5-6-122

of

of
of
of

of
of
of
of

TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-123

TROUBLESHOOTING / Troubleshooting B
Alarm Data
Data

Input Signal

Overheat alarm

Data when overheat indicator lights

Engine warning alarm

Data when engine warning indicator lights

Engine oil pressure alarm

Data when engine oil pressure indicator lights

Alternator indicator alarm

Data when alternatort indicator lights

Air cleaner restriction alarm

Data when air cleaner restriction indicator lights

Water separator alarm

Data when water separator indicator lights

Service brake oil level alarm

Data when air cleaner restrictiont indicator lights

Service brake oil pressure alarm

Data when brake oil lever indicator lights

Data when emergency steering operation indicator lights

10

Emergency
steering
operation
alarm
Steering oil pressure alarm

Data when steering oil pressure indicator lights

11

Transmission oil temperature alarm

Data when transmission oil temperature indicator lights

12

Hydraulic oil temperature alarm

Data when hydraulic oil temperature indicator lights

13

Transmission filter restriction alarm

Data when transmission filter restriction indicator lights

14

Transmission malfunction alarm

Data when transmission malfunction indicator lights

IMPORTANT: If the trouble occurs between each

controller and sensor, the data corresponding to this trouble is not
recorded in ICF.
Although the machine is normal
(The fault code is not displayed as
for all controllers, the monitor display and the machine operation are
normal) and the required data is not
recorded in ICX, execute this inspection.

T5-6-124

TROUBLESHOOTING / Troubleshooting B

Overheat switch

Controller sending data

on CAN
Monitor unit

ECM

Monitor unit

Engine oil pressure switch

Monitor unit

Alternator

Monitor unit

Air cleaner restriction switch

Monitor unit

Water separator level sensor

Monitor unit

Air cleaner restriction switch

Monitor unit

Hydraulic oil level switch

Monitor unit

Emergency steering sensor

Monitor unit

Main pump delivery pressure sensor

Monitor unit

Transmission oil temperature sensor

Monitor unit

Hydraulic oil temperature sensor

Monitor unit

Transmission filter restriction switch

Monitor unit

Torque converter input speed sensor

Torque converter output speed sensor
Transmission medium shaft sensor
Travel speed sensor
Forward/reverse lever
Forward/reverse switch
Brake pressure sensor

Monitor unit

Generated/Detected Data Position

Inspected Position
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)
Communication line between
unit and ICF (CAN line)

monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor
monitor

As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.

T5-6-125

TROUBLESHOOTING / Troubleshooting B
Alarm Data
Data

Input Signal
Check terminals #C5, #C11 of connector ICF-C in ICF,
1
terminals #33, #34 of connector monitor-2 in monitor unit
Engine warning alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
2
terminals #33, #34 of connector monitor-2 in monitor unit
Engine oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
3
terminals #33, #34 of connector monitor-2 in monitor unit
Alternator indicator alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
4
terminals #33, #34 of connector monitor-2 in monitor unit
Air cleaner restriction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
5
terminals #33, #34 of connector monitor-2 in monitor unit
Water separator alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
6
terminals #33, #34 of connector monitor-2 in monitor unit
Service brake oil level alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
7
terminals #33, #34 of connector monitor-2 in monitor unit
Service brake oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
8
terminals #33, #34 of connector monitor-2 in monitor unit
Emergency steering operation alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
9
terminals #33, #34 of connector monitor-2 in monitor unit
Steering oil pressure alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
10
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission oil temperature alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
11
terminals #33, #34 of connector monitor-2 in monitor unit
Hydraulic oil temperature alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
12
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission filter restriction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
13
terminals #33, #34 of connector monitor-2 in monitor unit
Transmission malfunction alarm
Check terminals #C5, #C11 of connector ICF-C in ICF,
14
terminals #33, #34 of connector monitor-2 in monitor unit
As for inspection method of the CAN line, refer to Troubleshooting A group in TROUBLESHOOTING section.
Overheat alarm

T5-6-126

TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.

How to Read Troubleshooting Flow Charts

YES (OK)

(2)

After completing the checking and/or measuring procedures in box

(1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1)
NO (NOT OK)

Key switch: ON

(3)

Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
will troubleshooting be unsuccessful but also damage to components may result.

Use the service mode in monitor and the diagnosing system / controller diagnosing
system in Dr. ZX.

Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.

NOTE: All harness end connector are seen from

the open-end side.

Harness End
Connector

Open End Side

Harness

T6L4-05-03-001

T5-7-1

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check the wiring connections first.

YES

Indicator does not light when

indicator light check operation
is performed.

Check if all indicators do not

light.

NO

YES

Check power line

Fuse
Disconnect connector 1-A.
Check for continuity between
terminal #2 of harness end
and fuse terminal #8 in fuse
box A.
Check if trouble occurs.

Conduct troubleshooting of
each indicator, which does not
light.

Faulty fuse #8 in fuse box A, or

open circuit in harness between
fuse #8 and monitor.

A
Faulty monitor unit.
NO

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 1-A
2

T183-05-04-013

T5-7-2

To A

TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-7-3

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER IN MONITOR
Check the wiring connections first.
NOTE: * Terminals L in the alternator are water-resistant type connectors so that it is not
practical to measure voltage at these terminals. Measure voltage at terminal R in
safety relay. Check for continuity between
terminal R in safety relay and terminal L in
the alternator first.

YES
When engine starts,
buzzer continues to
sound.

Faulty engine oil pressure system.

Check if engine oil

pressure indicator
lights.

YES

NO

Overheated engine.

Check if overheat indicator lights.

Faulty monitor unit.
NO

Although stop indicator or brake low

oil pressure indicator lights, or high
axle oil temperature
is detected, buzzer
does not sound.

NO

Normal.

Check if engine
-1
speed is 900 min
(rpm) or faster.

NO
Check if alternator inYES dicator lights.
YES

Conduct troubleshooting
of lighted indicator.

Check voltage at terminal

L in *alternator.
Engine speed:
900 min-1 (rpm) or faster

T5-7-4

TROUBLESHOOTING / Troubleshooting C

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-A
Safety Relay
Connector A

E
S

T183-05-04-013

Less than 12 V
or 35 V or higher

Faulty regulator or faulty alternator.

Less than 12 V
or 35 V or higher

Check voltage at terminal #2

on connector 2-A in monitor
Between 12 V unit.
and 35 V
Engine speed
900 min-1 (rpm) or faster

Open circuit in harness between terminal L in alternator

and monitor unit.
Faulty monitor unit.

Between 12 V
and 35 V

T5-7-5

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF
PERATURE GAUGE

COOLANT

TEM-

Check the wiring connections first.

YES

Coolant temperature gauge

pointer does not move at all.

Disconnect coolant temperature

sensor.
Connect harness end terminal
to vehicle frame.
Check if pointer swings to (H)
side.
Key switch: ON

NO

Disconnect connector 2-A.

Check if voltages at terminal #3 of monitor unit end
connector is 5V.

YES

Coolant temperature gauge

pointer swings over scale.

Disconnect coolant temperature sensor.

Check if pointer returns to
zero.
Key switch: ON
NO

Coolant temperature gauge

pointer keeps moving unstably.

Disconnect coolant temperature sensor.

Connect harness end terminal
to vehicle frame.
Check if pointer swings and is
stabilized to (H) side.

YES

Key switch: ON
NO

T5-7-6

Disconnect connector 2-A.

Check if voltages at terminal #3 of monitor unit end
connector is 5V.

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge

Faulty coolant temperature
sensor.

YES

Open circuit in harness between monitor unit and sensor.

Faulty monitor unit.
T4GB-05-07-005

NO

Faulty coolant temperature

sensor.

YES

Shorted circuit in harness

between monitor unit and
sensor.

Faulty monitor unit.

NO

Coolant Temperature Sensor

Coolant Temperature
C (F)
25 (77)
40 (104)
50 (122)
80 (176)
95 (203)
105 (221)
120 (248)

Resistance (k)
7.60.76
4.00.35
2.70.22
0.920.07
0.560.04
0.420.03
0.280.01

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-A

#3

Faulty coolant temperature

sensor.
T183-05-04-013

Faulty monitor unit.

T5-7-7

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TRANSMISSION OIL
TEMPERATURE GAUGE
Check the wiring connections first.

YES

Transmission oil temperature

gauge pointer does not move
at all.

Disconnect oil temperature

sensor.
Connect harness end terminal
to vehicle frame.
Check if pointer swings to (H)
side.
Key switch: ON

NO

Disconnect connector 2-A

in monitor unit.
Check if voltage at terminal
#5 of monitor unit end
connector is 5V.

YES

Transmission oil temperature

gauge pointer swings over
scale.

Disconnect oil temperature

sensor.
Check if pointer returns to
zero.
Key switch: ON
NO

YES

Transmission oil temperature

gauge pointer keeps moving
unstably.

Disconnect oil temperature

sensor.
Connect harness end terminal
to vehicle frame.
Check if pointer swings and is
stabilized to (H) side.
Key switch: ON

T5-7-8

NO

Disconnect connector 2-A

in monitor unit.
Check if voltage at terminal
#5 of monitor unit end
connector is 5 V.

TROUBLESHOOTING / Troubleshooting C

Transmission Oil Temperature Gauge

Faulty transmission oil temperature sensor.

YES

Open circuit in harness between monitor unit and sensor.

Faulty monitor unit.

NO

T4GB-05-07-006

Transmission Oil Temperature Sensor

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

Faulty transmission oil temperature sensor.

YES

Shorted circuit in harness

between monitor unit and
sensor.

Faulty monitor unit.

NO

Resistance (k)
7.60.76
4.00.35
2.70.22
0.920.07
0.560.04
0.420.03
0.280.01

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-A
5

Faulty transmission oil temperature sensor.

T183-05-04-013

Faulty monitor unit.

T5-7-9

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Check the wiring connections first.

YES

Fuel gauge pointer does not

move at all.

Disconnect fuel sensor.

Connect terminal #1 to terminal
#2 of harness end connector by
using a clip.
Check if pointer swings to
(FULL) side.
Key switch: ON

NO

Disconnect connector 2-A in

monitor unit.
Check if voltage at terminal #8
of monitor end connector is 5 V.

YES

Fuel gauge pointer swings over

scale.

Disconnect fuel sensor.

Check if pointer returns to zero.
Key switch: ON
NO

YES

Fuel gauge pointer keeps moving unstably.

Disconnect fuel sensor.

Connect terminal #1 to terminal
#2 of harness end connector by
using a clip.
Check if pointer swings and is
stabilized to (FULL) side.
Key switch: ON

T5-7-10

NO

Disconnect connector 2-A in

monitor unit.
Check if voltage at terminal #8
of monitor end connector is 5 V.

TROUBLESHOOTING / Troubleshooting C

Fuel Gauge

Upper Limit

Faulty fuel sensor.

1/2

YES

Open circuit in harness between monitor unit and sensor.

Lower Limit

Faulty monitor unit.

T4GB-05-07-007

NO

Fuel Sensor
Float
Upper Limit (FULL)

Faulty fuel sensor.

R134.5
106 mm

YES

Shorted circuit in harness

between monitor unit and
sensor.

14 mm
1/2

Faulty monitor unit.

NO
106 mm

Lower Limit (EMPTY)

T4GB-05-07-008

Faulty fuel sensor.

NOTE: 1 mm = 0.03937 in

Faulty monitor unit.

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-A

Float Position
Upper Limit (FULL)
1/2
Warning Level
Lower Limit (EMPTY)

Fuel Sensor

8
1

T183-05-04-013

T5-7-11

Resistance ()
10+0-4
385
773
90+10-0

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TURN SIGNAL INDICATORS (LEFT AND RIGHT)
Check the wiring connections first.
If the turn signal indicators (left and right) do not
blink, the flasher relay may be faulty.

YES

Although turn signal

lever is shifted, turn
signal light or turn
signal indicator at one
side does not blink.

When hazard light

switch is shifted,
check if all turn signal
lights or turn signal
indicators light or
blink.

Faulty turn signal lever.

YES
Replace turn signal relay
(right) (AR8) with turn signal
relay (left) (BR7).
NO Check if symptom is
switched.
NO

YES

Although turn signal

lever is not shifted,
turn signal light or turn
signal indicator blinks.

Replace turn signal

relay (right) (AR8)
with turn signal relay
(left) (BR7).
Check if symptom is
switched.
NO

T5-7-12

Faulty turn signal relay.

Burnt indicator light or open

circuit in harness between
turn signal lever and turn
signal relay.

Faulty turn signal relay.

Faulty turn signal lever or

shorted circuit in harness
between turn signal lever and
turn signal relay.

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HAZARD LIGHT INDICATOR
The hazard light indicator lights when the signal of
turn signal relay in left and right enters into the
hazard light switch. Therefore, although both turn
signal indicator light or blink and if the hazard light
indicator does not light, the harness between turn
signal relay and monitor unit may be faulty or the
monitor unit may be faulty. If the turn signal indicator at one side does not light or blink, refer to
troubleshooting that harness between turn signal
relay and hazard light switch may be faulty or the
turn signals (left and right) may be faulty in order
to conduct the remedy.
Check the wiring connections first.

T5-7-13

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HIGH BEAM INDICATOR
Check the wiring connections first.

Although dimmer
switch is turned to
HIGH beam position,
high beam indicator
does not light.

Although dimmer
switch is not in HIGH
beam position, high
beam indicator lights.

Replace high beam relay

YES (AR3) with parking brake
relay (BR1).
Check if high beam indicator lights.

YES

NO

Check if voltage at terminals #1 and #3 in high

beam relay (AR3) is 24
V respectively.

Faulty high beam relay (AR3).

Disconnect connector of
head light switch.
Check if voltage at terminal
#2 of harness end connector is 0 V.

NO

Faulty fuse or open circuit in

harness between fuse and
high beam relay (AR3).

YES

Faulty high beam relay (AR3).

Replace high beam relay

(AR3) with parking brake
relay (BR1).
Check if high beam indicator goes out.

YES

NO

Disconnect connector
2-B in monitor unit.
Check if high beam indicator goes out.

Faulty monitor unit.

NO

T5-7-14

Connect the disconnected

connector.
Disconnect connector of
head light switch.
Check if high beam indicator
goes out.

TROUBLESHOOTING / Troubleshooting C

Open circuit in harness between high beam relay (AR3)

and head light switch.

YES

Check for continuity between terminals #2 and

NO #4 of head light switch
end connector.

Connect the disconnected connector.

YES Disconnect connector
2-B in monitor unit.
Check if voltage at terminal #22 of harness
end connector is 0 V.

Open circuit in harness between high beam relay (AR3)

and monitor unit.

YES

Faulty logic circuit in monitor

unit or burnt indicator light.

NO

Faulty head light switch.

NO

YES

Faulty head light switch.

NO

Shorted circuit in harness between high beam relay (AR3)

and head light switch.

Connector (Harness end of connector viewed from the

open end side)
Head Light Switch Connector

Monitor Unit
Connector 2-B

High Beam Relay Connector

22

T4GB-05-05-002

T5-7-15

T183-05-04-003

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF WORKING LIGHT INDICATOR
Check if the working light switch and head light
switch are in the ON position.

If the clearance light indicator also does not light,

the common circuit for clearance light indicator
and working light indicator may be faulty. Refer to
the Malfunction of Clearance Light Indicator section.
Check the wiring connections first.

Disconnect connector 1-B

in monitor unit.
YES Check if voltage at terminal #23 of harness end
connector is 24 V.
Although working light
switch is turned to ON
position, working light
indicator does not
light.

Check if working light

lights.

Faulty working light indicator.

NO

Open circuit in harness between working light relay 1

(AR8) and monitor unit.

NO

Open circuit in harness between fuse and working light

relay 1 (AR8) or open circuit
in fuse.

YES

Replace working light relay 1

(AR8) with working light relay
2 (AR7).
Check if indicator lights.

Check if voltage at terminal #3 of working light reNO lay 1 (AR8) is 24 V.

Replace working light relay

1 (AR8) with working light
YES relay 2 (AR7).
Check if indicator goes
out.
Although working light
switch is turned to
OFF position, working
light indicator lights.

YES

YES

Faulty working light relay 1

(AR8).

NO
Check if working light
lights.
Shorted circuit in harness
between working light relay 1
(AR8) and monitor unit.

NO

T5-7-16

TROUBLESHOOTING / Troubleshooting C

YES

NO

Faulty working light relay

1 (AR8).

Check for continuity

between terminal #8
YES of working light
switch end connector
Disconnect connector
and vehicle frame.
of working light
Working light switch:
switch.
ON
Check if voltage at
terminal #8 of harness
end connector is 24
V.
NO

Connect the disconnected

connector.
Disconnect connector 1-B in
YES monitor unit.
Check if voltage at terminal
#23 of harness end connector is 24 V.

YES Faulty working light.

Open circuit in harness
between working light
relay 1 (AR8) and moniNO tor unit.
Faulty working light
switch.

NO

Open circuit in harness

between working light
relay 1 (AR8) and working light switch.
YES

Faulty working light

switch.

Disconnect connector of
working light switch.
Check if indicator goes out.

Shorted circuit in harness between working

light relay 1 (AR8) and
working light switch.

NO

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 1-B

Working Light Relay

Working Light Switch Connector
23
3

T183-05-04-003
T4GB-05-05-002

T5-7-17

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FORWARD/REVERSE
SWITCH INDICATOR
CAUTION: Turn the forward/reverse lever
and the forward/reverse switch to neutral and
turn the forward/reverse selector switch to
the ON position. If not, the indicator does not
light and the machine cannot be operated by
the forward/reverse switch.

Although forward/reverse selector

switch is turned to ON
position, indicator
does not light.

Disconnect connector 1-B

in monitor unit.
YES Check for continuity between terminal #34 of
harness end connector
and vehicle frame.
Forward/reverse
selector switch: ON

Check if the machine

can be operated by
the forward/reverse
switch.
Forward/reverse
selector switch: ON

YES

NO

YES
Disconnect connector
TCU.
Check if voltage at termiNO nal #30 of harness end
connector is 24 V.
Forward/reverse
selector switch: ON

NO

Open circuit in harness between terminal #34 of connector 1-B in monitor unit and
terminal #5 of connector
TCU, or faulty TCU.
Faulty connection of TCU
and connector, or faulty TCU.
Connect the disconnected
connector.
Disconnect connector of forward/reverse selector switch.
Check if voltage at terminal
#7 of harness end connector
is 24 V.

Faulty forward/reverse selector switch, or shorted circuit in harness between terminals #2 and #4 of connector.

YES

Although forward/reverse selector

switch is in OFF position, indicator lights.

Faulty connection of terminals in monitor unit and connector, faulty indicator, or

faulty monitor unit.

Turn forward/reverse
lever to Forward or
Reverse.
Check if machine
moves and indicator
goes out.

YES

Shorted circuit in harness

between terminals of harness
end connector in TCU, or
faulty TCU.

NO

Shorted circuit in harness

between terminal #5 in TCU
and terminal #34 of connector 1-B in monitor unit, or
faulty monitor unit.

Disconnect connector
TCU.
NO Check if indicator goes
out.

T5-7-18

TROUBLESHOOTING / Troubleshooting C

YES

Check for continuity

between terminals #2
and #7 of switch end in
forward/reverse selector switch.
Forward/reverse
selector switch: ON

Open circuit in harness

between terminal #2 in
forward/reverse selector
switch and terminal #30
in TCU.

YES

Faulty forward/reverse
selector switch.

NO

Open circuit in harness

between terminal #7 of
connector end in forward/reverse selector
switch and fuse.

NO

Connector TCU

5
30

Connector (Harness end of connector viewed from the

open end side)

Monitor Unit
Connector 1-B

Forward/Reverse Selector Switch Connector

2

T4GB-05-05-002

34

7
T4GB-05-05-001

T5-7-19

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF MAINTENANCE INDICATOR
The maintenance indicator lights when the hour
meter reaches the set replacement interval for
lubrication system and filter. (Refer to the operation manual.) The maintenance indicator lighting
is controlled in the logic circuit of monitor unit. If
the maintenance indicator lights during the time
when the maintenance indicator must go out, the
monitor unit may be faulty. If the maintenance indicator does not light during the time when the
maintenance indicator must light, the light or the
monitor unit may be faulty.

T5-7-20

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
The preheat system operates only when coolant
temperature is below the specification. (Refer to
the SYSTEM / Electrical Circuit group.)

In case the preheat system malfunctions, refer to

Troubleshooting B.

Check the wiring connections first.

Faulty coolant
temperature sensor.

YES
Preheat indicator
lights although preheat system does
not operate
(coolant temperature is more than
specification).

Disconnect connector of coolant

temperature sensor.
Check if preheat
indicator goes out.
Key switch: ON

YES

Disconnect connector A in ECM.

NO Check if preheat
indicator goes out.
Key switch: ON

NO

Faulty ECM.

Check for continuity between terminal #11 of harness

end connector A in
ECM and vehicle
frame.

YES

NO

Preheat indicator
does not light although preheat
system operates
(coolant temperature is lower than
specification).

Key switch: ON

YES
Disconnect connector A in ECM.
Connect terminal
#11 of harness end
connector to vehiNO
cle frame.
Check if preheat
indicator lights.
Key switch: ON

Connector (Harness end of connector viewed from the

open end side)

NO

Faulty ECM.

Connect terminal
#24 of connector
1-B in monitor unit
to vehicle frame.
Check if preheat
indicator lights.

YES

Open circuit in
harness between
ECM and monitor
controller.
Faulty monitor unit.

Without disconnect- NO
ing connector, connect connector to
vehicle frame by
using a clip from the
rear of connector.
Monitor Unit
Connector 1-B

ECM
Connector A

#11

Faulty monitor
controller.

Faulty coolant
temperature sensor

YES
Disconnect connector of coolant
temperature sensor.
Short harness end
connector.
Check if indicator
lights.

Shorted circuit in
harness between
ECM and monitor
unit.

#24

T4GB-05-05-002
T1GR-05-04-002

T5-7-21

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TRANSMISSION OIL
TEMPERATURE
Check the wiring connections first.

Indicator does not

light although engine
overheats.

Disconnect connector
of transmission oil
temperature sensor.
Connect terminal of
YES harness end to vehicle
frame.
Check if indicator
lights.

YES

Key switch: ON

NO

Check if indicator
lights when key
switch is turned to
ON position.

Key switch: ON
Without disconnecting
connector, connect connector to vehicle frame by
using a clip from the rear
of connector.

Key switch: ON

NO

YES

Indicator lights although oil temperature is low.

Disconnect terminal of transmission

oil temperature
sensor.
Check if indicator
goes out.
Key switch: ON
Engine: Stopped

Connect the disconnected terminal.

Connect terminal #5 of
connector 2-A in monitor
unit to vehicle frame.
Check if indicator lights.

YES

NO

Disconnect connector 2-A in

monitor unit.
Check if indicator
goes out.
Key switch: ON

T5-7-22

NO

TROUBLESHOOTING / Troubleshooting C

Faulty transmission oil

temperature sensor.

YES

Open circuit in harness

between monitor unit and
transmission oil temperature sensor.

Transmission Oil Temperature Indicator

Oil Temperature
Operation
Less than 110 C
OFF
(230 F)
120 C (248 F) or
ON
higher

Faulty monitor unit.

NO

Connector (Harness end of connector viewed from the

open end side)

Faulty monitor unit, or

burnt indicator light.

Monitor Unit
Connector 2-A

#5

T183-05-04-013

Faulty transmission oil

temperature sensor.

Shorted circuit in harness

between monitor unit and
transmission oil temperature sensor.

Faulty monitor unit.

T5-7-23

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC
TEMPERATURE INDICATOR

OIL

The hydraulic oil temperature indicator is not

turned on by the signal directly input from the
sensors. The signal data which inputs to other
controllers from the sensors once is input to the
monitor unit by using the CAN communication
and is proceeded in the logic circuit of monitor
unit.
When this trouble occurs, refer to Troubleshooting
A and remedy the trouble on fault code.
Although the fault code is not displayed and if the
trouble occurs after re-trial, the connection between monitor unit and terminal #33 or #34 of
connector 2-B in monitor unit may be faulty, or the
monitor unit may be faulty.
Hydraulic Oil Temperature Indicator
Oil Temperature
Operation
Less than 95 C
OFF
(203 F)
105 C (221 F) or
ON
higher

T5-7-24

TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-7-25

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION
OF
WARNING INDICATOR

TRANSMISSION

Although the fault code is not displayed in TCU

and if the trouble occurs, conduct this remedy.

Check the wiring connections first.

YES
Disconnect connector
TCU.
YES Connect terminal #52 of
harness end connector
to vehicle frame.
Check if indicator lights.
Although transmission is abnormal,
indicator does not
light.

When key switch is

turned to ON position, check if indicator lights.

NO

Key switch: ON
Without disconnecting connector, connect to vehicle
frame by using a clip from
the rear of connector.
NO

YES

Although transmission is not abnormal,

indicator lights.

Disconnect connector TCU.

Check if indicator
goes out.
Key switch: ON
Engine: Stopped

Connect the disconnected

connector.
Connect terminal #15 of
connector 1-A in monitor
unit to vehicle frame.
Check if indicator lights.

YES

NO

Disconnect connector
1-A in monitor unit.
Check if indicator goes
out.
NO

T5-7-26

TROUBLESHOOTING / Troubleshooting C

Faulty TCU.

YES

Open circuit in harness

between monitor unit and
TCU.

Faulty monitor unit.

NO

Faulty monitor unit, or

burnt indicator light.

Faulty TCU.

Connector TCU

Shorted circuit in harness

between monitor unit and
TCU.
#52

Faulty monitor unit.

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 1-A

T183-05-04-013

#15

T4GB-05-05-001

T5-7-27

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
Check the wiring connections first.

YES

Although air filter is

clogged, indicator
does not light.

Check if indicator
lights when key
switch is turned to
ON position.

Disconnect air filter restriction switch at plug

receptacle with light
YES
green cable.
Connect plug of harness
end to vehicle frame.
Check if indicator lights.
Key switch: ON

NO

Key switch: ON

NO

YES

Although air filter is

not clogged, indicator lights.

Disconnect plug of air

filter restriction switch.
Check if indicator goes
out.

Disassemble and
visually inspect.
Verify that air filter
is not moist.

Key switch: ON

YES

NO

Disconnect connector 1-A in

monitor unit.
Check if indicator
goes out.
Key switch: ON

T5-7-28

NO

Disconnect connector
1-A in monitor unit.
Check for continuity
between terminal #9 of
harness end connector
and air filter restriction
switch.

TROUBLESHOOTING / Troubleshooting C

Air Filter Restriction Switch Operational Resistance:

6.20.6 kPa (63558 mmH2O)

Faulty air filter restriction

switch.

YES

Faulty monitor unit.

NO

Open circuit in harness

between monitor unit and
air filter restriction switch.

Connector (Harness end of connector viewed from the

open end side)

Faulty monitor unit, or

burnt indicator light.

Monitor Unit
Connector 1-A

#9

Faulty air filter restriction

switch.

Shorted circuit in harness

between monitor unit and
air filter restriction switch.

Faulty monitor unit.

T5-7-29

T183-05-04-013

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
Although the fault code is not displayed in ECM
and if the trouble occurs, conduct this remedy.
NOTE: After the engine stops in 1 to 2 minutes,
pressure may remain inside. When the engine re-starts under this condition, the indicator may not light.

Disconnect connector
A in ECM.
Connect terminal #17
of harness end conYES nector to vehicle frame.
Check if indicator
lights.
Indicator does not
light although engine oil pressure is
low.

Key switch: ON

Check if indicator
lights when key
switch is turned to
ON position.

YES

Connect the disconnected

connector.
Connect terminal #8 of connector 1-A in monitor unit to
NO vehicle frame.
Check if indicator lights.
Key switch: ON
Without disconnecting connector, connect connector to
vehicle frame by using a clip
from the rear of connector.

Key switch: ON
Engine: Stopped

NO

YES

Indicator does not

go out after engine
is started.
Check oil filter for
clogging.

Disconnect connector A in ECM.

Check if indicator
goes out.
Key switch: ON
Engine: Stopped

YES

NO

Disconnect connector 1-A in monitor unit.

Check if indicator
goes out.
NO

T5-7-30

TROUBLESHOOTING / Troubleshooting C

Connector (Harness end of connector viewed from the

open end side)

Faulty ECM.

YES

Monitor Unit
Connector 1-A

Open circuit in harness between monitor unit and ECM.

Faulty monitor unit.

NO
#8

T183-05-04-013

ECM
Connector A

Faulty monitor unit, or burnt

indicator light.

Faulty oil system of ECM and

engine, or clogged oil filter.

Shorted circuit in harness

between monitor unit and
ECM.

Faulty monitor unit.

T5-7-31

#17

T1GR-05-04-002

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICATOR
Check the wiring connections first.

YES
Disconnect connector
of overheat switch.
Connect terminal of
YES
harness end to vehicle
frame.
Check if indicator
lights.
Indicator does not
light although engine
overheats.

Key switch: ON

Check if indicator
lights when key
switch is turned to
ON position.

NO

Key switch: ON
Without disconnecting
connector, connect
connector to vehicle
frame by using a clip
from the rear of connector.

Key switch: ON

NO

YES

Indicator lights although coolant

temperature is low.

Disconnect terminal of overheat

switch.
Check if indicator
goes out.
Key switch: ON
Engine: Stopped

YES

NO

Connect the disconnected connector.

Connect terminal #7 of
connector 1-A in monitor
unit to vehicle frame.
Check if indicator lights.

Disconnect connector 1-A in monitor

unit.
Check if indicator
goes out.
Key switch: ON

T5-7-32

NO

TROUBLESHOOTING / Troubleshooting C

Overheat Switch
Coolant Temperature
Operation
Lower than 1073 C
OFF
(2256F)
1073 C (2256 F) or
ON
higher

Faulty overheat switch.

YES

Open circuit in harness

between monitor unit and
overheat switch.
Faulty monitor unit.

NO

Faulty monitor unit or

burnt indicator light.

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 1-A

Faulty overheat switch.

#7

Shorted circuit in harness

between monitor unit and
overheat switch.

Faulty monitor unit.

T5-7-33

T183-05-04-013

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE WARNING
INDICATOR
Although the fault code is not displayed in ECM and if
the trouble occurs, conduct this remedy.

Although engine is
abnormal, indicator
does not light.

Although engine is
not abnormal, indicator lights.

When key switch is

turned to ON position, check if indicator lights.

Disconnect connector A in ECM.

Connect terminal
YES #6 of harness end
connector to vehicle frame.
Check if indicator
lights.

YES

NO

Faulty ECM.
Disconnect
connector 2-B
in monitor unit.
Connect terminal #21 of
monitor end to
vehicle frame.
Check if indicator lights.

YES

Open circuit in
harness between
ECM and monitor
unit.
Faulty monitor unit.

NO

NO

Faulty monitor
unit, or burnt indicator light.

YES

Faulty ECM.

Disconnect connector in ECM.

Check if indicator
goes out.

YES

Key switch: ON
Engine: Stopped
NO

Disconnect connector
2-B in monitor unit.
Check if indicator goes
out.

Shorted circuit in
harness between
ECM and monitor
unit.

Faulty monitor unit.

NO

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 2-B

ECM
Connector A
#6

#21
T1GR-05-04-002
T4GB-05-05-002

T5-7-34

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF STOP INDICATOR
When the following troubles occur, the stop indicator
lights in order to announce the trouble to the operator, stop the machine and repair the machine.
Although the machine is repaired and if the stop indicator does not go out, other indicator on monitor
must light. Refer to the pages corresponding to the
indicator in this group or conduct the remedy according to Troubleshooting A.
Although there is no trouble and if the stop indicator
does not go out, the logic circuit in monitor unit may
be faulty.
(When the abnormal value is detected, the stop indicator lights;)
Low engine oil pressure
Overheat of the engine (high temperature of engine coolant)
Low level of service brake oil (low level of hydraulic oil tank)
Low service oil pressure
High temperature of transmission oil
Low steering oil pressure
High temperature of hydraulic oil

T5-7-35

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF SERVICE INDICATOR
When the following troubles occur, the service indicator lights in order to announce the trouble to the
operator, stop the machine and maintain the machine.
Although the machine is maintained and if the service indicator does not go out, other indicator on
monitor must light. Refer to the pages corresponding to the indicator in this group or conduct the
remedy according to Troubleshooting A.
Although there is no trouble and if the service indicator does not go out, the logic circuit in monitor unit
may be faulty.
(When the abnormal value is detected, the service indicator lights;)
Faulty generation of the alternator
Clogged air cleaner
Emergency steering operation
Lighting the engine warning indicator
Lighting the transmission warning indicator
Lighting the maintenance indicator
High temperature of axle oil

T5-7-36

TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-7-37

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PARKING BRAKE INDICATOR
Although the fault code is not displayed in MC and
if the trouble occurs, conduct this remedy.

YES

Disconnect connector B
in MC. Check if indicator
goes out.

Although brake switch is

not turned to parking position, indicator lights.

YES
Disconnect connector
1-A in monitor unit.
NO Check if indicator goes
out.
NO

YES

When key switch is

turned to ON position,
check if indicator lights.

Although brake switch is

in parking position, indicator does not light.

Disconnect connector B
in MC.
YES Connect harness end
connector to vehicle
frame.
Check if indicator lights.
Key switch: ON
NO

Key switch: ON
Engine: Stopped

Connector (Harness end of connector viewed from the

open end side)
NO
Monitor Unit
Connector 1-A

MC
Connector

T183-05-04-013

#25

#17
T183-05-04-021

T5-7-38

TROUBLESHOOTING / Troubleshooting C

Faulty MC.

Shorted circuit in harness

between monitor unit and
MC.

Faulty monitor unit.

Faulty MC.

Connect the disconnected connector.

Connect terminal #17 of
connector 1-A in monitor
unit to vehicle frame.
Check if indicator lights.
Key switch: ON
Without disconnecting connector, connect to vehicle
frame by using a clip from
the rear of connector.

YES

Open circuit in harness between monitor unit and MC.

Faulty monitor unit.

NO

Faulty monitor unit, or burnt

indicator light.

T5-7-39

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF CLEARANCE LIGHT
INDICATOR
If the light is OFF and the clearance light and indicator light, the light switch may be faulty or the
harness between light switch and clearance light
or monitor unit may be shorted.
Check the wiring connections first.

YES
Indicator does not light.

Check if clearance light

lights.

Light switchON

Disconnect connector
1-B in monitor unit.
Check if voltage at terminal #21 of harness
end connector is 24 V.

To A

Faulty light switch.

NO

YES

Burnt indicator light.

NO

Open circuit in harness between light switch and monitor

unit.

Connector (Harness end of connector viewed from the

open end side)
Monitor Unit
Connector 1-B

#21

T4GB-05-05-002

T5-7-40

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE LOW OIL
PRESSURE INDICATOR
When this trouble occurs, the fault code corresponding to the service brake pressure switch in
monitor unit must be displayed. Refer to Troubleshooting A and conduct the remedy for this
trouble.
Although the fault cold is not displayed and if the
trouble occurs, the monitor unit may be faulty.
Service Brake Pressure Switch
Pressure
Voltage
Operation
10 Mpa (82 kgf/cm2)
1.32 V or higher
OFF
or higher
Less than 8 Mpa
Less than 1.15 V
ON
(102 kgf/cm2)

T5-7-41

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE LOW OIL
LEVEL INDICATOR
Check the wiring connections first.

YES
Disconnect plug of
YES hydraulic oil level
switch. Check if indicator lights.
Although hydraulic
oil is low, indicator
does not light.

Key switch: ON

When key switch is

turned to ON position, check if indicator lights.

NO

Key switch: ON
NO

YES

Although hydraulic
oil is enough, indicator lights.

Disconnect connector of
hydraulic oil level switch.
When terminal of harness end is shorted,
check if indicator goes
out.
Key switch: ON

YES

NO

Insert a clip into rear of

terminal #13 of connector 1-A in monitor
unit and connect to
vehicle frame.
Check if indicator goes
out.
Key switch: ON

T5-7-42

NO

Disconnect connector
1-A in monitor unit.
Check if indicator
lights.

TROUBLESHOOTING / Troubleshooting C

Faulty hydraulic oil level

switch.

YES

Shorted circuit in harness

between monitor unit and
hydraulic oil level switch.

Faulty monitor unit.

NO

Faulty monitor unit, or

burnt indicator light.

Faulty hydraulic oil level

switch.

Connector (Harness end of connector viewed from the

open end side)

Open circuit in harness

between monitor unit and
hydraulic oil level switch.

Monitor Unit
Connector 1-A

Faulty monitor unit.

T183-05-04-013

#13

T5-7-43

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION
OF
EMERGENCY
STEERING INDICATOR (Optional)
After checking if the fault code is not displayed on
Troubleshooting by Dr. ZX, conduct this remedy.

Although emergency steering

check switch is
pushed, emergency
steering pump unit
is not operated.

Disconnect connector of check switch.

Check for continuity
between terminals
#2 and #4 of check
switch end connector.

Connect connector of
check switch.
Disconnect connector
1-A in monitor unit.
YES Connect terminal #14 of
harness end connector
to vehicle frame.
When check switch is
turned ON, check for
continuity.

YES

NO

NO

Faulty alternator system.

Refer to remedy for Malfunction of Alternator Indicator in this group.

YES

After checking monitor

unit light, check if alternator indicator
lights.
Engine: Running
To A

NO

Faulty emergency steering check switch, or

shorted circuit in harness
between check switch and
monitor unit.

YES

When key switch is

turned ON, emergency steering
pump unit is running
and does not stop.

Open circuit in harness

between emergency
steering check switch and
monitor unit.

Faulty emergency steering check switch.

Key switch: ON

Although engine
starts, inspection of
emergency steering
pump unit is not
automatically operated.

To A

Disconnect connector
1-A in monitor unit.
Check if pump unit
stops.

YES

Key switch: ON
NO

Disconnect connector
2-A in monitor unit.
Check if pump unit
stops.
NO

T5-7-44

Shorted circuit in harness

between emergency
steering relay and monitor
unit, or faulty monitor unit.

To C

TROUBLESHOOTING / Troubleshooting C
YES

YES

Replace emergency
steering relay with
horn relay.
Check if horn
sounds.

Disconnect connector
2-A in monitor unit.
Connect terminal #11 of
harness end to vehicle
frame.
Check if pump unit is
operated.

Key switch: ON

Faulty monitor unit.

With connecting terminal

#11 of harness end
connector 2-A in monitor
unit to vehicle frame,
disconnect emergency
NO steering relay.
Connect terminal #2 of
harness end to vehicle
frame.
Check for continuity.

YES

NO

Faulty connector of
emergency steering
relay.

YES

Terminals #3 and #5 of
YES emergency steering relay are shorted. Check if
pump unit is operated.

Open circuit in harness between

emergency steering
relay and pump
unit, or faulty pump
unit.

NO

Blown fuse, or open

circuit in harness
between battery
relay and emergency steering relay.

Key switch: ON
NO

YES

Faulty emergency
steering relay.

Replace emergency
steering relay with
horn relay.
Check if pump unit
stops.
Key switch: ON

Shorted circuit in
wiring and power
circuit between
emergency steering
relay and emergency steering
pump unit, or faulty
emergency steering
pump unit.

NO

Connector (Harness end of connector viewed from the open end side)
Emergency Steering Check
Switch Connector
#4

Open circuit in harness between

monitor unit and
emergency steering
relay.
Faulty emergency
steering relay.

NO

Disconnect emergency steering relay.

Check if voltage at
terminals #1 and #3
of harness end is
about 24 V respectively.

Monitor Unit
Connector 1-A
Connector 2-A

Emergency Steering
Relay Connector
#2

#2

#1

#11
4

10

#5
#2

#14

T5-7-45

T183-05-04-013

#3

T183-05-04-003

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LOW STEERING OIL
PRESSURE INDICATOR (Optional)
When this trouble occurs, the fault code corresponding to the emergency steering pressure
switch in monitor unit must be displayed. Refer to
Troubleshooting A and conduct the remedy.
Although the fault cold is not displayed and if the
trouble occurs, the monitor unit may be faulty.

T5-7-46

TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-7-47

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF DISCHARGE WARNING INDICATOR
Check the wiring connections first.
NOTE: *Terminals L in the alternator are water-resistant type connectors so that it is not
practical to measure voltage at these terminals. Measure voltage at terminal R in
safety relay. Check for continuity between
terminal R in safety relay and terminal L in
the alternator first.

Between 12 V
and 35 V
Between 12 Check voltage at terV and 35 V minal #2 of connector
2-A in monitor unit.
When engine starts,
alternator indicator
does not go out.

Measure voltage at
terminal L in *alternator.

Engine: Running

Less than 12 V or
35 V or higher

Engine: Running
Less than 12 V or
35 V or higher

Between 12 V
and 35 V
YES

Check voltage at
terminal L in
*alternator.
Engine: Running

YES Check if engine starts.

Although charging
is low, alternator
indicator does not
light.

When key switch is

turn to ON position,
check if indicator
lights.

NO

Key switch: ON
NO

T5-7-48

Less than 12 V or
35 V or higher

TROUBLESHOOTING / Troubleshooting C
Connector (Harness end of connector viewed from the
open end side)
Monitor Unit
Connector 2-A

Safety Relay
Connector A

#2
E
S

T183-05-04-013

Faulty monitor unit.

Faulty harness between terminal L in alternator and

monitor unit.

Faulty regulator, or faulty alternator.

Check voltage at
terminal #2 of
connector 2-A in
monitor unit.

Between 12 V
and 35 V

Less than 12 V or
Engine: Running 35 V or higher

Faulty monitor unit.

Faulty harness between terminal L in alternator and
monitor unit.
Faulty alternator.

Refer to Engine System

Troubleshooting in Troubleshooting B.
Faulty monitor unit, or faulty
alternator indicator.

T5-7-49

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF MONITOR DISPLAY
The data on monitor display is not displayed by
the signal directly input from the sensors except
one part. The signal data which inputs to other
controllers from the sensors once is input to the
monitor unit by using the CAN communication
and is proceeded in the logic circuit of monitor unit.
Therefore, check if the CAN communication is
normal first and check if the sensors corresponding to the trouble are normal.
Description
Data on liquid
crystal display

Data on data
display

Cause of Trouble

Neutral indicator
Forward/reverse indicator
Driving mode indicator
Hold indicator
Speedometer
Automatic mode indicator
Clutch cut-off indicator
Ride control indicator
Model
Displayed on service mode
when starting only
Clock (24 hours)
Fuel consumption amount
Average fuel consumption amount
Odometer
Displayed on service mode
when starting only
Engine speed
Displayed on service mode
when starting only
Hydraulic
oil Displayed on service mode
temperature
when starting only
Fault code
Displayed on service mode
when starting only
Transmission oil Displayed on service mode
temperature
when starting only
Other data
Displayed on normal mode
when starting only
Remainder time that hydraulic oil can be used
Remainder time that hydraulic oil filter can be
used
Remainder time that transmission oil can be
used
Remainder time that transmission oil filter can be
used
Remainder time that engine oil can be used
Remainder time that engine oil filter can be used
Remainder time that fuel filter can be used
Hour meter

Coolant temperature

Displayed on service mode

when starting only

T5-7-50

If the data of monitoring function can be displayed on

Dr. ZX, CAN communication between monitor unit
and other controllers is faulty. If the data cannot be
displayed on Dr. ZX, the sensor system detecting the
related signal is faulty. (As for the machine, some
trouble must occur. Refer to Troubleshooting A and
conduct the remedy.)
Refer to T5-7-51.
If the data of monitoring function can be displayed on
Dr. ZX, CAN communication between monitor unit
and other controllers is faulty. If the data cannot be
displayed on Dr. ZX, the sensor system detecting the
related signal is faulty. (As for the machine, some
trouble must occur. Refer to Troubleshooting A and
conduct the remedy.)

As for these troubles, the liquid crystal display in

monitor unit may be faulty or the logic circuit may be
faulty.

The alternator is faulty, the harness between terminal

L in the alternator and terminal #2 of connector 2-A in
monitor unit is faulty, or the clock circuit in monitor
unit may is faulty.
Refer to T5-7-52.

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF RIDE CONTROL INDICATOR
Check the wiring connections first.

YES
Disconnect connector
1-A in monitor unit.
YES Connect terminal #10 of
harness end to vehicle
frame.
Check for continuity.
When ride control
switch is turned ON,
indicator does not
light.

Ride control switch: ON

Check if ride control

is operated correctly.

NO
YES

NO

Disconnect connector of
ride control switch.
Connect terminal #7 of
harness end to vehicle
frame.
Check if indicator lights.
NO

Check if ride control is

operated.

YES

NO

Connector (Harness end of connector viewed from the

open end side)

Disconnect connector
1-A in monitor unit.
Check if indicator goes
out.
NO

Ride Control Switch Connector

10

Faulty harness between ride control

switch and monitor
unit.
Faulty ride control
switch.

Faulty harness between terminal #7 of

ride control switch
and monitor unit.

Faulty ride control

switch.

YES

When ride control

switch is turned
OFF, indicator does
not go out.

Faulty monitor unit.

Shorted circuit in
harness between
ride control switch
and monitor unit.

Faulty monitor unit.

Monitor Unit
Connector 1-A

10

#7
T183-05-04-013

T5-7-51

TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE COOLANT
TEMPERATURE DISPLAY
This trouble on coolant temperature operation and
data on monitor display is displayed according to
the signal from the same coolant temperature
sensors. Therefore, when this trouble occurs, the
coolant temperature operation must be faulty.
Refer to the remedy for Malfunction Coolant Temperature Operation in this group and remedy this
trouble first. Although the coolant temperature
operation is not faulty and if this trouble occurs,
the monitor unit is faulty.

T5-7-52

TROUBLESHOOTING / Electrical System Inspection

PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Remove 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 circuiting.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
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
L
Or

Color
Red
Blue
Orange

Code
W
G
Lg

Y
Br
Gr

Yellow
Brown
Gray

B
P
V

Color
White
Green
Light
green
Black
Pink
Violet

NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials O and Or both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Do not
confuse them with color coded wires.

T5-8-1

TROUBLESHOOTING / Electrical System Inspection

3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the
wire itself. Release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to Instructions for
Disconnecting Connector on page T5-8-3.)
2) The water-resistant connectors keep water
out. If water enters them, water will not
easily drain from them. When checking the
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors,
reconnect only after the connectors are
thoroughly dried.
3) Before connecting terminal connectors,
check that no terminals are bent or coming
off. In addition, as most connectors are
made of brass, check that no terminals are
rusting.
4) When connecting terminal connectors
provided with a lock, insert them together
until the lock clicks.
5) Pull the harness near the connector in order
to check if it is correctly connected.
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) 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.
3) When checking the connector by using a
tester, insert a tester probe from the harness
end of connector in order not to damage the
terminal inside connector.

T5-8-2

Right

Wrong

T107-07-06-001

Right
Rust
Wrong
(Deformation)
Wrong
(Separation)
T107-07-06-002

Wind a Piece of Wire

Tester Probe

Sharpen the end of the Wire

T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection

INSTRUCTIONS
CONNECTORS

FOR

DISCONNECTING
Pull and Separate Type

Push, Unlock and Separate Type

NOTE: Connectors will not be easily separated
even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
The lock is located on female side connector (harness end side).

T107-04-05-004

IMPORTANT: Before pulling and separating, release the lock of connector in the
solenoid valve by using a pair of
pincers.

T107-04-05-002

Raise Lock, Pull and Separate Type

T107-04-05-003

T4GB-05-06-003

T5-8-3

TROUBLESHOOTING / Electrical System Inspection

Unlock, Move the Lever and Pull Type
NOTE: When unlocking, release the lock by one
hand, slowly pull the lever by another hand,
and separate the connector.

T4GB-05-06-001

T4GB-05-06-002

Rotate the Lock and Pull Type

NOTE: Pinch the harness end connector, rotate
the projection part counterclockwise while
pushing, and separate the connector.

T4GB-05-06-007

T5-8-4

TROUBLESHOOTING / Electrical System Inspection

(Blank)

T5-8-5

TROUBLESHOOTING / Electrical System Inspection

FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a tester in
order to correctly inspect fuse continuity. Inspect the
fuse by following the instructions described below.
1. Turn Key Switch ON
When the key switch is turned ON, current from
terminal M of key switch activates the battery relay so that electric power is supplied to all circuits.
(Refer to the circuit diagram.)
2. Remove the fuse box cover. Set the tester voltage in order to meet the circuit specification to be
measured.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the
machine. Touch the terminals located away from
the center of the fuse box with the positive probe
of tester one at a time. When normal continuity of
a fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
NOTE: All terminals located along the lengthwise
centerline of the fuse box are connected to
the power source, while terminals located
away from the center of the fuse box are
connected to loads (accessories). Therefore, test all fuses in the same method except for the glow plug relay circuit fuse.
Check the glow plug relay circuit fuse with
the key switch turned ON according to the
procedure in step 3.

T5-8-6

TROUBLESHOOTING / Electrical System Inspection

(Fuse Box A)

(Fuse Box B)

10

20

30

40

19

29

39

18

17

16

15

4
3

14
13

12

11

28
27
26
25
24
23
22
21

38
37
36
35
34
33
32
31

M178-07-034

Fuse NO. Capacity

Connected to
1
10 A
Option (Seta Heater)
2
10 A
12V Converter
3
Option 1
4
15 A
Wiper (Front)
5
5A
Head Light (Right)
6
10 A
Cigar Lighter
7
10 A
TCU Power Source
8
10 A
Controller Power Source
9
5A
Parking Brake Relay
10
5A
Neutral Relay
11
5A
Reverse Light / Buzzer
12
10 A
Brake Lamp Relay
13
20 A
Working Light (Front)
14
10 A
Horn
15
5A
Head Light (Left)
16
15 A
Option (Side Wiper 1)
17
15 A
Option (Side Wiper 2)
18
15 A
Option (Window Heater (Front))
19
15 A
Option (Window Heater (Side))
20
10 A
Option (Window Heater (Rear))
21
10A
Option (Fog Lamp)
22
20A
Working Light (Rear)
23
5A
Air Conditioner 1
24
20A
Air Conditioner 2
25
10A
Wiper (Rear)
26
10A
Emergency Steering Pump Unit
27
20A
Ignition
28
15A
Flusher
29
5A
Load Damp Relay
30
5A
Radio
31
10A
Option (Beacon Light)
32
10A
High Beam
33
10A
Controller (Key: ON)
34
10A
TCU (Key: ON)
35
30A
ECM (Key: ON)
36
5A
Clearance Lamp 1
37
5A
Clearance Lamp 2
38
10A
MC (Key: ON)
39
10A
Option (Control Unit Power Source)
40
5A
Monitor Unit

T5-8-7

M178-07-034

TROUBLESHOOTING / Electrical System Inspection

FUSIBLE LINK INSPECTION
Inspection
1. Open either battery box cover from left and right
of the machine. Remove the negative cable from
the battery.
2. Open the engine cover on left side of the machine with the front attachment side forward.
3. Remove bolts (M10) (2 used) from the L type
cover. Remove the cover. There are fusible links
(65A) (2 used).
4. Open the black box. There are fusible links (50A)
(2 used) (100A in total).
5. Visually inspect the fusible link.
6. Install the negative cable to the battery.
T4GB-05-06-004

Replacement
1. Check if the negative cable is removed from either battery box from left and right of the machine.
2. Open the engine cover on left side of the machine with the front attachment side forward.
3. Remove bolts (M10) (2 used) from the L type
cover. Remove the cover. There are fusible links
(65A) (2 used).
4. Open the black box. There are fusible links (50A)
(2 used) (100A in total).
5. Pull out and replace the fusible link.
6. Install the negative cable to the battery.
T4GB-05-06-008

Fusible Link (100A)

T5-8-8

Fusible Link (65A)

TROUBLESHOOTING / Electrical System Inspection

BATTERY VOLTAGE CHECK
1. Turn the key switch OFF.
2. Open the battery box cover on left side of the
machine with the front attachment side forward.
3. Check voltage between the battery positive
terminal and the vehicle frame (ground).

Ground to vehicle
frame.

Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace
the battery.
4. Start the engine. Check voltage between the
battery positive terminal and the vehicle frame
(ground).
Normal Voltage: 26 to 28 V
T4GB-05-06-004

NOTE: If voltage is abnormal, check the charging

system.

T5-8-9

Battery Positive
Terminal

TROUBLESHOOTING / Electrical System Inspection

ALTERNATOR CHECK
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator may be faulty.
How to Check Alternator
1. Turn the key switch to the ON position. Confirm
that the alternator indicator comes on.
2. Measure voltage between terminals B and E of
the alternator.
If the measured voltage is around 24 V, the alternator circuit can be considered normal.
If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors
of alternator circuit might be cause of the malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator or the ground line to alternator
might be open circuit.
3. Next, start the engine and measure voltage generated while as the alternator rotates.
As described above, measure voltage between
terminals B and E on the end of alternator.
If voltage is around 28 V, the alternator is operating normally.
If the measured voltage is equal to battery voltage (around 24V), there is some trouble with the
alternator or the regulator.

T4GB-05-06-006

T5-8-10

TROUBLESHOOTING / Electrical System Inspection

(Blank)

T5-8-11

TROUBLESHOOTING / Electrical System Inspection

CONTINUITY CHECK
Harness

Single-line continuity check

Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
NOTE: When the one end connector is far apart
from the other, connect one end of
connector (A) to the machine chassis using
a clip. Then, check continuity of the
harness through the vehicle frame as
illustrated.

Connect to
the vehicle
frame.

Connect to
the vehicle
frame.

If the ohm-meter reading is: 0 = Continuity

= Discontinuity

Single-line short-circuit check

Disconnect both end connectors of the harness and
check continuity between one end connector of the
harness and the vehicle frame:
If the ohm-meter reading is:
0 = Short circuit is present.
= No short circuit is present.

Short-circuit
between the
harness and
the vehicle
frame.

T107-07-05-003

T5-8-12

TROUBLESHOOTING / Electrical System Inspection

Multi-line continuity check
Disconnect both end connectors of the harness,
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
If the ohm-meter reading is , 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).

First short-circuit

A
B
C

a
b
c

Second short-circuit

NOTE: 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).

T107-07-05-004

If the ohm-meter reading is:

0 = Line (B) - (b) has discontinuity.
= Line (A) - (a) has discontinuity.
Multi-line short-circuit check
Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C).
If the ohm-meter reading is:
0 = Short-circuit exists between the lines.
= No short-circuit exists between the lines.
Short-circuit between harnesses.
A
B
C

a
b
c

T107-07-05-005

T5-8-13

TROUBLESHOOTING / Electrical System Inspection

VOLTAGE
MENT

AND

CURRENT

MEASURE-

Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge
if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the location to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine
Power Source
Circuit

Key Switch

Location to be Measured

Specification

OFF
OFF
OFF
OFF
OFF
OFF

Between (2) and (1): One Battery

Between (3) and (2): One Battery
Between (3) and (1): Two Batteries
Between (4) and Ground: Battery Power
Between (5) and Ground: Fusible Link
Between (1) and Ground: Backup Current*

10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
6 mA

START
START

Between (6) and Ground: Key Switch

Between (7) and Ground: Glow Plug

20 to 25 V
20 to 25 V

START
START
START
START
START
START

Between (8) and Ground: Key Switch

Between (9) and Ground: Battery Relay (Coil)
Between (10) and Ground: Battery Relay (Switch)
Between (11) and Ground: Starter (B)
Between (12) and Ground: Starter (S)
Between (13) and Ground: Starter Relay 2 (S)

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

Fast Speed

ON

26 to 30 V

Fast Speed

ON

Fast Speed
Fast Speed

ON
ON

Between (14) and Ground: Alternator (B) / Generating

Voltage
Between (10) and Ground: Battery Relay / Generating
Voltage
Between (15) and Ground: Generating Voltage
Between (16) and Ground: Monitor

ONOFF
ONOFF
ONOFF
ONOFF

Between (14) and Ground: Alternator (B)

Between (15) and Ground: Starter Relay 1 (R)
Between (17) and Ground: Load Damp Relay
Between (10) and Ground: Battery Relay

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

ON

Between (18) and Ground: Radio

20 to 25 V

Stopped
Stopped
Stopped
Stopped
Stopped
Stopped

Preheat Circuit
Started
Started

Starting Circuit
Started
Started
Started
Started
Started
Started

Charging Circuit
26 to 30 V
13 to 30 V
13 to 30 V

Surge Voltage
Prevention Circuit
Idle Speed
Idle Speed
Idle Speed
Idle Speed

Accessory Circuit
Stopped

NOTE: *Measure after disconnecting the negative

cable from the battery.

T5-8-14

TROUBLESHOOTING / Electrical System Inspection

Head Light Switch

Key Switch

8
Fuse Box A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

48

MC
592

TCU

Load Damp
Relay

GPS

464

Neutral Relay

594
76

ICX
1 3 54 2
1 3 54 2

33

Monitor
Unit

17

67

119
233

16

Radio

Fuse Box B

60
56
283
284
233
24

Glow Relay

ECM

119
117
114
120
118
115

Glow Plug
Fuel
Injection
Solenoid
Valve

18

Coolant
Temperature
Sensor

3
Battery Relay

13

Starter Relay 1

21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

Battery

Fusible Link

Fuse (100A)

10

15
11
14

Starter Motor

12
T4GB-05-06-009

T5-8-15

TROUBLESHOOTING / Electrical System Inspection

5-V Circuit

Voltage between terminal #1 and the vehicle

frame
With the key switch turned OFF, disconnect the
connector.
Measure voltage between the terminal of 5V power
source on machine harness end connector and the
vehicle frame (ground).

Signal or
Ground

Power
Power
Source
Source
1

Two Polarities

Key switch: ON
Tester black probe (negative):

Vehicle frame (ground)

Tester red probe (positive):

Terminal of 5V power source

T107-07-05-006

Evaluation:
If the measured voltage is within 50.5 V, the circuit
up to terminal of 5V power source is normal.
IMPORTANT: Altough terminal #1 is the teminal of
power source on the illustlation, all
the terminals are not terminals of
power source. Before measurement,
check the electrical circuit diagram
for the connector to be measured.

Voltage between terminal #1 and the ground

terminal
With the key switch turned OFF, disconnect the
sensor connector.
Measure voltage between the terminal of 5V power
source on machine harness end connector and the
ground terminal.

Power
Source Signal Ground
1
2
3

Three Polarities

Power
Source

Two Polarities

T107-07-05-007

Signal or
Ground
2

Key switch: ON
Tester black probe:
Ground terminal
(terminal #2 or #3)
Tester red probe:
Terminal of 5V power source
Evaluation:
If the measured voltage is within 50.5 V, the
circuits up to terminal of 5V power source and
ground terminal are normal.

Three Polarities

IMPORTANT: Altough terminal #1 is the teminal of

power source, terminal #2 is the
signal and #3 is the ground terminal
respectively on the illustlation, all
the connectors are not arranged
similarly.
Before
measurement,
check the electrical circuit diagram
for the connector to be measured.

T5-8-16

Power
Source
1

T107-07-05-008

Signal
2

Ground
3

T107-07-05-009

TROUBLESHOOTING / Electrical System Inspection

CHECK BY FALSE SIGNAL

Two Polarities

Turn the key switch OFF and disconnect the sensor

connector. Turn the key switch ON. Connect terminal
of power source and signal terminal on machine harness end connector. (Power voltage is used as a false
signal.)
Check this state by using the monitor function of Dr.
ZX. If the displayed value is the maximum value, the
circuits up to MC and machine harness end connector
are normal. If ON is displayed, the pressure switch
circuits are normal.
IMPORTANT: Altough terminal #1 is the teminal of
power source, terminal #2 is the
signal and #3 is the ground terminal
respectively on the illustlation, all
the connectors are not arranged
similarly.
Before
measurement,
check the electrical circuit diagram
for the connector to be measured.

Power
Source

Signal

Connect

T107-07-05-010

Three Polarities

IMPORTANT: Do not connect terminal of power

source and signal terminal to
ground terminal or to the vehicle
frame (ground) when checking a
three-polarity connector.

Power
Source Signal Ground
1

Connect

T107-07-05-011

NOTE: Some kinds of sensors can be monitored

by using the service mode of monitor.
(Refer to the TROUBLESHOOTING / Diagnosing Procedure group.)

T5-8-17

TROUBLESHOOTING / Electrical System Inspection

(Blank)

T5-8-18

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Hitachi Construction Machinery Co. Ltd

Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

Hitachi Ref. No.

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY:

MODEL:
PUBLICATION NO.:

YOUR NAME:
DATE:
FAX:

(Located at the right top corner in the cover page)

PAGE NO.:
(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

THE ATTACHED DIAGRAM LIST

(The following diagrams are attached to this manual.)
ZW220/250 ELECTRIC CIRCUIT DIAGRAM 1 (EU STANDARD)
ZW220/250 ELECTRIC CIRCUIT DIAGRAM 2 (EU STANDARD)
ZW220/250 LIFT ARM PROXIMITY SWITCH HARNESS (EU STANDARD, GENERAL STANDARD)
ZW310 LIFT ARM PROXIMITY SWITCH HARNESS
ZW220/250 LIFT ARM ANGLE SENSOR HARNESS (EU STANDARD, GENERAL STANDARD) (OPTIONAL)
ZW310 LIFT ARM ANGLE SENSOR HARNESS (OPTIONAL)
ZW220/250 FRONT LIGHT HARNESS (EU STANDARD, GENERAL STANDARD)
ZW310 FRONT LIGHT HARNESS
ZW220/250 FRONT HARNESS (EU STANDARD, GENERAL STANDARD)
ZW310 FRONT HARNESS
ZW220/250 CENTER HARNESS (EU STANDARD, GENERAL STANDARD)
ZW310 CENTER HARNESS
ZW220/250 FRONT CONSOLE HARNESS 1 (EU STANDARD, GENERAL STANDARD)
ZW310 FRONT CONSOLE HARNESS 1
ZW220/250 FRONT CONSOLE HARNESS 2 (EU STANDARD, GENERAL STANDARD)
ZW310 FRONT CONSOLE HARNESS 2
ZW220/250 SIDE CONSOLE HARNESS 1 (EU STANDARD, GENERAL STANDARD)
ZW310 SIDE CONSOLE HARNESS 1
ZW220/250 SIDE CONSOLE HARNESS 2 (EU STANDARD, GENERAL STANDARD) (FOR STANDARD TWO
LEVER PILOT VALVE)
ZW310 SIDE CONSOLE HARNESS 2 (FOR STANDARD TWO LEVER PILOT VALVE)
ZW220/250 SIDE CONSOLE HARNESS 3 (EU STANDARD, GENERAL STANDARD) (FOR OPTIONAL JOY
STICK LEVER PILOT VALVE)
ZW310 SIDE CONSOLE HARNESS 3 (FOR OPTIONAL JOY STICK LEVER PILOT VALVE)
ZW220/250 REAR CONSOLE HARNESS (EU STANDARD)
ZW220/250 TRANSMISSION HARNESS (EU STANDARD)
ZW220/250 REAR FRAME HARNESS (EU STANDARD, GENERAL STANDARD)
ZW220/250 ENGINE HARNESS (EU STANDARD, GENERAL STANDARD)
ZW220 HYDRAULIC CIRCUIT DIAGRAM (EU STANDARD)
ZW250 HYDRAULIC CIRCUIT DIAGRAM (EU STANDARD)