Hitachi ZW 180 Technical Manual
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Hitachi ZW 180 Technical Manual

Hitachi ZW 180 Technical Manual

Wheel loader
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  • Page 3: Additional References

    • Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us- product information and service procedures. age.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162 ADDITIONAL REFERENCES •...

  • Page 4: Units Used

    INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and • CAUTION: signal words are used to alert the reader to the Indicated potentially hazardous situation which could, potential for personal injury of machine damage. if not avoided, result in personal injury or death.

  • Page 5: Recognize Safety Information

    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 oper- ating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...

  • Page 6: Follow Safety Instructions

    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...

  • Page 7: Wear Protective Clothing

    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. SA-438 Be sure to wear the correct equipment and clothing for the job.
  • Page 8 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 operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

  • Page 9: Adjust The Operator's Seat

    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.
  • Page 10 SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Addi- tionally the operator may be crushed by the over- turning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly ex- amine webbing, buckle and attaching hardware.

  • Page 11: Jump Starting

    SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in seri- ous injury or death. • Start the engine only when seated in the opera- tor's seat. • NEVER start the engine while standing on the track or on ground.
  • Page 12 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 condi- tions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
  • Page 13 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 poten- tial hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure...

  • Page 14: Keep Riders Off Machine

    SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as be- ing struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
  • Page 15 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 in- dicated 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.
  • Page 16 SAFETY AVOID INJURY FROM ROLLAWAY ACCI- DENTS • 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 ma- chine. • Do not park the machine on a grade. •...
  • Page 17 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. •...

  • Page 18: Avoid Tipping

    SAFETY AVOID POSITIONING BUCKET OVER ANYONE • Never allow the bucket to pass over co-workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket may cause serious personal accidents and/or damage to the machine. •...
  • Page 19 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 •...

  • Page 20: Precautions For Operation

    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...
  • Page 21 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.

  • Page 22: Store Attachments Safely

    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 •...

  • Page 23: Handle Fluids Safely-Avoid Fires

    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, possi- bly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks.

  • Page 24: Practice Safe Maintenance

    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.

  • Page 25: Support Machine Properly

    SAFETY • Sufficiently illuminate the work site. Use a main- tenance 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, anti- freeze fluid, or window washer fluid may catch fire.
  • Page 26 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.

  • Page 27: Prevent Burns

    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. •...

  • Page 28: Avoid High-Pressure Fluids

    SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing se- rious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. •...

  • Page 29: Prevent Fires

    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.
  • Page 30 SAFETY EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the fol- lowing 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. •...

  • Page 31: Avoid Heating Near Pressurized Fluid Lines

    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.

  • Page 32: Prevent Battery Explosions

    Keep bystanders out of the work site during op- SA-029 eration. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.

  • Page 33: Handle Chemical Products Safely

    DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the en- vironment 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.
  • Page 34 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...
  • Page 35 Group 8 Ride Control Valve reserved to make changes at any time Group 9 Drive Unit without notice. Group 10 Axle Group 11 Brake Valve Group 12 Others COPYRIGHT (C) 2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...

  • Page 36: Workshop Manual

    WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 BASE MACHINE (TRAVEL Group 1 Precautions for Disassembling SYSTEM) and Assembling Group 1 Tire Group 2 Tightening Torque Group 2 Drive Unit Group 3 Painting Group 3 Axle Group 4 Bleeding Air from Hydraulic Oil Group 4 Propeller Shaft Tank Group 5 Brake Valve...
  • Page 37 SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 5 Component Test Operational Performance Tests ....T4-1-1 Primary Pilot Pressure ........T4-5-1 Preparation for Performance Tests ....T4-1-2 Secondary Pilot Pressure ......T4-5-3 Solenoid Valve Set Pressure ......T4-5-4 Group 2 Standard Main Pump Delivery Pressure ......T4-5-6 Operational Performance Main Relief Pressure ........T4-5-8...
  • Page 38 (Blank) 4GDT-4-2...
  • Page 39 OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quan- The machine performance does not always deteriorate titatively check all system and functions on the ma- as the working hours increase. However, the machine chine. performance is normally considered to reduce in pro- portion to the increase of the operation hours.
  • Page 40 OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.
  • Page 41 OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL PERFORMANCE STANDARD TABLE The standard performance values are listed in the Acceletor Pedal : Full Stroke table below. Refer to the Group T4-3 or later for Driving Mode Switch : H Mode performance test procedures. Work Mode Switch : N Mode : 50±5 °C (122±9 °F) Hydraulic Oil Temperature...
  • Page 42 OPERATIONAL PERFORMANCE TEST / Standard Performance Reference PERFORMANCE TEST DESIGNATION Remarks Standard Page TRAVEL SPEED T4-4-1 km/h First Gear (Forward/Reverse) 8.0/8.0±0.8 Value indicated on Dr. ZX ↑ Second Gear (Forward/Reverse) 13.0/13.0±1.3 ↑ Third Gear (Forward/Reverse) 24.5/24.5±3.8 ↑ Fourth (Forward/Reverse) 38.0/38.0±3.8 SERVICE BRAKE CAPACITY 14.0 or less T4-4-2...
  • Page 43 OPERATIONAL PERFORMANCE TEST / Standard Reference PERFORMANCE TEST DESIGNATION Performance Standard Remarks Page CONTROL LEVER OPERATING FORCE T4-4-12 N (kgf, lbf) Lift Arm Raise (STD/MF) 11 (1.1, 2.5)/ 19 (1.9, 4.3) or less Lift Arm Raise Detent (STD/MF) 17 (1.7, 3.8)/ 30 (3.1, 6.8) or less Lift Arm Raise Detent Release (STD/MF) 40 (4.1, 9)/...

  • Page 44: Tire Inflation

    OPERATIONAL PERFORMANCE TEST / Standard Performance Reference PERFORMANCE TEST DESIGNATION Remarks Standard Page CONTROL LEVER STROKE T4-4-13 Lift Arm Raise Position (STD/MF) 34±5/63±10 Lift Arm Raise Detent Position (STD/MF) 54±5/80±10 Lift Arm Lower Position (STD/MF) 34±5/63±10 Lift Arm Lower Float Position (STD/MF) 54±5/80±10 Bucket Lever Tilt Position (STD/MF) 34±5/63±10...
  • Page 45 OPERATIONAL PERFORMANCE TEST / Standard Performance Reference PERFORMANCE TEST DESIGNATION Remarks Standard Page +1.0 PRIMARY PILOT PRESSURE T4-5-1 -0.5 +142 , 580 MPa (kgf/cm , psi) +0.5 SECONDARY PILOT PRESSURE T4-5-3 -0.3 , 538 MPa (kgf/cm , psi) SOLENOID VALVE SET PRESSURE T4-5-4 MPa (kgf/cm , psi)
  • Page 46 OPERATIONAL PERFORMANCE TEST / Standard (Blank) T4-2-6...
  • Page 47 OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q CURVE P-Q Control (Torque Control) (REFERENCE: Measured at Test Stand) • Rated Pump Speed: 2200 min (rpm) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F) L/min Flow Rate Delivery Pressure MPa (kgf/cm T4GB-04-02-001 Delivery Pressure Flow Rate...
  • Page 48 OPERATIONAL PERFORMANCE TEST / Standard P-Q Control by Pump Control Pilot Pressure Signal (REFERENCE: Measured at Test Stand) • Rated Pump Speed: 2200 min (rpm) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F) L/min Flow Rate MPa (kgf/cm Pump Control Pressure T4GD-04-02-001 Pi1−Pi2 Pump Control Pressure...
  • Page 49 OPERATIONAL PERFORMANCE TEST / Standard SENSOR ACTIVATING RANGE 1. Checking Method • Hydraulic Oil Temperature: 50 ± 5 °C (122±9 °F) • Unless specified: Engine Work Mode Speed Switch Fast Idle • Monitor each sensor by using Dr. ZX. 2. Sensor Activating Range Specification Item Operation...
  • Page 50 OPERATIONAL PERFORMANCE TEST / Standard (Blank) T4-2-10...

  • Page 51: Engine Speed

    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 unreli- able.
  • Page 52 OPERATIONAL PERFORMANCE TEST / Engine Test Clutch Cut Position Parking Brake Brake Pedal Control Lever (Bucket) Switch Switch Slow Idle Transporting position (with no load) No control lever operation Fast Idle Transporting position Fully depressing (with no load) No control lever operation Fast Idle Transporting position (when engine...
  • Page 53 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 after the engine stops.
  • Page 54 OPERATIONAL PERFORMANCE TEST / Engine Test (Blank) T4-3-4...

  • Page 55: Travel Speed

    OPERATIONAL PERFORMANCE TEST / Wheel Loader Test TRAVEL SPEED Summary: 6. Convert the measurement value into km/h. 1. The overall performance of the travel drive system Measurement value (seconds) = S (sec) (torque converter through transmission) is judged Converted value (hourly speed) = A (km/h) by measuring the time necessary for traveling 50 50 ×...
  • Page 56 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test SERVICE BRAKE FUNCTION CHECK Summary: Evaluation: 1. The overall performance of the service brake is Refer to Performance Standard Table in Group T4-2. judged. 2. The braking capability of the brake is an item of safety control.
  • Page 57 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test SERVICE BRAKE WEAR AMOUNT 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 inspection plug (1) of the axle. Loosen in- spection plug (1).
  • Page 58 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. Conduct the performance test correctly.
  • Page 59 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test (Blank) T4-4-5...
  • Page 60 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test BUCKET STOPPER AND BELL CRANK STOPPER CLEARANCE Summary: Wear and deformation conditions of the bucket stopper (dump end and crowd end) and the clear- ance between the bell crank stopper and the cross tube are measured.
  • Page 61 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test Evaluation: 1. Bucket Dump Stopper 2. Bucket Crowd Stopper 1-1. Cylinder Strokes (A, B) 2-1. Cylinder Strokes (D, E) Bucket Cylinder Lift Arm Cylinder Bucket Cylinder Lift Arm Cylinder Model Model ZW180 285 mm (11.2”) 990 mm (3’...
  • Page 62 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test HYDRAULIC CYLINDER CYCLE TIME Lift Arm Cylinder: Summary: (for Lifting) 1. The overall performance of the cylinders drive system (between main pump and each cylinder) is judged by measuring the operating time of the cylinders for the lift arm, bucket and steeering.
  • Page 63 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test Measurement: 1. Select the pedal, switches and FNR lever as fol- lows. Parking Brake Work Mode Accelerator Pedal FNR Lever Switch Switch Lift Arm Full Stroke (for Lifting) (Engine: Fast Idle) Lift Arm Neutral (for Lowering) (Engine: Fast Idle)
  • Page 64 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.
  • Page 65 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 the ground.
  • Page 66 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 forces are measured. 2. Maximum operating force of the levers, pedals, and steering wheel are measured. 3.
  • Page 67 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 levers is performed at the tip of the grip. Measurement of each pedals is performed at the top of the pedal.
  • Page 68 OPERATIONAL PERFORMANCE TEST / Wheel Loader Test (Blank) T4-4-14...
  • Page 69 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 brake piping, and replacing hydraulic oil.
  • Page 70 OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve set pressure in the charging block if necessary. 1. Remove plug (1) from the relief valve. : 30 mm 2. Remove shim (2) from the relief valve. 3.
  • Page 71 OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Push the air bleed valve of the hydraulic oil tank and release any remaining pressure. 3. Measure pressure at the location between the pi- lot valve and the main valve. Disconnect the pilot hose in the circuit to be Pilot Valve measured.
  • Page 72 OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE Measure the solenoid valve set pressure by using both Dr. ZX and a pressure gauge. Preparation: 1. Stop the engine. 2. Push the air bleed valve of the hydraulic oil tank and release any remaining pressure.
  • Page 73 OPERATIONAL PERFORMANCE TEST / Component Test Solenoid Valve Set Pressure Adjustment Proce- dure IMPORTANT: O-ring on the thread part may come off the sealing surface and oil leak may occur. Do not loosen and tighten the adjusting screw exces- sively. Do not loosen the adjusting screw more than 1.2 turns.

  • Page 74: Table Of Contents

    OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be meas- ured by using Dr. ZX. Summary: Measure the main pump delivery pressure in order to check performance of the main pump. Pressure Gauge Preparation:...
  • Page 75 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-7...

  • Page 76: Push The Air Bleed Valve Of The Hydraulic Oil Tank And Release Any Remaining Pressure

    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 perform- Pressure ance of the main relief valve.
  • Page 77 OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Valve Pressure Adjustment Procedure 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.

  • Page 78: Maintain Hydraulic Oil Temperature At 50±5 °C (122±9 °F)

    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 perform- ance of the steering relief valve.
  • Page 79 OPERATIONAL PERFORMANCE TEST / Component Test Steering Relief Valve Pressure Adjustment Pro- cedure Steering Relief Valve 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.
  • Page 80 OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF PRESSURE Summary: 1. The circuit pressure must be increased by 4. Install Dr. ZX and select the monitoring function. applying an external force while blocking the Start the engine. Check for any oil leaks at the return circuit from the control valve.
  • Page 81 OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Pressure Adjusting Procedure NOTE: In principle, adjust the overload relief valve pressure on a test stand. Adjust the pressure of the overload relief valve with adjusting screw (2) after loosening lock nut (1). 1.
  • Page 82 OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE • P-Q Control (Torque Control) 5. Install a pressure gauge to the main pump. (Refer Summary: to the page on Main Pump Relief Pressure.) Main pump performance is checked by measuring : 6 mm the pump flow rate by using a hydraulic tester 6.
  • Page 83 OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the 2. Standard Flow Rate specified engine speed by using the following Refer to the Performance Standard Table in Group formulas: T4-2. Qc = (Ns × Q) ⁄ Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 2200 min...
  • Page 84 OPERATIONAL PERFORMANCE TEST / Component Test • Pilot Characteristics Summary: 7. Remove the vacuum pump. Loosen the plug on Main pump performance is checked by measuring top of the pump casing. Bleed air from the pump the pump flow rate by using a hydraulic tester casing until oil only comes out of the plug installed at the main pump delivery port to be clearance.
  • Page 85 OPERATIONAL PERFORMANCE TEST / Component Test Delivery Hose (To Control Valve) T1F3-04-05-010 Port Pi2 Port Pi1 Pilot Steering Valve Port P Port P Hose in Pilot T4GB-04-05-025 Steering Valve Charging Block T4GB-04-05-026 Emergency Pressure Reducing Steering Valve Port Position Check Block To Return Piping or Hydraulic Oil Tank Port E...

  • Page 86: Regulator Adjustment

    OPERATIONAL PERFORMANCE TEST / Component Test REGULATOR ADJUSTMENT T4GB-04-05-016 1 - Lock Nut (Minimum Flow 4 - Adjusting Screw (Maximum 7 - Lock Nut Lock Nut Rate) Flow Rate) (P-Q Control) (P-Q Control) 2 - Adjusting Screw (Minimum 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw Flow Rate)
  • Page 87 OPERATIONAL PERFORMANCE TEST / Component Test Adjustment Item Adjustment Procedure Remarks 2. Pilot Pressure Characteristics Loosen lock nut (1) and turn 1) Do not turn adjusting screw (2) more adjusting screw (2). than one turn. Turn adjusting screw (2) 1/4 a 2) Securely tighten lock nut (1) after turn clockwise and the pump flow adjustment.
  • Page 88 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 brake piping, and replacing hydraulic oil.
  • Page 89 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.
  • Page 90 OPERATIONAL PERFORMANCE TEST / Component Test PARKING BRAKE PRESSURE CAUTION: If air is mixed in the brake system, Evaluation: the brake function is reduced and serious Refer to the Performance Standard Table in Group hazard may occur. Bleed air from the brake T4-2.
  • Page 91 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-23...
  • Page 92 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 brake piping, and replacing hydraulic oil.
  • Page 93 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.
  • Page 94 OPERATIONAL PERFORMANCE TEST / Component Test SERVICE BRAKE WARNING SET PRESSURE (DECREASE) (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 brake piping, and replacing hydraulic oil.
  • Page 95 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement: 1. Select the following switch positions. FNR Lever Parking Brake Switch P (Parking) Measurement: 1. Stop the engine. Turn the key switch to the ON position. 2. Measure the pressure when warning buzzer sounds by depressing the brake pedal several times.
  • Page 96 OPERATIONAL PERFORMANCE TEST / Component Test SERVICE 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 brake piping, and replacing hydraulic oil.
  • Page 97 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement: 1. Select the following switch positions. FNR Lever Parking Brake Switch Measurement: 1. Stop the engine. Turn the key switch to the ON position. 2. Set the engine control dial to slow idle. 3.

  • Page 98: Transmission Clutch Pressure

    OPERATIONAL PERFORMANCE TEST / Component Test TRANSMISSION CLUTCH PRESSURE Summary: Measure each operating pressure of the transmission clutch at each port of the transmission control valve. Forward Clutch Pressure Preparation: Reverse Clutch 1. Stop the engine. Pressure 2. Remove the plug from the port. Install a hose, an adapter and a pressure gauge.
  • Page 99 OPERATIONAL PERFORMANCE TEST / Component Test TORQUE CONVERTER PRESSURE (INLET Torque Converter AND OUTLET) Inlet Pressure Check Port Summary: Measure inlet pressure and outlet pressure of the torque converter pressure at the port of the torque converter housing. Preparation: 1. Stop the engine. 2.
  • Page 100 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-32...
  • Page 101 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, the transmission control valve or the clutch pack •...
  • Page 102 OPERATIONAL PERFORMANCE TEST / Adjustment Learning 1. Connect the calibration switch to the connector Calibration (6-pole, gray) in the relay box in 10 seconds after Switch turning the key switch OFF (the battery relay is tuned OFF). At this time, return the calibration start switch to neutral.
  • Page 103 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 Error Display starting...
  • Page 104 OPERATIONAL PERFORMANCE TEST / Adjustment NOTE: If error No. 5, 7 or 8 is displayed, stop the engine. Disconnect the calibration switch from the connector and solve the trouble. Then, start calibration again. T4-6-4...
  • Page 105 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. Error 000108 The key is turned into OFF.
  • Page 106 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 the angle sensor, Replacement of the angle sensor •...
  • Page 107 OPERATIONAL PERFORMANCE TEST / Adjustment 5. Connect calibration switch (5) to connector (4) Relay Box (6-pole, gray) in the 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.

  • Page 108: Drive Belt Tension Adjustment

    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 the drive belt occurs. If the drive belt is too tight, the water pump and the bearing of the alternator are damaged.
  • Page 109 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 110 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 111: Troubleshooting Section

    SECTION 5 TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure Group 3 e-Wheel Introduction ..........T5-1-1 Outline .............T5-3-1 Diagnosing Procedure ......T5-1-2 List of Daily Report Data......T5-3-2 How to Operate Service Mode of List of Frequency Distribution Data ...T5-3-3 Monitor ...........T5-1-6 List of Total Operationg Hours ....T5-3-4 Display List of Monitor Service Mode ..T5-1-7 List of Alarm ..........T5-3-5 List of failure ..........T5-3-6...
  • Page 112 Transmission Failure Components in Ride Control Valve ..T5-4-32 Front View of Transmission ....T5-4-36 MC Fault Code 11600 ......T5-5-76 Side View of Transmission .....T5-4-37 MC Fault Code 11601 ......T5-5-77 Rear View of Transmission .....T5-4-38 MC Fault Code 11602 ......T5-5-78 Cross-Sectional Drawing of MC Fault Code 11904 ......T5-5-79 Torque Converter........T5-4-39 MC Fault Code 11905 ......T5-5-80...
  • Page 113 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...
  • Page 114 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 4GDT-5-4...

  • Page 115: Introduction

    TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Refer to the inspection and troubleshooting proce- dures after any machine trouble has occurred. The inspection and troubleshooting procedures are pre- sented 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;...

  • Page 116: Diagnosing Procedure

    TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the System Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.
  • Page 117 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 obtain further...
  • Page 118 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.
  • Page 119 TROUBLESHOOTING / Diagnosing Procedure Note that the fault codes displayed do not necessarily indicate machine trouble. 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”.

  • Page 120: How To Operate Service Mode Of Monitor

    TROUBLESHOOTING / Diagnosing Procedure HOW TO OPERATE SERVICE MODE OF MONITOR In case the engine starts in normal, the monitor is How to Used Monitor in Service Mode started in normal mode and only the items, which can 1. Whenever pushing the monitor display selector be displayed in normal mode, are displayed on the (up) in the monitor, the display in information dis- liquid crystal display (LCD).

  • Page 121: Display List Of Monitor Service Mode

    TROUBLESHOOTING / Diagnosing Procedure DISPLAY LIST OF MONITOR SERVICE MODE Display Description Monitored Result Unit Remark Order Model Service Mode Clock (24 hour) hh:mm Normal Mode Hour Meter hour Normal Mode Odometer km or mile Normal Mode (“Mile” is dis- played when pushing the mode selection switch.) Fuel...
  • Page 122 TROUBLESHOOTING / Diagnosing Procedure Display Description Monitored Result Unit Remark Order Engine Speed Service Mode °C Coolant Temperature Service Mode °C Transmission Oil Tem- Service Mode perature °C Hydraulic Oil Tempera- Service Mode ture Fault Code ERROR Service Mode T5-1-8...

  • Page 123: Outline

    TROUBLESHOOTING / Dr. ZX OUTLINE Dr. ZX is used for diagnosis of the electrical system including MC (main controller), ECM (engine control module), ICF (information controller) and the monitor unit. Dr. ZX is connected to ICF and the failure of each controller and each sensor is displayed as a fault code.

  • Page 124: Operation

    TROUBLESHOOTING / Dr. ZX OPERATION 1. Connect Palm (Dr. ZX) to the diagnosing con- Fuse Box Dr. ZX Connector nector in the cab by using the Hot Sync cable and the harness. 2. Turn the key switch ON or start the engine. 3.
  • Page 125 TROUBLESHOOTING / Dr. ZX Start Initial Screen Password Setup Screen • Input Password Input the former pass- When the password has unset word (6 characters or Communication more). Error Then, input the same • Check Communication Harness password in order to When the password •...

  • Page 126: Self-Diagnostic Result

    TROUBLESHOOTING / Dr. ZX SELF-DIAGNOSTIC RESULT The self-diagnostic result of each controller is dis- played. After starting Dr. ZX, push Self-Diagnostic Results. T1V7-05-03-001 T1V7-05-03-008 T4GB-05-02-052 Function Selection Screen Controller Self- Diagnosis Screen NOTE: Main C/U: Engine C/U: Monitor Unit: Monitor Unit Information C/U: NOTE: Self-diagnosis of ICF controller is done on the next page.
  • Page 127 TROUBLESHOOTING / Dr. ZX Self-Diagnosis Push Fault of ICF Controller. In case of no faulty, No Fault is dis- After starting push played. Self-Diagnostic Results. To the lower T4GB-05-02-052 T1V7-05-03-001 T1V7-05-03-008 Controller Self-Diagnosis Screen Function Selection Screen By changing the page, the forward or backward controller is displayed.

  • Page 128: Select Controller

    TROUBLESHOOTING / Dr. ZX SELECT CONTROLLER Select the failure-diagnosis controller. After starting Dr. ZX, push Select Controller. T4GB-05-02-053 Function Selection Screen T1V7-05-03-001 Controller Selection Screen NOTE: Main C/U: Engine C/U: Monitor Unit: Monitor Unit Information C/U: T5-2-6...

  • Page 129: Main Controller

    TROUBLESHOOTING / Dr. ZX MAIN CONTROLLER Main Menu • Monitor Display Title Screen To display the control signals of MC and the input status from each switch and sensor. • Setup To adjust target the engine idling speed, the en- gine warming-up speed and so on.
  • Page 130 TROUBLESHOOTING / Dr. ZX MAIN MENU MONITOR DISPLAY Dr. ZX displays the control signals from MC and the input status from the switches and the sensors MC List of Monitor Item Item Data Unit Required Engine Speed Control instruction value of engine speed to ECM Hydraulic Fan Target Speed Control instruction value to fan flow rate control valve Actual Engine Speed...
  • Page 131 TROUBLESHOOTING / Dr. ZX Item Data Unit Hold Mode Enabled/disabled status of hold mode OFF ON Option FNR Mode Enabled/disabled status of FNR switch use mode NotAct Acr Auto/Manual Selection Selected status (auto/manual) of travel mode selector switch Manual Auto Auto Gear Shifting Mode Selected status (gear shifting timing) of travel mode selector L1-4 N2-4 H1-4...
  • Page 132 TROUBLESHOOTING / Dr. ZX Monitor Display After starting Dr. ZX, push Select Push Start. Push Main C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-002 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push OK. Push Monitor Display. To the lower T4GB-05-02-004 T1V7-05-03-012 T4GB-05-02-054...
  • Page 133 TROUBLESHOOTING / Dr. ZX Push Rec. No. and the recording Push Record. screen for Rec. No. is made. To the lower T4GB-05-02-008 T1V7-05-03-096 T1V7-05-03-097 Select Write Data-Bank Screen Monitor Screen If Rec. No. has not been recorded If Rec. No. has already been re- yet and push Overwrite, data is corded and push Overwrite, data is Push Comment.

  • Page 134: Setting

    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 Data Request Speed Ⅰ Calibration Adjustment of engine idling speed Warning Up Speed Calibration Adjustment of engine warming-up speed Warming Up Control Deactivation Selection (enable/ disable) of engine warming-up control...
  • Page 135 TROUBLESHOOTING/ Dr. ZX Setting • Parameter Change After starting Dr. ZX, push Select Push Start. Push Main C/U. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GD-05-02-002 Title Screen Controller Selection Screen Function Selection Screen Push Setup. Push OK. To the lower T4GB-05-02-004 T1V7-05-03-012 T1V7-05-03-016...
  • Page 136 TROUBLESHOOTING/ Dr. ZX Parameter Input Example: Engine Control Target Speed I Correc- tion Input Value = Normal Value Check Adjustment and push Exec. Input the value and push Exec. Push ESC and return to Parameter Push ESC and return to Parameter Change Selection Screen.
  • Page 137 TROUBLESHOOTING/ Dr. ZX Input Value = Current Value Input the value and push Exec. Push Exec. Push ESC and return Push ESC and return to Parameter to Parameter Change Selection Push Request Speed I Calibration. Change Selection Screen. Screen. To the lower T4GB-05-02-016 T4GD-05-02-005...
  • Page 138 TROUBLESHOOTING/ Dr. ZX Input Value > Maximum Value (Input Value < Minimum Value) Push Re-Input and return to Pa- rameter Input Screen. Push Max Input the value and push Execution and the maximum value is input. Push ESC and return to Parameter Push ESC and return to Parameter Push Request Speed I Calibration.
  • Page 139 TROUBLESHOOTING/ Dr. ZX When the input value cannot be divided Example: Pump Control Set Torque Calibration Push Re-Input and return to Pa- rameter Input Screen. Push A or B Input the value and push Execu- and the value of A or B is input. tion.
  • Page 140 TROUBLESHOOTING/ Dr. ZX Status Selection Example： Engine Control Warming Up Control Deactivation Flag Push OFF and push Exec. Push Check contents and push Execute. ESC and return to Parameter Push ESC and return to Parameter Push Warming Up Ctrl Deactiva- Change Selection Screen.
  • Page 141 TROUBLESHOOTING/ Dr. ZX RECORDED DATA DISPLAY After starting Dr. ZX, push Select Push Disp Record Push Main C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-002 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push HOLD and the monitor are Push and select No. Push Exec stopped temporarily.

  • Page 142: Password Change

    TROUBLESHOOTING/ Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Push Password. Push Main C / U. Controller. To the lower T4GB-05-02-053 T1V7-05-03-001 T1V7-05-03-011 Title Screen Controller Selection Screen Function Selection Screen Input the registered password and Input the new password and push Input the new password again and push OK.

  • Page 143: Engine Controller

    TROUBLESHOOTING / D r. ZX ENGINE CONTROLLER Main Menu • Monitor Display Dr. ZX displays the input status from the sensors and the control signals of ECM. Disp. Record Data recorded in ECM can be displayed by one time by using Dr. ZX. Password The password can be changed.

  • Page 144: Monitor Display

    TROUBLESHOOTING / D r. ZX MONITOR DISPLAY ECM List of Monitor Item Item Unit Data Selecting Monitoring Engine Torque Engine Torque Input signal from ECM Actual Engine Speed Actual Engine Input signal from crank speed sensor and cam angle (Engine Speed) Speed sensor Coolant...
  • Page 145 TROUBLESHOOTING / D r. ZX (Blank) T5-2-23...
  • Page 146 TROUBLESHOOTING / D r. ZX Monitor Display After starting Dr. ZX, push Select Push Start. Push Engine C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-002 T1V7-05-03-001 Title Screen Controller Selection Screen Function Selection Screen Push Monitor Display. Push OK. To the lower T4GD-05-02-009 T4GB-05-02-061...
  • Page 147 TROUBLESHOOTING / D r. ZX Push Rec. No. and the recording Push Record. screen for Rec. No. is made. To the lower T1V7-05-03-133 T1V7-05-03-134 T1V7-05-03-135 Monitor Screen Select Write Data-Bank Screen If Rec. No. has already been If Rec. No. has not been recorded recorded and push Overwrite, data yet and push Overwrite, data is is overwritten.

  • Page 148: Recorded Data Display

    TROUBLESHOOTING / D r. ZX RECORDED DATA DISPLAY After starting Dr. ZX, push Select Push Disp. Record. Push Engine C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-002 T1V7-05-03-001 Title Screen Controller Selection Screen Function Selection Screen Push HOLD and the monitor is Push and select No.

  • Page 149: Password Change

    TROUBLESHOOTING / D r. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Push Password. Push Engine C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-002 T1V7-05-03-001 Title Screen Controller Selection Screen Function Selection Screen Input the new password and push Input the new password again and Input the registered password and push OK.
  • Page 150 TROUBLESHOOTING / D r. ZX (Blank) T5-2-28...

  • Page 151: Icf Controller

    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, which are re- corded in ICF, can be downloaded to Dr.

  • Page 152: Information C/U Various Setup

    TROUBLESHOOTING / Dr. ZX INFORMATION C/U VARIOUS SETUP ICF List of Controller Data Setting Item Item Range of Data Information C/U: Initialize Initialize/ESC Enter Model and Serial No. Model ASCII (4 characters) 0 to 9, A to Z Serial No. 000000 to 999999 Enter Date and Time 2000 to 2100...
  • Page 153 TROUBLESHOOTING / Dr. ZX Information C/U：Initialize After starting Dr. ZX, push Select Push Start. Push Information C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Controller Selection Screen Title Screen Function Selection Screen Push Information C/U: Various Push Information C/U: Initialize. Push OK.
  • Page 154 TROUBLESHOOTING / Dr. ZX Enter Model and Serial No. After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push Information C/U: Various Push OK. Push Enter Model and Serial No.
  • Page 155 TROUBLESHOOTING / Dr. ZX Enter Date and Time After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Function Selection Screen Controller Selection Screen Title Screen Push Information C/U: Various Push OK. Push Enter Time.
  • Page 156 TROUBLESHOOTING / Dr. ZX Control Data: Initialize After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push Information C/U: Various Push OK. Push Control Data: Initialize. setup.
  • Page 157 TROUBLESHOOTING / Dr. ZX Satellite Terminal: Initialize After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push and move to the next screen of Information C/U: Various Setup Screen.
  • Page 158 TROUBLESHOOTING / Dr. ZX Satellite Terminal No. Confirmation After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Function Selection Screen Controller Selection Screen Title Screen Push and move to the next screen of Information C/U: Various Setup Screen.
  • Page 159 TROUBLESHOOTING / Dr. ZX Communicating State Check After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GD-05-02-013 Title Screen Controller Selection Screen Function Selection Screen Push and move to the next screen of Information C/U: Various Setup Screen.
  • Page 160 TROUBLESHOOTING / Dr. ZX Satellite Comm. Start / Stop After starting Dr. ZX, push Select Push Start. Push Information C/U. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GD-05-02-013 Title Screen Function Selection Screen Controller Selection Screen Push and move to the next screen of Information C/U: Various Setup Screen.
  • Page 161 TROUBLESHOOTING / Dr. ZX Data Download After starting Dr. ZX, push Select Push Start. Controller. Push Information C/U. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Controller Selection Screen Title Screen Function Selection Screen While downloading data, Download Screen is displayed. Push OK. Push Data Download.

  • Page 162: Save Data Check

    TROUBLESHOOTING / Dr. ZX SAVE DATA CHECK After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Function Selection Screen Controller Selection Screen Title Screen Data saved in ICF is displayed. Push OK and return to Main Menu Screen.

  • Page 163: Password Change

    TROUBLESHOOTING / Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Push Password. Push Information C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Input the registered password and Input the new password and push Input the new password again and push OK.
  • Page 164 TROUBLESHOOTING / Dr. ZX (Blank) T5-2-42...

  • Page 165: Monitor Unit

    TROUBLESHOOTING / Dr. ZX MONITOR UNIT Main Menu • Monitoring Dr. ZX displays the input status 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...

  • Page 166: Monitoring

    OFF ON Continuity status to stop indicator Engine STOP Switch OFF ON Model Selector Switch 1 Switch 1 OFF, switch 2 ON: ZW 180 OFF ON Switch 1 OFF, switch 2 OFF: ZW220/250 Model Selector Switch 2 OFF ON Switch 1 ON, switch 2 OFF: ZW310...
  • Page 167 TROUBLESHOOTING / Dr. ZX Monitoring After starting Dr. ZX, push Select Push Monitor Unit. Push OK. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GB-05-02-040 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push item for monitoring and push OK. Refer to T5-2-44 as for the monitoring item.

  • Page 168: Various Settings

    TROUBLESHOOTING / Dr. ZX VARIOUS SETTINGS Monitor Unit List of Setup Item Item Data Internal Hour Meter Sync. Synchronization of hour meter data in both monitor unit and ICF MC List of Adjustment Data Adjustment Mini- Adjustment Mini- Data Adjustable Range Remark mum Unit mum Unit...

  • Page 169: Internal Hour Meter Synchronization

    TROUBLESHOOTING / Dr. ZX INTERNAL HOUR METER SYNCHRONI- ZATION After starting Dr. ZX, push Select Push Monitor Unit. Push OK. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GB-05-02-040 Controller Selection Screen Monitor Controller Screen Function Selection Screen Push Internal Hour Meter Sync. Push Start.

  • Page 170: Password Change

    TROUBLESHOOTING / Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Push Monitor Unit. Push OK. Controller. To the lower T1V7-05-03-001 T4GB-05-02-053 T4GB-05-02-040 Controller Selection Screen Monitor Controller Screen Function Selection Screen Input the registered password and Input the new password and push Push Password.

  • Page 171: Outline

    TROUBLESHOOTING / e-Wheel OUTLINE ICF (Information Controller) saves the input signals from various sensors and switches of the machine as data by using CAN from each controller. Various input signals are recorded as “list of daily re- port data”, “list of frequency distribution data”, “list of total operating hours”, “list of alarm”...

  • Page 172: List Of Daily Report Data

    TROUBLESHOOTING / e-Wheel LIST OF DAILY REPORT DATA Item Details Date Date of daily report data The value of the final remained fuel during a day when Fuel Level the engine stops Fuel Usage Amount The value of fuel used during a day Machine Hour Meter Hour meter cumulative hours Engine Operating Hours...

  • Page 173: List Of Frequency Distribution Data

    TROUBLESHOOTING / e-Wheel LIST OF FREQUENCY DISTRIBUTION DATA Item Details Output Shaft Speed Distribution Frequency distribution of output shaft speed Pump Load Distribution Frequency distribution of main pump delivery pressure Axle Oil Temperature Distribution Frequency distribution of axle oil temperature Travel Load Distribution Frequency distribution of travel torque Radiator Coolant Temperature Distribution...

  • Page 174: List Of Total Operationg Hours

    TROUBLESHOOTING / e-Wheel LIST OF TOTAL OPERATING HOURS Item Details Hour Meter (ICF) Hour meter’s value accumulated inside ICF Hour Meter (Monitor Unit) Hour meter’s value accumulated in monitor unit Engine Operating Hour Total engine operating hours Traveling Distance Total traveling distance Manual Transmission Operating Hours Total manual transmission operating hours Automatic Transmission Operating Hours...

  • Page 175: List Of Alarm

    TROUBLESHOOTING / e-Wheel LIST OF ALARM Item Details Overheat Alarm Date when the overheat indicator lights Engine Warning Alarm Date when the engine warning indicator lights Engine Oil Pressure Alarm Date when the engine oil pressure indicator lights Alternator Indicator Alarm Date when the alternator indicator lights Air Filter Restriction Alarm Date when the air filter restriction indicator lights...

  • Page 176: List Of Failure

    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 occurs, which is difficult to identify, 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.

  • Page 177: How To Download And Upload Data Of Icf

    TROUBLESHOOTING / e-Wheel HOW TO DOWNLOAD AND UPLOAD DATA OF ICF Dr.ZX Connector After the data saved in ICF is downloaded to Dr. ZX, is Fuse Box uploaded to the personal computer, and is uploaded to the center server by using LAN, the data can be used as “e-Service”.
  • Page 178 TROUBLESHOOTING / e-Wheel Data Download After starting Dr. ZX, push Select Push Start. Push Information C/U. Controller. To the lower Controller Selection Screen Title Screen Function Selection Screen T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 While downloading data, Data Download Screen is displayed. Push OK. Push Data Download.
  • Page 179 TROUBLESHOOTING / e-Wheel How to Upload Data from Dr. ZX (Palm) to Personal Computer 1. Connect the cable to Dr. ZX. Connect the USB cable to the personal computer. Dr. ZX 2. Push the Hot Sync button. (Palm) NOTE: When pushing the Hot Sync button and uploading the data to the personal com- puter, the Palm Desktop software attached with Dr.

  • Page 180: Various Setup Of Icf And Satellite Communication Terminal By Using Dr.zx

    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 Select Information Controller Select Information C/U: Various Setup Enter Date and Time...
  • Page 181 TROUBLESHOOTING / e-Wheel 1.1 Select Information Controller After starting Dr. ZX, push Select Push Start. Push Information C/U. Controller. To the lower T4GB-05-02-053 T1V7-05-03-001 Controller Selection Screen Function Selection Screen Title Screen Push OK. To the lower T4GD-05-02-012 ICF Controller Screen 1.2 Select Information C/U: Various Setup Push Information C/U: Various Setup.
  • Page 182 TROUBLESHOOTING / e-Wheel 1.3 Enter Date and Time Push Enter Date and Time. Push Set or ESC and return to In- formation C/U: Various Setup Push ESC and return to Main Screen. Menu Screen. Enter Date and Time YY, MM, DD, HH and MM 2004 The focused item is displayed reversely.
  • Page 183 TROUBLESHOOTING / e-Wheel 1.4 Enter Model and Serial No. Push Enter Model and Serial No. Select Item Information C/U: Initialize To the lower Enter Model and Serial Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen Push Exec and model and serial Push OK after inputting model No.
  • Page 184 TROUBLESHOOTING / e-Wheel 1.5 Information C/U: Initialize Push Information C/U: Initialize. Select Item Information C/U: Initialize To the Enter Model and Serial lower Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen Push Init and the controller oper- ating data is initialized.
  • Page 185 TROUBLESHOOTING / e-Wheel 1.6 Satellite Terminal: Initialize Push Satellite Terminal: Initialize. Display the next screen of Infor- Push Exec. Push ESC and return to Main mation C/U: Various Setup Push ESC and return to Informa- Menu Screen. Screen. tion C/U: Various Setup Screen. Select Item Satellite Terminal: Initialize Select Item...
  • Page 186 TROUBLESHOOTING / e-Wheel 1.7 Satellite Terminal Serial No. Check Push Satellite Terminal No. Confir- mation. Confirm serial no. (12 digits). Push ESC and return to Informa- Push ESC and return to Main tion C/U: Various Setup Screen. Menu Screen. Select Item Satellite Terminal No.
  • Page 187 TROUBLESHOOTING / e-Wheel 1.8 Satellite Terminal, Commu- nicating State Check Push Communicating State Check. Push ESC and return to Main Menu Screen. Check communicating state. Select Item Communicating State Check Check the enclosed state. ICF⇔Satellite Terminal Satellite Terminal: Initial- ・ Conn UnCon: Faulty harness Satellite Terminal No.
  • Page 188 TROUBLESHOOTING / e-Wheel Enter Satellite Comm. Start/Stop Push ▼ and move to the next screen of Information C/U: Vari- ous Setup Screen. Push Enter Satellite Comm. Start/Stop. Select Item Satellite Terminal: Initial- To the Satellite Terminal No. lower Confirmation Communicating State Check Enter Satellite Comm.
  • Page 189 TROUBLESHOOTING / e-Wheel 1.10 Control Data: Initialize Push Control Data: Initialize. Select Item Information C/U: Initialize To the Enter Model and Serial lower Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen Push Init and the controller oper- ating data is initialized.
  • Page 190 TROUBLESHOOTING / e-Wheel 2. Self-Diagnosing Push Fault of ICF Controller. If there is no trouble, No Problem is After starting push displayed. Self-Diagnostic Result. Self-diagnosing of controllers Select Function below hasn completed. Self-Diagnostic Result Engine Controller No Problem To the Select Controller lower Fault...
  • Page 191 TROUBLESHOOTING / e-Wheel (Blank) T5-3-21...

  • Page 192: List Of Icf Fault Code

    TROUBLESHOOTING / e-Wheel LIST OF ICF FAULT CODE Fault Code Details Remedy 14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing. CAN Communication Error If this error code is displayed after retrial, check the following item. • Check the CAN communication line (check the harness). 14001-2 Abnormal Flash Memory Execute retry B in self-diagnosing and execute the following...

  • Page 193: List Of Fault Code Of Sattellite

    TROUBLESHOOTING / e-Wheel LIST OF FAULT CODE OF SATELLITE COMMUNICATION TERMINAL Fault Code Details Remedy 14100-2 Internal Error Execute retry B in self-diagnosing. Abnormal EEPROM If this error code is displayed after retrial, replace the control- ler. 14101-2 Internal Error Abnormal IB/OB Queue 14102-2 Internal Error...
  • Page 194 TROUBLESHOOTING / e-Wheel SATELLITE COMMUNICATION SYSTEM Communication Antenna The satellite communication system is used for main- tenance of the machine, “e-Service” by transmitting various data of the machine regularly via a low earth Antennal orbit satellite. NOTE: Depending on the circumstances of the machine (ex.
  • Page 195 TROUBLESHOOTING / e-Wheel On the machine equipped with the satellite communi- cation system, the data are sent according to the con- dition as follows: Data type sent from the machine by using satellite communication: Items Kinds of Data Condition Periodical Daily Report Data, Latest Location Infor- The data are sent once a day.
  • Page 196 TROUBLESHOOTING / e-Wheel (Blank) T5-3-26...

  • Page 197: Main Component (Overview)

    TROUBLESHOOTING / Component Layout MAIN COMPONENT (OVERVIEW) T4GD-01-02-005 1 - Bucket 4 - Head Light 7 - Rear Working Light 10 - Lift Arm Cylinder 2 - Bell Crank 5 - Front Working Light Rear Combination Light 11 - Lift Arm (Turn Signal, Hazard Light, Clearance Light, Brake Light, Reverse Light)

  • Page 198: Main Component (Upperstructure)

    TROUBLESHOOTING / Component Layout MAIN COMPONENT (UPPERSTRUCTURE) T4GD-01-02-006 Charging Block Control Valve 11 - Fuel Tank 16 - Oil Cooler Pilot Valve Stop Valve 12 - Intercooler 17 - Muffler Brake Valve Pilot Shut-Off Valve 13 - Torque Converter Cooler 18 - Coolant Reservoir Steering Pilot Valve Pilot Filter...

  • Page 199: Main Component (Travel System)

    TROUBLESHOOTING / Component Layout MAIN COMPONENT (TRAVEL SYSTEM) T4GD-01-02-007 1 - Front Axle Pump Device Rear Axle Steering Accumulator 2 - Propeller Shaft (Front) Transmission Propeller Shaft (Rear) Brake Pressure Sensor 3 - Steering Cylinder T5-4-3...

  • Page 200: Electric System (Overview)

    TROUBLESHOOTING / Component Layout ELECTRIC SYSTEM (OVERVIEW) (Refer to T5-4-5) Engine and Fan Pump (Refer to T5-4-10) Pump Device (Refer to T5-4-11) Drive Unit (Refer to T5-4-11) T4GD-01-02-008 1 - Hydraulic Oil Level Switch Battery Emergency Steering Pump 10 - Lift Arm Proximity Switch Delivery Pressure Switch 2 - Air Filter Restriction Switch Fuel Level Sensor...

  • Page 201: Electrical System (Cab)

    TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (CAB) 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 3 - Speaker 5 - Brake Lamp Switch 6 - Front Wiper Motor 2 - Auxiliary Switch Panel 4 - Rear Wiper Motor (Optional)
  • Page 202 TROUBLESHOOTING / Component Layout Controller and Relays T4GB-01-02-006 T4GD-01-02-002 T4GC-01-02-002 1 - Flusher Relay Parking Brake Relay 1 17 - Emergency Steering Relay 25 - Overheat Relay (B-R2) (A-R10) 2 - Option Controller 10 - Parking Brake Relay 2 18 - Turn Signal Relay (Left) 26 - Engine Oil Pressure Relay (Optional) (A-R9)
  • Page 203 TROUBLESHOOTING / Component Layout Right Console T4GD-01-02-003 T4GB-01-02-023 1 - DDS (Down Shift) Switch 6 - Auxiliary Control Lever 11 - Emergency Steering 15 - FNR Selector Switch (Optional) Check Switch (Optional) 2 - Bucket Control Lever 7 - Quick Coupler Switch (Optional) 12 - Fan Reversing Switch 16 - Cigar Lighter 3 - Lift Arm Control Lever...
  • Page 204 TROUBLESHOOTING / Component Layout Monitor and Switches T4GD-01-02-003 T4GB-01-02-024 1 - Monitor Panel 5 - Work Mode Selector Switch 9 - Front Wiper Switch 12 - Rear Wiper Switch (Refer to T5-4-9) 2 - Driving Mode Switch 6 - Clutch Cut Position Switch 10 - FNR Lever/Shift Switch 13 - Working Light Switch 3 - Turn Signal Lever /Head Light...
  • Page 205 TROUBLESHOOTING / Component Layout Monitor Panel T4GD-01-02-001 23 22 1 - Engine Coolant 10 - Parking Brake Indicator 19 - Discharge Warning Indicator 28 - Engine Failure Indicator Temperature Gauge 2 - Transmission Oil 11 - Clearance Light Indicator 20 - Lever Steering Indicator 29 - Overheat Indicator Temperature Gauge (Optional)

  • Page 206: Engine And Fan Pump

    TROUBLESHOOTING / Component Layout ENGINE AND FAN PUMP View A T4GD-01-02-009 1 - Common Rail Pressure 5 - Ambient Pressure Sensor 9 - Engine Speed Sensor 12 - Starter Sensor (Crankshaft) 2 - Intake Manifold Pressure/ 6 - Engine Oil Pressure Switch 10 - Engine Oil Filter 13 - High-Pressure Pump Intake Manifold Temperature...

  • Page 207: Pump Device

    TROUBLESHOOTING / Component Layout PUMP DEVICE T4GB-01-02-009 DRIVE UNIT T4GD-01-02-004 1 - Main Pump Steering Relief Valve 11 - Transmission Output 16 - 2nd Speed Clutch Solenoid Speed Sensor Valve 2 - Regulator Torque Converter Input 12 - Transmission Middle Shaft 17 - 3rd Speed Clutch Solenoid Speed Sensor Sensor...

  • Page 208: Control Valve

    TROUBLESHOOTING / Component Layout CONTROL VALVE T4GB-01-02-027 1 - Over Load Relief Valve 3 - Over Load Relief Valve 4 - Make-Up Valve 5 - Main Relief Valve (Lift Arm: Bottom side) (Bucket: Rod Side) (Lift Arm: Rod Side) 2 - Over Load Relief Valve (Bucket: Bottom Side) T5-4-12...

  • Page 209: Ride Control Valve

    TROUBLESHOOTING / Component Layout RIDE CONTROL VALVE CHARGING BLOCK T4GB-01-02-013 T4GB-01-02-014 FAN MOTOR T4GB-01-02-012 1 - Overload Relief Valve 5 - Service Brake Accumulator Pilot Relief Valve 11 - Reverse Control Solenoid (Front) Valve 2 - Ride Control Solenoid Valve 6 - Service Brake Accumulator Pump Torque Control 12 - Relief Valve...

  • Page 210: Steering Valve

    TROUBLESHOOTING / Component Layout STEERING VALVE T4GB-01-02-020 EMERGENCY STEERING PUMP (OPTIONAL) T4GB-01-02-010 1 - Overload Relief Valve 3 - Electric Motor 5 - Check Valve Relief Valve 2 - Overload Relief Valve 4 - Gear Pump T5-4-14...
  • Page 211 TROUBLESHOOTING / Component Layout (Blank) T5-4-15...

  • Page 212: Components In Control Valve

    TROUBLESHOOTING / Component Layout COMPONENTS IN CONTROL VALVE T4GB-03-02-003 T5-4-16...
  • Page 213 TROUBLESHOOTING / Component Layout T4GB-03-02-004 1 - Bucket Flow Control Valve 4 - Overload Relief Valve 7 - Restriction Valve 10 - Load Check Valve (Bucket: Rod Side) (Arm Lift Circuit) 2 - Negative Control Valve 5 - Overload Relief Valve 8 - Low-pressure Relief Valve 11 - Load Check Valve (Lift Arm: Bottom Side)
  • Page 214 TROUBLESHOOTING / Component Layout T4GB-03-02-003 T5-4-18...
  • Page 215 TROUBLESHOOTING / Component Layout ※ Section A T4GB-03-02-005 ※ Section B T4GB-03-02-006 1 - Bucket Flow Control Valve 4 - Overload Relief Valve Restriction Valve 10 - Load Check Valve (Bucket: Rod Side) (Arm Lift Circuit) 2 - Negative Control Valve 5 - Overload Relief Valve Low-pressure Relief Valve 11 - Load Check Valve...
  • Page 216 TROUBLESHOOTING / Component Layout T4GB-03-02-003 T5-4-20...
  • Page 217 TROUBLESHOOTING / Component Layout ※ Section C ※ Section D ※ Section E T4GB-03-02-007 1 - Bucket Flow Control Valve 4 - Overload Relief Valve Restriction Valve 10 - Load Check Valve (Bucket: Rod Side) (Arm Lift Circuit) 2 - Negative Control Valve 5 - Overload Relief Valve Low-pressure Relief Valve 11 - Load Check Valve...

  • Page 218: Components In Steering Valve

    TROUBLESHOOTING / Component Layout COMPONENTS IN STEERING VALVE Port A Port T Port B Port Pa Port Pb Port P Port DR Port LS T4GB-03-04-002 Port A: Pressure for Steering Port B: Pressure for Steering Port Pa: Pilot Pressure for Port Pb: Pilot Pressure for Right Left...
  • Page 219 TROUBLESHOOTING / Component Layout T4GB-03-04-001 1 - Spool 3 - Overload Relief Valve 5 - Variable Orifice 2 - Overload Relief Valve 4 - Lord Check Valve 6 - Fixed Orifice T5-4-23...
  • Page 220 TROUBLESHOOTING / Component Layout Port A Port T Port B Port Pa Port Pb Port P Port DR Port LS T4GB-03-04-002 Port A: Pressure for Steering Port B: Pressure for Steering Port Pa: Pilot Pressure for Port Pb: Pilot Pressure for Right Left Steering Right...
  • Page 221 TROUBLESHOOTING / Component Layout Section A ※ Port P Port DR Port T ※ Section B Port LS Port B Port A Port Pb Port Pa T4GB-03-04-003 Section C ※ T4GB-03-04-006 1 - Spool 3 - Overload Relief Valve Variable Orifice 7 - Passage A 2 - Overload Relief Valve 4 - Lord Check Valve...

  • Page 222: Components In Charging Block

    TROUBLESHOOTING / Component Layout COMPONENTS IN CHARGING BLOCK T4GD-03-07-001 1 - Service Brake Accumulator Priority Valve 16 - Port BR3 （To Parking Brake） (Front) 2 - Adaptor 10 - Pilot Relief Valve 17 - Port PS2 (To Main Pump Regulator and Ride Control Valve (Optional)) 3 - Port M2 11 - Port DR (To Hydraulic Oil Tank)
  • Page 223 TROUBLESHOOTING / Component Layout Port for Attaching Service Brake Port for Attaching Accumulator (Rear) Service Brake Accumulator (Front) Pump Torque Control Proportional Solenoid Valve Port for Attaching Pilot Accumulator T4GD-03-07-002 T5-4-27...
  • Page 224 TROUBLESHOOTING / Component Layout T4GD-03-07-001 1 - Service Brake Accumulator Priority Valve 16 - Port BR3 （To Parking Brake） (Front) 2 - Adaptor 10 - Pilot Relief Valve 17 - Port PS2 (To Main Pump Regulator and Ride Control Valve (Optional)) 3 - Port M2 11 - Port DR (To Hydraulic Oil Tank) 18 - Pilot Accumulator...
  • Page 225 TROUBLESHOOTING / Component Layout Section V-V ※ Section U-U ※ Section T-T ※ Section S-S ※ T4GD-03-07-004 ※Refer to T5-4-27. T5-4-29...
  • Page 226 TROUBLESHOOTING / Component Layout T4GD-03-07-001 1 - Service Brake Accumulator 9 - Priority Valve 16 - Port BR3 （To Parking Brake） (Front) 2 - Adaptor 10 - Pilot Relief Valve 17 - Port PS2 (To Main Pump Regulator and Ride Control Valve (Optional)) 3 - Port M2 11 - Port DR (To Hydraulic Oil Tank) 18 - Pilot Accumulator...
  • Page 227 TROUBLESHOOTING / Component Layout ※ Section Z-Z ※ Section Y-Y ※ Section X-X ※ Section W-W T4GB-03-06-004 ※Refer to T5-4-27. T5-4-31...

  • Page 228: Components In Ride Control Valve

    TROUBLESHOOTING / Component Layout COMPONENTS IN RIDE CONTROL VALVE Lift Arm Cylinder Ride Control Accumulator Ride Control Valve To Hydraulic Oil Tank From Charging Block T4GB-03-08-002 1 - Ride Control Solenoid Valve 3 - Overload Relief Valve 5 - Drain Plug 2 - Charge-Cut Spool 4 - Spool T5-4-32...
  • Page 229 TROUBLESHOOTING / Component Layout T4GB-03-08-001 T5-4-33...
  • Page 230 TROUBLESHOOTING / Component Layout Lift Arm Cylinder Ride Control Accumulator Ride Control Valve To Hydraulic Oil Tank From Charging Block T4GB-03-08-002 1 - Ride Control Solenoid Valve Overload Relief Valve Drain Plug 2 - Charge-Cut Spool Spool T5-4-34...
  • Page 231 TROUBLESHOOTING / Component Layout ※ Section A To Ride Control Accumulator Port Pi Port SP Port B Port A Port T T4GB-03-08-003 ※Refer to T5-4-33. T5-4-35...

  • Page 232: Front View Of Transmission

    TROUBLESHOOTING / Component Layout FRONT VIEW OF TRANSMISSION T4GD-03-09-003 1 - Breather 3 - Oil Feed Port 5 - Rotation Sensor (A) 7 - Vehicle Speed Sensor 2 - Control Valve 4 - Charging Pump 6 - Rotation Sensor (B) T5-4-36...

  • Page 233: Side View Of Transmission

    TROUBLESHOOTING / Component Layout SIDE VIEW OF TRANSMISSION T4GD-03-09-004 1 - Converter Inlet Pressure 4 - Forward Clutch Pressure 7 - 2nd Speed Clutch Pressure 10 - Parking Brake Pressure Port Port Port Port 2 - Regulator Valve 5 - Reverse Clutch Pressure 8 - 3rd Speed Clutch Pressure 11 - Parking Brake Release Port...

  • Page 234: Rear View Of Transmission

    TROUBLESHOOTING / Component Layout REAR VIEW OF TRANSMISSION Ｄ T4GD-03-09-001 Section D-D 1 - Engine Speed Sensor 4 - Hose Converter Outlet Pressure Relief Valve Port 2 - From Oil Cooler To Oil Cooler Hydraulic Oil Temperature Spring Sensor Mounting Port 3 - Suction Tube T5-4-38...

  • Page 235: Cross-Sectional Drawing Of Torque Converter

    TROUBLESHOOTING / Component Layout CROSS-SECTIONAL DRAWING OF TORQUE CONVERTER T4GD-03-09-018 1 - Cover Wheel 4 - Stator Wheel 7 - Impeller Wheel 10 - Guide Carrier 2 - Input Plate 5 - Input Guide 8 - Impeller Hub 11 - Turbine Shaft 3 - Turbine Wheel 6 - Stator Hub 9 - Pump Drive Gear...

  • Page 236: Cross-Sectional Drawing Of Transmission

    TROUBLESHOOTING / Component Layout CROSS-SECTIONAL DRAWING OF TRANSMISSION Section B-B ※ Section C-C ※ Section A-A ※ T4GD-03-09-002 1 - Charging Pump 5 - Parking Brake 9 - Rear Output Flange 13 - Torque Converter 2 - Pump Drive Shaft 6 - Front Output Flange 10 - 1st/2nd Speeds Clutch 14 - Reverse Clutch...

  • Page 237: Cross-Sectional Drawing Of Clutch Shaft

    TROUBLESHOOTING / Component Layout CROSS-SECTIONAL DRAWING OF CLUTCH SHAFT T4GD-03-09-007 1 - Hub Gear Bleed Valve Disc 11 - Shaft 2 - End Plate Seal Ring (Outer) Plate 12 - Plug 3 - Return Spring Clutch Piston 10 - Hub Gear 13 - Seal Ring 4 - Seal Ring (Inner) T5-4-41...

  • Page 238: Cross-Sectional Drawing Of Transmission Regulator Valve

    TROUBLESHOOTING / Component Layout CROSS-SECTIONAL DRAWING OF TRANSMISSION REGULATOR VALVE Normal state Small Hole of Regulator Spool Regulator Spool Spring Back Ch Output Port Port P T4GC-03-09-025 From Charging Pump Overflowing state Regulator Spool Back Chamber Spring To Transmission Control Valve From To Torque T4GC-03-09-026...

  • Page 239: Cross-Sectional Drawing Of Transmission Control Valve

    TROUBLESHOOTING / Component Layout CROSS-SECTIONAL DRAWING OF TRANSMISSION CONTROL VALVE From Charging Pump T4GD-03-09-011 1 - Solenoid Body 7 - Reverse Emergency Travel 13 - 2nd Speed Modulation 19 - 4th Speed Proportional Spool Spool Solenoid Valve 2 - Valve Body 8 - Reverse Modulation Spool 14 - 2nd Speed Modulation 20 - 3rd Speed Proportional...
  • Page 240 TROUBLESHOOTING / Component Layout (Blank) T5-4-44...

  • Page 241: Troubleshooting A Procedure

    TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A in case any fault codes are displayed after diagnosing by using Dr. ZX or the ser- vice mode of the monitor unit. • How to Read Troubleshooting Flow Charts YES (OK) After completing the checking and/or measuring procedures in box (1), ・...

  • Page 242: Mc Fault Code List

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE LIST Controller Hardware Failure Fault Trouble Cause Influenced Control Code 11000-2 Abnormal EEPROM Faulty MC All Controls 11001-2 Abnormal RAM Faulty MC All Controls 11002-2 Abnormal A/D (Analog to Digi- Faulty MC All Controls tal) Conversion 11003-3 Abnormal Sensor Voltage...
  • Page 243 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remark There is something wrong with machine operation. Retrial B Replace MC. There is something wrong with machine operation. Retrial B Replace MC. As the latest, normal value AD (analog to digital conversion) is Retrial B enabled, the machine may be operated incorrectly or slowly.
  • Page 244 TROUBLESHOOTING / Troubleshooting A Engine Failure Fault Trouble Cause Influenced Control Code 11103-3 Abnormal Accelerator Pedal Voltage: more than 4.75 V Pump Torque Decrease Con- High Voltage trol Engine Accelerator Pedal Control 11103-4 Abnormal Accelerator Pedal Voltage: less than 0.25 V Pump Torque Decrease Con- Low Voltage trol...
  • Page 245 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy The accelerator pedal is inoperable. Retrial B As engine speed kept at 1000 min (1000 rpm), the work may be Check the harness. inoperable. Replace the accelerator pedal. Replace MC.
  • Page 246 TROUBLESHOOTING / Troubleshooting A Pump Failure Fault Trouble Cause Influenced Control Code 11204-3 Abnormal Pump Delivery Output voltage: more than Disable Pump Torque Decrease Pressure Sensor High Volt- 4.75 V Control 11204-4 Abnormal Pump Delivery Output voltage: less than Disable Pump Torque Decrease Pressure Sensor Low Voltage 0.25 V Control...
  • Page 247 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As the pump is controlled by pump standard torque control, the Retrial B performance of the front attachment becomes low. Check the harness. Fuel consumption becomes bad. Replace the pump delivery pressure sensor.
  • Page 248 TROUBLESHOOTING / Troubleshooting A Pilot Failure Fault Trouble Cause Influenced Control Code 11312-3 Abnormal Brake Pedal Pres- Voltage: more than 4.75 V Clutch Cut Control sure Sensor High Voltage 11312-4 Abnormal Brake Pedal Pres- Voltage: less than 0.25 V Clutch Cut Control sure Sensor Low Voltage 11313-3 Abnormal Parking Brake Pres-...
  • Page 249 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As clutch cut control is disabled, the clutch cut is inoperable. Retrial B Fuel consumption becomes bad. Check the harness. Replace the brake pedal pressure sensor. Replace MC. As clutch cut control is disabled, the clutch cut is inoperable.
  • Page 250 TROUBLESHOOTING / Troubleshooting A Proportional Solenoid Valve Failure Fault Trouble Cause Influenced Control Code 11412-2 Abnormal Feedback of Hydraulic The feedback current Hydraulic Drive Cooling Drive Fan Flow Rate Control Sole- to MC becomes the Control noid Valve uncertain value. 11412-3 Abnormal Feedback High Current of The feedback current...
  • Page 251 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As the fan rotation is kept at maximum, the machine starts slowly. Retrial B Fuel consumption becomes bad. Check the harness. (Feedback line from the flow rate control solenoid valve to MC) Replace the hydraulic drive fan flow rate control solenoid valve.
  • Page 252 TROUBLESHOOTING / Troubleshooting A Fault Trouble Cause Influenced Control Code 11414-4 Abnormal Feedback Low Current of The feedback current All Transmission Controls Transmission Clutch Speed 1 Pro- to MC is 20 mA or less. portional Solenoid Valve 11415-2 Abnormal Feedback of Transmission The feedback current All Transmission Controls Clutch Speed 2 Proportional Sole-...
  • Page 253 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As speed is kept at speed 2 in spite of the shift switch, Retrial B there is some influence on the work. Check the harness. (Feedback line from the speed 1 proportional solenoid valve to MC) Replace the speed 1 proportional solenoid valve.
  • Page 254 TROUBLESHOOTING / Troubleshooting A Fault Trouble Cause Influenced Control Code 11417-3 Abnormal Feedback High Current of The feedback current All Transmission Controls Transmission Clutch Speed 4 Pro- to MC exceeds the portional Solenoid Valve upper limit. 11417-4 Abnormal Feedback Low Current of The feedback current All Transmission Controls Transmission Clutch Speed 4 Pro-...
  • Page 255 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As speed is kept at speed 2 in spite of the shift switch, Retrial B there is some influence on the work. Check the harness. (Feedback line from the speed 4 proportional solenoid valve to MC) Replace the speed 4 proportional solenoid valve.
  • Page 256 TROUBLESHOOTING / Troubleshooting A Transmission Failure Fault Trouble Cause Influenced Control Code 11600-3 Abnormal Vehicle Speed Sensor The abnormal value below All Transmission Controls is detected with the clutch connected. • Vehicle speed sensor=0 • Middle shaft sensor>300 • Torque converter output speed sensor>500 min •...
  • Page 257 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy As travel speed is calculated at the middle shaft sensor, Retrial B there is no influence on the machine. Travel speed moves Check the harness. over about 2 km/h when shifting the gears. Replace the vehicle speed sensor.
  • Page 258 TROUBLESHOOTING / Troubleshooting A CAN Data Reception Failure Fault Trouble Cause Influenced Control Code 11910-2 Actual Engine Speed Receive Faulty Harness Transmission Control Error Faulty ECM (Error judgment of engine Sent from ECM pulse sensor) 11914-2 Radiator Coolant Temperature Faulty Harness Hydraulic Drive Fan Cooling Receive Error Faulty Monitor Unit...
  • Page 259 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy Error of the torque converter input speed sensor cannot be Retrial B judged. Check the CAN communication line. Replace the engine speed sensor. Replace MC. As the fan rotation is always kept at maximum, the machine Retrial B starts slowly.
  • Page 260 TROUBLESHOOTING / Troubleshooting A Other Failures Fault Trouble Cause Influenced Control Code 11901-3 Hydraulic Temperature Voltage: more than 4.52 V Auto-Warming Up Control Sensor High Voltage Hydraulic Drive Fan Cooling Control 11901-4 Hydraulic Temperature Voltage: less than 0.23 V Auto-Warming Up Control Sensor Low Voltage Hydraulic Drive Fan Cooling Control...
  • Page 261 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs Remedy In low temperature (hydraulic oil temperature is less than 0 Retrial B °C (32 °F)), the auto-warming up control is impossible. Check the harness. Fuel consumption becomes bad. Replace the hydraulic oil temperature sensor.

  • Page 262: Ecm Fault Code List

    TROUBLESHOOTING / Troubleshooting A ECM FAULT CODE LIST Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 84-2 Wheel-Based Vehicle Speed-Data Erratic, Inter- Engine speed limited to Maximum Engine Speed mittent, or Incorrect. The ECM lost the vehicle without VSS parameter value. Cruise control, speed signal.
  • Page 263 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 97-3 Water in Fuel Indicator Sensor Circuit-Voltage None on performance. No water in fuel warning Above Normal, or Shorted to High Source. High available. voltage detected at the water in fuel circuit. 97-4 Water in Fuel Indicator Sensor Circuit-Voltage None on performance.
  • Page 264 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 100-18 Engine Oil Rifle Pressure-Data Valid but Below Engine protection TORQUE derate. Normal Operational Range-Moderately Severe Level. 102-2 Intake Manifold 1 Pressure-Data Erratic, Inter- Engine power derate. mittent, or Incorrect.
  • Page 265 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 105-0 Intake Manifold 1 Temperature-Data Valid but Progressive Engine protection SPEED derate Above Normal Operational Range-Most Severe increasing in severity from time of alert. If Engine Level. Intake manifold air temperature signal in- Protection Shutdown feature is enabled, engine dicates intake manifold air temperature above will shut down 30 seconds after stop Indicator...
  • Page 266 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 110-2 Engine Coolant Temperature-Data Erratic, Inter- The ECM will estimate engine coolant tempera- mittent, or Incorrect. The engine coolant tem- ture. perature reading is not changing with engine op- erating conditions.
  • Page 267 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 111-18 Coolant Level-Data Valid but Below Normal Op- None on performance. erational Range-Moderately Severe Level. Low coolant level has been detected. 157-0 Injector Metering Rail 1 Pressure-Data Valid but None or possible engine noise associated with Above Normal Operational Range-Most Severe higher injection pressures (especially at idle or...
  • Page 268 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 157-18 Injector Metering Rail 1 Pressure-Data Valid but Possibly hard to start, low power, or engine Below Normal Operational Range-Moderately smoke. Severe Level. The ECM has detected that fuel pressure is lower than commanded pressure.
  • Page 269 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 441-3 Auxiliary Temperature Sensor Input 1 Cir- None on performance. cuit-Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit de- tected at the OEM auxiliary temperature circuit. 441-4 Auxiliary Temperature Sensor Input 1 Cir- None on performance.
  • Page 270 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 625-2 OEM Datalink Cannot Transmit-Data Erratic, In- None on performance termittent, or Incorrect. Communications within the OEM datalink network is intermittent. 627-2 Power Supply Lost With Ignition On-Data Erratic, Possible no noticeable performance effects or Intermittent, or Incorrect.
  • Page 271 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 639-9 SAE J1939 Multiplexing PGN Timeout Er- At least one multiplexed device will not operate ror-Abnormal Update Rate. The ECM expected properly. information from a multiplexed device but did not receive it soon enough or did not receive it at all.
  • Page 272 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 651-5 Injector Solenoid Driver Cylinder 1 Circuit-Current Engine can possibly misfire or run rough. Below Normal, or Open Circuit. High resistance detected on injector Number 1 circuit or no cur- rent detected at Number 1 Injector driver or return pin when the voltage supply at the harness is on.
  • Page 273 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 656-5 Injector Solenoid Driver Cylinder 6 Circuit-Current Engine can possibly misfire or run rough. Below Normal, or Open Circuit. High resistance detected on injector Number 6 circuit or no cur- rent detected at Number 6 injector driver or return pin when the voltage supply at the harness is on.
  • Page 274 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 723-2 Engine Camshaft Speed / Position Sensor-Data Possible low power. Erratic, Intermittent, or Incorrect. Camshaft en- gine speed sensor intermittent synchronization. 723-7 Engine Speed / Position Camshaft and Crank- Engine will run derated.
  • Page 275 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 1075-3 Electric Lift Pump for Engine Fuel Supply Cir- Engine may be difficult to start. cuit-Voltage Above Normal, or Shorted to High Source. High voltage or open detected at the fuel lift pump signal circuit.
  • Page 276 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 1377-2 Multiple Unit Synchronization Switch-Data Er- None on performance. ratic, Intermittent, or Incorrect. 1388-3 Auxiliary Pressure Sensor Input 1 Circuit-Voltage None on performance. Above Normal, or Shorted to High Source. High signal voltage detected at the OEM pressure circuit.
  • Page 277 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Description (Reason) Fault Effect (Dr. ZX) 3510-4 Sensor Supply 2 Circuit-Voltage Below Normal, Engine power derate. or Shorted to Low Source. Low voltage detected at the sensor supply number 2 circuit. 3512-3 Sensor Supply 4 Circuit-Voltage Above Normal, Engine will only idle.

  • Page 278: Icf Fault Code List

    TROUBLESHOOTING/ Troubleshooting A ICF FAULT CODE LIST Fault Code Trouble Cause 14000-2 Abnormal CAN Communication Data cannot be received due to the noise on the CAN bus line. 14001-2 ICF: Flash Memory: Read / Write The internal memory is abnormal when the key is turned ON. Error 14002-2 ICF: External RAM: Read / Write...
  • Page 279 TROUBLESHOOTING/ Troubleshooting A Remedy If trouble is not resolved after retrial B, check the CAN communication bus line. After initializing the information C/U by using Dr. ZX, retry in the troubleshooting. If the error code is displayed after retrial, ICF may be broken. Replace ICF.

  • Page 280: Satellite Terminal Fault Code List

    TROUBLESHOOTING/ Troubleshooting A SATELLITE TERMINAL FAULT CODE LIST Fault Code Trouble Cause 14100-2 Satellite Communication Terminal: The internal memory is abnormal. Abnormal EEPROM 14101-2 Satellite Communication Terminal: The internal memory is abnormal. Abnormal IB/OB Queue 14102-2 Satellite Communication Terminal: The data cannot be received from the satellite terminal. Abnormal Local Loop Back 14103-2 Satellite Communication Terminal:...
  • Page 281 TROUBLESHOOTING/ Troubleshooting A Remedy Retrial B Replace the ICF controller. Retrial B Replace the ICF controller. Retrial B Check the communication antenna for the satellite. Replace the ICF controller. Retrial B Check the communication antenna for the satellite. Replace the ICF controller. Retrial B Replace the ICF controller.

  • Page 282: Monitor Unit Fault Code List

    TROUBLESHOOTING/ Troubleshooting A MONITOR UNIT FAULT CODE LIST Fault Code Trouble Cause 13306-2 Abnormal EEPROM Failure reading EEPROM occurs. 13308-2 Abnormal CAN Communication Bus off occurs beyond five times. 13312-2 Abnormal Transmission Shorted ground circuit in the transmission oil temperature Temperature Sensor sensor.

  • Page 283: Controller Hardware Failure Mc Fault Codes 11000 To 11002

    TROUBLESHOOTING / Troubleshooting A CONTROLLER HARDWARE FAILURE MC FAULT CODES 11000 to 11002 Fault Code Trouble Cause Influenced Control 11000-2 Abnormal EEPROM Faulty MC All Controls 11001-2 Abnormal RAM Faulty MC All Controls 11002-2 Abnormal A/D Conversion Faulty MC All Controls *Normal.

  • Page 284: Mc Fault Code 11003

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11003 Fault Code Trouble Cause Influenced Control 11003-3 Abnormal Sensor Voltage Shorted circuit in harness All Controls Faulty sensor Faulty MC Faulty any sensors. Disconnect connectors of Disconnect all connectors at all sensors corresponding MC end.

  • Page 285: Mc Fault Code 11004

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11004 Fault Code Trouble Cause Influenced Control • 11004-2 Abnormal Shorted circuit All Pump Controls • Communication harness All Transmission Controls • Faulty MC All Engine Controls • Hydraulic Drive Fan Cooling Control •...

  • Page 286: Can Harness Check

    TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK • Check the wiring connections first. Open circuit in CAN harness between MC and ECM. Check for continuity in CAN harness between MC and ECM. Check for continuity in CAN harness · Key switch: OFF between MC and ·...
  • Page 287 TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between ground Disconnect all circuit and CAN circuit. connectors in MC, ICF, ECM and monitor unit. Check for continuity between CAN circuit and ground circuit in MC, ICF, ECM and monitor unit. To A ·...
  • Page 288 TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness. Check the Connect connector connection of MC in MC. and connector. Check if fault code Connect all 11004-2 is Faulty MC. connectors except displayed. connector MC-C in · Key switch: ON Check if resistance Check the between terminals...
  • Page 289 TROUBLESHOOTING / Troubleshooting A Check the connection of ECM and connector. Faulty ECM. Check the connection of monitor unit and Connect connector in connector. monitor unit. Check if fault code Faulty monitor unit. 11004-2 is displayed. · Key switch: ON Failure in any controller of MC, ICF, ECM and monitor unit.
  • Page 290 TROUBLESHOOTING / Troubleshooting A CAN Harness Continuity Check 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 #46 of harness end of connector ECM-B in ECM.
  • Page 291 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...
  • Page 292 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 #33 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...
  • Page 293 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Ground Circuit Connector IMPORTANT: Before continuity check, turn the key Connector MC-C switch OFF. (Harness end) • In case of continuity, the circuit between CAN circuit and ground circuit is shorted. •...
  • Page 294 TROUBLESHOOTING / Troubleshooting A Between CAN Circuit (Low Side) and Ground Circuit Connector Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A2 Connector MC-C of harness end of connector MC-A. (Harness end) #C15 Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A13 of harness end of connector MC-A.
  • Page 295 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Ground Circuit Check for continuity between terminal #46 of Connector ECM-B (Harness end) harness end of connector ECM-B and terminal #1 of harness end of connector ECM-A. Check for continuity between terminal #46 of harness end of connector ECM-B and terminal #2 of harness end of connector ECM-A.
  • Page 296 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Ground Circuit Connector ICF-C (Harness end) Check for continuity between terminals #C5 and #C9 of harness end of connector ICF-C. Check for continuity between terminals #C5 and #C14 of harness end of connector ICF-C. Check for continuity between terminals #C5 and T1V1-05-04-002 #C14...
  • Page 297 TROUBLESHOOTING / Troubleshooting A • Monitor Unit Monitor Unit Connector Monitor-2B Between CAN Circuit (High Side) and Ground (Harness end) Circuit Check for continuity between terminal #33 of harness end of connector monitor-2B and terminal #19 of harness end of connector monitor-2A. Check for continuity between terminal #33 of harness end of connector monitor-2B and terminal T4GB-05-05-002...
  • Page 298 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Power Circuit Connector IMPORTANT: Before continuity check, turn the key Connector MC-C switch OFF. (Harness end) • In case of continuity, the circuit between CAN circuit and power circuit is shorted. •...
  • Page 299 TROUBLESHOOTING / Troubleshooting A Between CAN Circuit (Low Side) and Power Circuit Connector Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A2 Connector MC-C of harness end of connector MC-A. (Harness end) #C15 Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A12 of harness end of connector MC-A.
  • Page 300 TROUBLESHOOTING / Troubleshooting A • Check for continuity between terminal #46 of harness end of connector ECM-B and terminal #1 Connector ECM-B of harness end of connector ECM-A. (Harness end) Check for continuity between terminal #46 of harness end of connector ECM-B and terminal #2 of harness end of connector ECM-A.
  • Page 301 TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Power Monitor Unit Circuit Connector Monitor-2B (Harness end) Check for continuity between terminal #33 of harness end of connector monitor-2B and terminal #1 of harness end of connector monitor-1A. T4GB-05-05-002 Monitor Unit Connector Monitor-1A...
  • Page 302 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Key Signal Circuit Connector IMPORTANT: Before continuity check, turn the key Connector MC-C (Harness end) switch OFF. • In case of continuity, the circuit between CAN circuit and key signal circuit is shorted.
  • Page 303 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Key Signal Circuit Connector ECM-B (Harness end) Check for continuity between terminals #46 and #39 of harness end of connector ECM-B. T4GD-05-05-001 Between CAN Circuit (Low Side) and Key Signal Circuit Connector ECM-B Check for continuity between terminals #47 and...
  • Page 304 TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Key Signal Monitor Unit Connector Monitor-2B Circuit (Harness end) Check for continuity between terminal #33 of harness end of connector monitor-2B and terminal #2 of harness end of connector monitor-1A. T4GB-05-05-002 Monitor Unit Connector Monitor-1A...
  • Page 305 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.

  • Page 306: Engine Failure Mc Fault Code 11103

    TROUBLESHOOTING / Troubleshooting A ENGINE FAILURE MC FAULT CODE 11103 Fault Code Trouble Cause Influenced Control • 11103-3 Abnormal Accelerator Pedal Voltage: more than 4.75 V Pump Torque Decrease High Voltage Control • Engine Accelerator Pedal Control • 11103-4 Abnormal Accelerator Pedal Voltage: less than 0.25 V Pump Torque...

  • Page 307: Mc Fault Code 11105

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11105 Fault Code Trouble Cause Influenced Control • 11105-3 Abnormal Torque Converter Engine speed=0 min Hydraulic Drive Fan Cooling Input Shaft Sensor ECM engine speed>500 min Control Disconnect connector Open circuit in hranees MC-C in MC.

  • Page 308: Pump Failure Mc Fault Code 11204

    TROUBLESHOOTING / Troubleshooting A PUMP FAILURE MC FAULT CODE 11204 Fault Code Trouble Cause Influenced Control • 11204-3 Abnormal Pump Delivery Output voltage: more than Disable Pump Torque Pressure Sensor High Voltage 4.75 V Decrease Control • 11204-4 Abnormal Pump Delivery Output voltage: less than 0.25 Disable...

  • Page 309: Pilot Failure Mc Fault Code 11312

    TROUBLESHOOTING / Troubleshooting A PILOT FAILURE MC FAULT CODE 11312 Fault Code Trouble Cause Influenced Control • 11312-3 Abnormal Brake Pedal Voltage: more than 4.75 V Clutch Cut Control Pressure Sensor (Service Brake Pressure Sensor) High Voltage • 11312-4 Abnormal Brake Pedal Voltage: less than 0.25 V...

  • Page 310: Mc Fault Code 11313

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11313 Fault Code Trouble Cause Influenced Control • 11313-3 Abnormal Parking Brake Output voltage: more than Parking Brake Indicator Control Pressure Sensor High Voltage 4.75 V • 11313-4 Abnormal Parking Brake Output voltage: less than 0.25 Parking Brake Indicator Control Pressure Sensor Low Voltage Disconnect connector...

  • Page 311: Proportional Solenoid Valve Failure Mc Fault Code 11412

    TROUBLESHOOTING / Troubleshooting A PROPORTIONAL SOLENOID VALVE FAILURE MC FAULT CODE 11412 Fault Code Trouble Cause Influenced Control 11412-2 Abnormal Feedback of Hydraulic The feedback current to MC Hydraulic Drive Fan Cooling Drive Fan Flow Rate Control becomes the uncertain value. Control Solenoid Valve 11412-3...

  • Page 312: Mc Fault Code 11413

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11413 Fault Code Trouble Cause Influenced Control • 11413-2 Abnormal Feedback of Pump The feedback current to MC Pump Standard Torque Control Torque Control Solenoid Valve becomes the uncertain value. • 11413-3 Abnormal Feedback High The feedback current to MC...

  • Page 313: Mc Fault Code 11414, 11415, 11416, 11417, 11418, 11419

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODES 11414, 11415, 11416, 11417, 11418, 11419 Fault Code Trouble Cause Influenced Control • 11414-2 Abnormal Feedback of The feedback current to MC All Transmission Controls Transmission Clutch Speed 1 becomes the uncertain value. Proportional Solenoid Valve •...
  • Page 314 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • 11418-2 Abnormal Feedback of The feedback current to MC All Transmission Controls Transmission Clutch Forward becomes the uncertain value. Proportional Solenoid Valve • 11418-3 Abnormal Feedback High The feedback current to MC All Transmission Controls Current of Transmission Clutch exceeds the upper limit.
  • Page 315 TROUBLESHOOTING / Troubleshooting A Faulty proportional Replace connector of solenoid valve. proportional solenoid valve. Retry. Check if fault Faulty MC. code disappears. Check for continuity in harness between MC and proportional solenoid valve. · Refer to the tabel below. Open circuit in harness. Connector (Harness end of connector viewed from the open end side) Connector MC-A...

  • Page 316: Transmission Failure Mc Fault Code 11600

    TROUBLESHOOTING / Troubleshooting A TRANSMISSION FAILURE MC FAULT CODE 11600 Fault Code Trouble Cause Influenced Control 11600-3 Abnormal Vehicle Speed Sensor The abnormal value below is All Transmission Controls detected with clutch connected. • Vehicle speed sensor=0 • Middle shaft sensor>300 •...

  • Page 317: Mc Fault Code 11601

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11601 Fault Code Trouble Cause Influenced Control • 11601-3 Abnormal Torque Converter The abnormal value below is Pump Torque Decrease Output Speed Sensor detected with clutch Control connected. • Torque converter output speed sensor=0 min •...

  • Page 318: Mc Fault Code 11602

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11602 Fault Code Trouble Cause Influenced Control • 11602-3 Abnormal Transmission Middle The abnormal value below is All Transmission Controls Shaft Sensor detected with clutch connected. • Middle shaft sensor =0 min • Vehicle speed sensor>500 •...

  • Page 319: Mc Fault Code 11904

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11904 Fault Code Trouble Cause Influenced Control 11904-2 Abnormal FNR Lever The forward/reverse signals All Transmission Controls are turned ON for 80 ms or longer at the same time. Shorted circuit in harness between between connector of FNR lever and Disconnect connector...

  • Page 320: Mc Fault Code 11905

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11905 Fault Code Trouble Cause Influenced Control 11905-2 Abnormal FNR Switch The forward/reverse signals All Transmission Controls are turned ON for 80 ms or longer at the same time. Shorted circuit in harness between between connector of FNR switch and Disconnect connector...

  • Page 321: Can Data Reception Failure Mc Fault Codes 11910, 11920

    TROUBLESHOOTING / Troubleshooting A CAN DATA RECEPTION FAILURE MC FAULT CODES 11910, 11920 Fault Code Trouble Cause Influenced Control • Actual Engine Speed Receive Faulty Harness Pump Torque Decrease Control 11910-2 • Error Faulty ECM Hydraulic Drive Fan Cooling Sent from ECM Control •...

  • Page 322: Can Harness Check Mc Fault Codes 11910, 11920

    TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODES 11910, 11920 • Check the wiring connections first. Shorted circuit in CAN harness between ground Disconnect all circuit and CAN circuit. connectors of MC, ICF, ECM and monitor unit. Check for continuity between ground circuit (MC, ICF, ECM, Check for continuity...
  • Page 323 TROUBLESHOOTING / Troubleshooting A Check the connections of Connect connector MC and connector. in MC. Check if fault code 11004-2 is Faulty MC. displayed. · Key switch: ON Check the connections of Connect connector ECM and connector. in MC. Check if fault code 11004-2 is Faulty ECM.
  • Page 324 TROUBLESHOOTING / Troubleshooting A (Blank) T5-5-84...

  • Page 325: Mc Fault Code 11914

    TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11914 Fault Code Trouble Cause Influenced Control • 11914-2 Radiator Coolant Faulty Harness Hydraulic Drive Fan Cooling Control Temperature Receive Error Faulty Monitor Unit Sent from Monitor Unit Monitor Unit Dr. ZX CAN Harness T5-5-85...

  • Page 326: Can Harness Check Fault Code 11914

    TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK FAULT CODE 11914 • Check the wiring connections first. Disconnect all Open circuit in CAN connectors of MC, ICF, harness between ground ECM and monitor unit. circuit and CAN circuit. Check for continuity between ground circuit Check for continuity (MC, ICF, ECM,...
  • Page 327 TROUBLESHOOTING / Troubleshooting A Check the connections of Connect connector MC and connector. in MC. Check if fault code 11004-2 is displayed. Faulty MC. · Key witch: ON Check the connections of Connect connector monitor unit and in monitor unit. connector.
  • Page 328 TROUBLESHOOTING / Troubleshooting A (Blank) T5-5-88...

  • Page 329: Other Failures Mc Fault Code 11901

    TROUBLESHOOTING / Troubleshooting A OTHER FAILURES MC FAULT CODE 11901 Fault Code Trouble Cause Influenced Control • 11901-3 Hydraulic Temperature Voltage: more than 4.52 V Auto Warming-Up Control • Sensor High Voltage Hydraulic Drive Fan Cooling Control • Auto Warming-Up Control 11901-4 Hydraulic Temperature...

  • Page 330: Check

    TROUBLESHOOTING / Troubleshooting PROPORTIONAL SOLENOID VALVE Proportional TROUBLE CHECK Solenoid Valve When the harness in the proportional solenoid valve is faulty, the fault code may be not detected. If the trouble related proportional solenoid valve, disconnect the connectors between MC the and T1V1-05-06-008 proportional solenoid valve.
  • Page 331 TROUBLESHOOTING / Troubleshooting Circuit Condition in Trouble Trouble Fault Code Damaged Parts in MC Shorted circuit in harness Resistance × between A-B and C-D T1V1-05-06-015 • Open circuit in A- B None • Harness in side A is shorted to △...
  • Page 332 TROUBLESHOOTING / Troubleshooting A (Blank) T5-5-92...

  • Page 333: Ecm Fault Code Contrast List

    TROUBLESHOOTING / Troubleshooting A ECM FAULT CODE CONTRAST LIST Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 84-2 Wheel-Based Vehicle Speed-Data Erratic, Inter- Service Indicator mittent, or Incorrect. The ECM lost the vehicle speed signal. 84-10 Wheel-Based Vehicle Speed Sensor Circuit Service Indicator tampering has been detected-Abnormal Rate of...
  • Page 334 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 97-3 Water in Fuel Indicator Sensor Circuit-Voltage Service Indicator Above Normal, or Shorted to High Source. High voltage detected at the water in fuel circuit. 97-4 Water in Fuel Indicator Sensor Circuit-Voltage Service Indicator...
  • Page 335 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 100-18 Engine Oil Rifle Pressure-Data Valid but Below Service Indicator Normal Operational Range-Moderately Severe Level. 102-2 Intake Manifold 1 Pressure-Data Erratic, Inter- 2973 Service Indicator mittent, or Incorrect.
  • Page 336 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 105-0 Intake Manifold 1 Temperature-Data Valid but Stop Indicator Above Normal Operational Range-Most Severe Level. Intake manifold air temperature signal indicates intake manifold air temperature above engine protection critical limit.
  • Page 337 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 110-2 Engine Coolant Temperature-Data Erratic, Inter- Service Indicator mittent, or Incorrect. The engine coolant tem- perature reading is not changing with engine op- erating conditions. 110-3 Engine Coolant Temperature 1 Sensor Cir- Service Indicator...
  • Page 338 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 111-18 Coolant Level-Data Valid but Below Normal Op- Service Indicator erational Range-Moderately Severe Level. Low coolant level has been detected. 157-0 Injector Metering Rail 1 Pressure-Data Valid but Stop Indicator Above Normal Operational Range-Most Severe Level.
  • Page 339 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 157-18 Injector Metering Rail 1 Pressure-Data Valid but Service Indicator Below Normal Operational Range-Moderately Severe Level. The ECM has detected that fuel pressure is lower than commanded pressure. 168-16 Battery 1 Voltage-Data Valid but Above Normal Service Indicator...
  • Page 340 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 441-3 Auxiliary Temperature Sensor Input Cir- Service Indicator cuit-Voltage Above Normal, or Shorted to High Source. High signal voltage or open circuit de- tected at the OEM auxiliary temperature circuit. 441-4 Auxiliary Temperature Sensor Input 1 Cir- Service Indicator...
  • Page 341 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 625-2 OEM Datalink Cannot Transmit-Data Erratic, In- 1633 Service Indicator termittent, or Incorrect. Communications within the OEM datalink network is intermittent. 627-2 Power Supply Lost With Ignition On-Data Erratic, 1117 None Intermittent, or Incorrect.
  • Page 342 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 639-9 SAE J1939 Multiplexing PGN Timeout Er- Service Indicator ror-Abnormal Update Rate. The ECM expected information from a multiplexed device but did not receive it soon enough or did not receive it at all. 639-13 SAE J1939 Multiplexing Configuration Error-Out Service Indicator...
  • Page 343 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 651-5 Injector Solenoid Driver Cylinder 1 Circuit-Current Service Indicator Below Normal, or Open Circuit. High resistance detected on injector Number 1 circuit or no cur- rent detected at Number 1 Injector driver or return pin when the voltage supply at the harness is on.
  • Page 344 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 656-5 Injector Solenoid Driver Cylinder 6 Circuit-Current Service Indicator Below Normal, or Open Circuit. High resistance detected on injector Number 6 circuit or no cur- rent detected at Number 6 injector driver or return pin when the voltage supply at the harness is on.
  • Page 345 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 723-2 Engine Camshaft Speed / Position Sensor-Data 2322 None Erratic, Intermittent, or Incorrect. Camshaft en- gine speed sensor intermittent synchronization. 723-7 Engine Speed / Position Camshaft and Crank- Service Indicator shaft Misalignment-Mechanical System Not Re- sponding Properly or Out of Adjustment.
  • Page 346 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 1075-3 Electric Lift Pump for Engine Fuel Supply Cir- 2265 Service Indicator cuit-Voltage Above Normal, or Shorted to High Source. High voltage or open detected at the fuel lift pump signal circuit.
  • Page 347 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 1377-2 Multiple Unit Synchronization Switch-Data Er- Service Indicator ratic, Intermittent, or Incorrect. 1388-3 Auxiliary Pressure Sensor Input 1 Circuit-Voltage Service Indicator Above Normal, or Shorted to High Source. High signal voltage detected at the OEM pressure circuit.
  • Page 348 TROUBLESHOOTING / Troubleshooting A Fault Code Fault Code Fault Description (Cause) Lighting Indicator (Dr. ZX) (INSITE) 3510-4 Sensor Supply 2 Circuit-Voltage Below Normal, Service Indicator or Shorted to Low Source. Low voltage detected at the sensor supply number 2 circuit. 3512-3 Sensor Supply 4 Circuit-Voltage Above Normal, 2185...

  • Page 349: Icf, Satellite Terminal Fault Codes 14000To14003

    TROUBLESHOOTING / Troubleshooting A ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003 Fault Code Trouble Remedy 14000-2 Abnormal CAN Communication Execute retrial B in self-diagnosing. If this error code is displayed after retrial, check the following item. • Check the CAN communication line (harness). 14001-2 ICF: Flash Memory Execute retrial B in self-diagnosing and execute the...
  • Page 350 TROUBLESHOOTING / Troubleshooting A Information C/U：Initialize After starting Dr. ZX, push Select Push Start. Push Information C/U. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Controller Selection Screen Title Screen Function Selection Screen Push Information C/U: Various Push Information C/U: Initialize. Push OK.
  • Page 351 TROUBLESHOOTING / Troubleshooting A Control Data: Initialize After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push Information C/U: Various Push OK. Push Control Data: Initialize. setup.
  • Page 352 TROUBLESHOOTING / Troubleshooting A Enter Model and Serial No. After starting Dr. ZX, push Select Push Information C/U. Push Start. Controller. To the lower T4GB-05-02-053 T4GD-05-02-013 T1V7-05-03-001 Title Screen Function Selection Screen Controller Selection Screen Push Information C/U: Various Push OK. Push Enter Model and Serial No.

  • Page 353: Icf, Satellite Terminal Fault Codes 14006, 14008, 14100 To 14106

    TROUBLESHOOTING / Troubleshooting A ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106 Fault Code Trouble Remedy 14006-2 ICF: Satellite Communication Execute retrial B in self-diagnosing. Terminal Communication Error If this error code is displayed after retrial, check the following item.
  • Page 354 TROUBLESHOOTING / Troubleshooting A Fault Codes 14102-2, 14103-2 Communication GPS Antenna Antenna T4GB-05-07-002 Satellite Terminal Communication Antenna GPS Antenna T1V1-05-06-004 T5-5-114...

  • Page 355: Monitor Unit Fault Codes 13306, 13308

    TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODES 13306, 13308 Fault Code Trouble Remedy 13306-2 Abnormal EEPROM If this error code is displayed after retrial, replace the monitor unit. 13308-2 Abnormal CAN Communication Execute retrial. Refer to “Check CAN Harness” (T5-5-54). T5-5-115...

  • Page 356: Monitor Unit Fault Code 13312

    TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13312 Fault Code Trouble Remedy 13312-2 Abnormal Transmission Execute retrial. Temperature Sensor Check the transmission oil temperature sensor and the harness. Shorted circuit in harness With sensor connector between monitor unit and disconnected, check for sensor.

  • Page 357: Monitor Unit Fault Code 13314

    TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13314 Fault Code Trouble Remedy 13314-3 Service Brake Pressure Sensor High Execute retrial. Voltage Check the service brake pressure sensor and the harness. 13314-4 Service Brake Pressure Sensor Low Execute retrial. Voltage Check the service brake pressure sensor and the harness.
  • Page 358 TROUBLESHOOTING / Troubleshooting A (Blank) T5-5-118...

  • Page 359: Troubleshooting B Procedure

    TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when no fault code is displayed on the service mode 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.
  • Page 360 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 machine Item Symptoms in control sys- Function...
  • Page 361 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) T2-1, T2-4 Monitor Item: MC: 11904 switch, Selected speed gear, Actual speed gear, Backward alarm, Neutral signal MC Monitor Item: Selected T2-1, T2-4 speed gear, Actual speed gear, Speed gear...
  • Page 362 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This switch sends the MC makes FNR switch The machine cannot travel FNR Switch command signal on control disabled during the forward/reverse by using the forward/reverse to MC.
  • Page 363 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) • MC Monitor Item: Implement Although the FNR lever is operated and T2-1 MC: 11905 FNR switch, Selected speed the FNR switch operation is disabled gear, Actual speed gear, during the work, this contition is normal.
  • Page 364 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This sensor sends the MC fixes engine speed to As the accelerator pedal is Accelerator Pedal Sensor command signal on 1100 min depressed and engine speed...
  • Page 365 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) • MC Monitor Item: Required If MC malfunctions, ECM set engine MC: 11103 T2-1 engine speed deviation, En- speed to 1100min .
  • Page 366 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This sensor sends the signal Air temperature cannot be Just after the engine starts, Fresh Air Temperature on air temperature to MC.
  • Page 367 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) • MC Monitor Item: Outside air The cooling fan rotates slowly just after temperature the engine starts. At this time, if the air conditioner switch is turned ON, the air conditioning becomes weak.
  • Page 368 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This sensor sends the signal MC cannot calculate travel If the travel speed sensor Transmission Middle on trasmission middle shaft speed.
  • Page 369 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) MC: 5160, 5660, 5665, MC Monitor Item: Middle T2-1, T3-9 5670, 5675, 5680, 5685 gear speed MC: 11602 MC Monitor Item: Travel T2-1, T3-9 speed, Transmission output speed...
  • Page 370 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This valve supplies front/rear Main pump delivery flow rate pressure difference Negative Control Valve in pressures at the orifice in cannot controlled...
  • Page 371 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) If vehicle becomes small, pump delivery T2-3, T3-2 pressure becomes over 2 MPa (20kgf/cm when the engine speed is at fast idle in neutral.
  • Page 372 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This valve supplies lift arm Pressure cannot Ride control is not operated. Ride Control Valve cylinder bottom pressure to accumulated (Shock when traveling is...
  • Page 373 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) • MC Monitor Item: Ride con- vehicle speed sensor T2-1, T2-3, T3-8 trol proportional valve out- malfunctions, MC makes ride control put, Ride control propor- disabled.
  • Page 374 TROUBLESHOOTING / Troubleshooting B Item Symptoms in machine Symptoms in control sys- Parts Function operation when trouble tem when trouble occurs. occurs. • • • This block divides pilot pump Stable pressure cannot be brake pressure Charging Block pressure oil into the brake supplied to the brake circuit indicator lights.
  • Page 375 TROUBLESHOOTING / Troubleshooting B Descriptions of Control Evaluation by Fault Evaluation by Monitor NOTE (Operational Principle Code Function Section in T/M) T2-3, T3-7 T2-3, T3-7 Monitor Unit: 13314 Monitor Unit Monitor Item: T2-3, T3-7 Service brake pressure T2-3, T3-7 MC: 11413 MC Monitor Item: Pump dis- T2-1, T2-3, T3-7 placement proportional valve...

  • Page 376: Correlation Between Trouble Symptoms And Part Failures

    TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES Related, required to check This table indicates the relationship between machine : Related. However, in case this component fails, other trouble troubles and parts contributing to the cause of the symptom will be more noticeable so that this component will trouble if failed.
  • Page 377 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at scribed provided that each trouble occurs the same time, find out all faulty compo- independently. nents while checking all suspected com- ponents in each trouble symptom.
  • Page 378 TROUBLESHOOTING / Troubleshooting B Front Attachment System Troubleshooting Trouble All front attachments does not All front attachment opera- Certain front attachment is Symptom move. tions are slow/ weak. slow/ weak. Parts Shift Switch Work Mode Selector Switch Accelerator Pedal Sensor Lift Arm Proximity Switch Torque Converter Input Speed Sensor Torque Converter Output Speed Sen-...
  • Page 379 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at scribed provided that each trouble occurs the same time, find out all faulty compo- independently. nents while checking all suspected com- ponents in each trouble symptom.
  • Page 380 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at scribed provided that each trouble occurs the same time, find out all faulty compo- independently. nents while checking all suspected com- ponents in each trouble symptom.
  • Page 381 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-23...
  • Page 382 TROUBLESHOOTING / Troubleshooting B Travel System Troubleshooting Machine does Machine does Machine moves with Even if travel speed is Trouble travel for- travel forward or re- lever in neutral. turned up or down, Symptom ward/reverse. verse. travel speed gear is not changed.
  • Page 383 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at scribed provided that each trouble occurs the same time, find out all faulty compo- independently. nents while checking all suspected com- ponents in each trouble symptom.
  • Page 384 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at scribed provided that each trouble occurs the same time, find out all faulty compo- independently. nents while checking all suspected com- ponents in each trouble symptom.
  • Page 385 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-27...
  • Page 386 TROUBLESHOOTING / Troubleshooting B Brake System Troubleshooting Trouble Symptom Parking brake is not Parking brake is Service brake effi- released. not locked. ciency is bad or low. Parts Parking Brake Relay 1 Parking Brake Relay 2 Monitor Unit Parking Brake Switch Parking Brake Service Brake Pilot Pump...
  • Page 387 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-29...
  • Page 388 TROUBLESHOOTING / Troubleshooting B Steering/Other System Troubleshooting Trouble Symptom Steering cylinder op- Air conditioner is eration is slow or does faulty. not move. 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...
  • Page 389 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-31...

  • Page 390: Engine System Troubleshooting

    TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate. As current from the key switch is IMPORTANT: not routed to the starter relay with the FNR lever or FNR switch in Forward or Reverse position, the starter does not rotate. (Re- fer to SYSTEM / Electrical Sys- tem.) •...
  • Page 391 TROUBLESHOOTING / Troubleshooting B Faulty starter, or faulty harness between starter and battery relay. Check if voltage at terminal A in battery relay is 24 V. Check if voltage at Faulty battery relay. terminal #1 of har- ness end of con- Disconnect connector nector in neutral re- of starter relay.
  • Page 392 TROUBLESHOOTING / Troubleshooting B E-2 Even if starter rotates, engine does not start • Check the wiring connections first. • Check if the fuel system is faulty, the fuel filter is clogged, or the fuel pump works properly when the key is turned ON. Faulty ECM relay.
  • Page 393 TROUBLESHOOTING / Troubleshooting B Open circuit in har- ness or fuse be- Disconnect tween key switch connector ICF-C and monitor unit. in ICF. Check if voltage between terminal #C7 of harness Check if voltage Open circuit in har- end of connector between terminal ness or fuse be- and body is...
  • Page 394 TROUBLESHOOTING / Troubleshooting B E-3 Engine is difficult to start at low temperature • Check the battery. NOTE: When there is no fault in any of the follow- • Check the wiring connections first. ings and starting of engine is not smooth only when the engine is cold, the fuel pump performance may be deteriorated.
  • Page 395 TROUBLESHOOTING / Troubleshooting B Faulty intake-air heater, faulty intake-air heater relay or faulty EMC. Check for continuity be- tween terminal #42 of harness end of connector ECM-B and body. Open circuit in harness be- tween terminal A in intake-air heater relay and ECM. Open circuit in harness be- tween terminal B in intake-air heater relay and ECM.
  • Page 396 TROUBLESHOOTING / Troubleshooting B E-4 Even if accelerator pedal is depressed, en- gine 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.
  • Page 397 TROUBLESHOOTING / Troubleshooting B E-5 Even if key switch is turned OFF, engine does not stop. • Check the wiring connections first. • The trouble may occur such that even if accel- erator pedal is depressed, engine speed remains unchanged. Execute the troubleshooting proce- dures on this trouble.
  • Page 398 TROUBLESHOOTING / Troubleshooting B E-6 Engine stalls during operation under ad- verse 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 when the key is turned ON.

  • Page 399: Front Attachment System Troubleshooting

    TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROU- BLESHOOTING F-1 All front attachments do not move. Faulty pilot shut-off valve. Check if pressure at port P in pilot shut-off valve is within specification. Normal. Disassemble, · Specification: + 0.5 clean and adjust MPa (38 −...
  • Page 400 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.
  • Page 401 TROUBLESHOOTING / Troubleshooting B Faulty MC. Monitor pump dis- placement propor- tional solenoid valve output of MC monitor item by using Dr. ZX. Check if output is 1 Check if pressure at MPa (10 kg/cm ) or port ST in main pump To B less.
  • Page 402 TROUBLESHOOTING / Troubleshooting B 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.
  • Page 403 TROUBLESHOOTING / Troubleshooting B F-4 Front attachment moves with lever in neu- tral. • 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. Faulty pilot valve.
  • Page 404 TROUBLESHOOTING / Troubleshooting B F-5 Front attachment drifts remarkably. Normal. Check if cylinder drift Replace with other in each front attach- overload relief valve ment is within speci- temporarily. fication. Check if symptom · Engine: Running disappears. · Refer to OPERA- Lock pilot shut-off TIONAL PER- ·...
  • Page 405 TROUBLESHOOTING / Troubleshooting B Scored control valve spool, broken spring, or loose spool end. Check if oil leaks in cylinders. · Refer to the fol- Faulty cylinder. (Replace lowings. seal kit.) Faulty overload relief valve. T5-6-47...
  • Page 406 TROUBLESHOOTING / Troubleshooting B F-6 Bucket is slow during combined operation. Refer to “F-3 Certain front attachment is slow/ weak” in T5-6. Check if each cylinder speed in front attach- ment is normal. · Engine: Running · Refer to OPERA- Faulty bucket flow rate TIONAL PER- control valve in control...
  • Page 407 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-49...
  • Page 408 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 con- sumption becomes bad, this trouble may come out.
  • Page 409 TROUBLESHOOTING / Troubleshooting B F-8 Lift arm height kickout is not operated. • Check the wiring connections first. Connect terminal #2 of harness end of con- Faulty electromagnet nector in electromag- at lift arm raise side. net at lift arm raise side to body.
  • Page 410 TROUBLESHOOTING / Troubleshooting B F-9 Lift arm float is not operated. • Check the wiring connections first. Faulty electromagnet at lift arm lower side. Connect terminal #1 of harness end of connec- tor in electromagnet at lift arm lower side to body.
  • Page 411 TROUBLESHOOTING / Troubleshooting B F-10 Bucket auto leveler is not operated. • Check the wiring connections first. Connect terminal #2 of harness end of Faulty electromagnet connector in elec- at bucket tilt side. tromagnet at bucket tilt side to body. Operate bucket.
  • Page 412 TROUBLESHOOTING / Troubleshooting B F-11 Lift arm auto leveler is not operated. (Op- tional) • Check the wiring connections first. To A Check if boom angle of MC monitor item by using Dr. ZX is 3.78±0.5 V with lift arm at the highest position.
  • Page 413 TROUBLESHOOTING / Troubleshooting B Faulty lift arm auto leveler switch. Disconnect abnor- mal connector in lift arm auto leveler Connect terminal #2 of switch. harness end of con- Ground terminal #2 nector in lift arm auto of harness end of Open circuit in har- leveler switch to body.
  • Page 414 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 mal- function.
  • Page 415 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-57...
  • Page 416 TROUBLESHOOTING / Troubleshooting B F-13 Ride control is not effective. • Check the wiring connections first. • When trouble occurs in main circuit system and pilot oil system 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.
  • Page 417 TROUBLESHOOTING / Troubleshooting B Faulty MC. Monitor transmis- sion output speed of TCU monitor item on Dr. ZX. Check if 850 min displayed on Dr. ZX Faulty vehicle speed screen when travel- sensor. ing at 10 km/h. If travel speed in- creases or decreases at former section, dis- Faulty vehicle speed...

  • Page 418: Travel System Troubleshooting

    TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Machine does travel for- ward/reverse. • • Machine can travel only when the following con- Check the wiring connections first. • ditions are present. If the followings are normal, the transmission and FNR Lever: F or R axles (front, rear) may be faulty.
  • Page 419 TROUBLESHOOTING / Troubleshooting B Monitor parking brake pressure switch of To B monitor unit monitor item on Dr. ZX. Open circuit in har- Check if pressure is ness in MC or be- displayed by using tween MC and moni- outline characters on tor unit.
  • Page 420 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 are normal, the pilot pump, pilot filter and pilot relief valve may be normal.
  • Page 421 TROUBLESHOOTING / Troubleshooting B T-3 Machine moves with lever in neutral. Faulty FNR lever. Monitor selected travel speed gear of MC monitor item on Dr. Check if item except N is displayed. Faulty MC. · Travel: Forward Monitor actual travel speed gear of MC monitor item on Dr.
  • Page 422 TROUBLESHOOTING / Troubleshooting B T-4 Even if travel speed is turned up or down, travel speed gear is not changed. • If the vehicle speed sensor malfunctions or if two • Check the wiring connections first. wirings in the shift switch are opened, travel •...
  • Page 423 TROUBLESHOOTING / Troubleshooting B Connect connector in Faulty MC. shift switch. Set travel speed to 4th speed. Disconnect connector MC-B in MC. Check for continuity between terminals #B5 and #B14 of harness Faulty shift switch or open end of connector. circuit in harness.
  • Page 424 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 SYSTEM / Control Sys- • tem. Travel speed gear cannot be turned up by the •...
  • Page 425 TROUBLESHOOTING / Troubleshooting B Connect connector in up-shift/down-shift switch. Faulty MC. Disconnect connector MC-B in MC. Turn up-shift switch Check for continuity between terminal #B2 of harness end of con- Faulty up-shift/down-shift nector and body. switch or open circuit in harness.
  • Page 426 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 SYSTEM / Control Sys- When auto 1-4L, 2-4N or 1-4H in the travel mode tem.
  • Page 427 TROUBLESHOOTING / Troubleshooting B Connect connector in up-shift/down-shift Faulty MC. switch. Disconnect connector MC-B in MC. Turn down-shift side in up-shift/down-shift switch and down-shift switch ON alternately. Check for continuity Faulty switch without con- between terminal #B9 tinuity or open circuit in of harness end of con- harness.
  • Page 428 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 SYSTEM / Control Sys- Check the wiring connections first. tem. • When auto 1-4L, 2-4N or 1-4H in the travel mode selector switch is selected, hold control is not op- erated.
  • Page 429 TROUBLESHOOTING / Troubleshooting B Connect connector in Faulty MC. hold switch. Disconnect connector MC-B in MC. Turn hold switch ON. Check for continuity between terminal #B4 of harness end of con- Faulty hold switch or open nector and body. circuit in harness. ·...
  • Page 430 TROUBLESHOOTING / Troubleshooting B T-8 Travel mode is not shifted. • Check the wiring connections first. • Refer to T2-1-30 to 31 in SYSTEM / Control Sys- tem. Refer to Troubleshooting Monitor auto gear shift- ing mode of MC moni- tor item on Dr.
  • Page 431 TROUBLESHOOTING / Troubleshooting B Faulty travel mode selec- Connect connector in tor switch or faulty har- travel mode selector ness. switch. Disconnect monitor · As for the harness in travel unit connector 1-B in mode selector switch, the monitor unit. harness which correct cur- Check if voltages at rent does not flow through...
  • Page 432 TROUBLESHOOTING / Troubleshooting B T-9 Clutch cut-off is not operated. • Check the wiring connections first. • Refer to T2-1-36 to 37 in SYSTEM / Control Sys- tem. Monitor clutch cut-off Refer to Troubleshooting mode of MC monitor item on Dr. ZX. Shift clutch cut-off posi- tion switch to S, N and D in this order.
  • Page 433 TROUBLESHOOTING / Troubleshooting B Faulty clutch cut-off posi- Connect connector in tion switch or faulty har- clutch cut-off position ness. switch. Disconnect monitor · As for the harness in unit connector 1-B in clutch cut-off position monitor unit. switch, the harness which Check if voltages at correct current does not terminals #B28, #B29,...

  • Page 434: Brake System Troubleshooting

    TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM TROUBLESHOOTING B-1 Parking brake is not released. • Check the wiring connections first. To A Replace parking brake relays 1, 2 with other general relays. Check if parking brake is operated properly. Faulty parking brake re- ·...
  • Page 435 TROUBLESHOOTING / Troubleshooting B Disconnect connector in parking brake To B switch. Measure current at connector of switch end. Install parking brake Check if all questions relay 1. Faulty parking brake are Yes. Disconnect monitor switch. connector 2-A in · Discontinuity between monitor unit.
  • Page 436 TROUBLESHOOTING / Troubleshooting B Hold parking brake To D switch in OFF position. Check if voltage at terminals #1 and #2 of Open circuit in har- harness end of parking ness between ter- brake solenoid valve is Install all electric parts, minal #1 of parking 24 V.
  • Page 437 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-79...
  • Page 438 TROUBLESHOOTING / Troubleshooting B B-2 Parking brake is not locked. • Check the wiring connections first. Disconnect connector in parking brake switch. Turn parking brake switch ON. Check for continuity Replace parking brake between terminals #7 Faulty parking brake relay 2 with other general and #6 of switch end.
  • Page 439 TROUBLESHOOTING / Troubleshooting B Shorted power circuit. Disconnect connector in parking brake solenoid valve. Check if voltage between terminals #1 and #2 of harness end is 24 V. Stuck spool in parking brake solenoid valve. · Engine: Running · Parking brake switch: ON T5-6-81...
  • Page 440 TROUBLESHOOTING / Troubleshooting B B-3 Service brake efficiency is bad or low. Faulty pilot pump. Disassemble, clean and adjust pilot relief valve. Check if brake is oper- ated properly. Monitor service brake End. pressure of monitor · Refer to OPERATIONAL unit monitor item on Dr.
  • Page 441 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-83...

  • Page 442: Steering System Troubleshooting

    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. Connect hoses to ports To A Pa and Pb in steering valve. Disconnect hoses from port A in right and left stop valve.
  • Page 443 TROUBLESHOOTING / Troubleshooting B Faulty steering pilot valve. Connect hose to port A in stop valve. Check if pressure at port P in steering pilot valve End. +0.5 is 3.7 KPa (38 -0.3 kgf/cm Disassemble, clean and adjust pilot relief ·...
  • Page 444 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-86...

  • Page 445: Other System Troubleshooting

    TROUBLESHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING O-1 Air conditioner is faulty 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 •...
  • Page 446 TROUBLESHOOTING / Troubleshooting B • Change Displayed Fault Code 1. When displaying more than one fault code, push Temperature Control Switch either upper or lower side of the temperature control switch. The following fault code is dis- played. NOTE: When the displayed fault code is changed, the buzzer sounds.
  • Page 447 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 machine’s air conditioning system. < Air Conditioner Trouble Report >...
  • Page 448 TROUBLESHOOTING / Troubleshooting B Cooling Circuit Piping and/or parts are stained with oil, Bubbles can be seen in sight Refrigerant pressure respond to gas detector. glass. in both high and low-pressure sides is low. No oil stain is found or gas detector does not respond.
  • Page 449 TROUBLESHOOTING / Troubleshooting B Re tighten or replace parts. Gas leaks from piping joints and/or parts. Normal leakage of refrigerant from hoses. Refill refrigerant. Improper adjustment (excessive restriction) of expansion valve. Readjust or replace expansion valve. Remove clog, or replace receiver and/or expansion Clogged expansion valve.
  • Page 450 TROUBLESHOOTING / Troubleshooting B Cooling Circuit Case connection. Louver resonance. Fan contacts case, or foreign matter enters case. Blower fan connection. Brush friction noise, metal and/or thrust washer contact noise. Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or suc- tion gas noise).
  • Page 451 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.
  • Page 452 TROUBLESHOOTING / Troubleshooting B Compressor Compressor does not rotate. Clutch terminal voltage is normal 24 V. Inoperable Clutch terminal voltage is low. cooling system Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and Check for oil and refrigerant leaks from parts other than low side compressor and pipe joints by using gas detector.
  • Page 453 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.
  • Page 454 TROUBLESHOOTING / Troubleshooting B Compressor Compressor rotation is abnormally draggy. Overheating is susceptible to occur. Refer to the Cooling Circuit Troubleshooting Ta- Trouble other than compressor. ble on T5-6-90. Noise is heard when clutch is OFF. Abnormal noise Noise is heard when clutch is ON. T5-6-96...
  • Page 455 TROUBLESHOOTING / Troubleshooting B Broken clutch bearing due to overly tightened belt. Replace. Shaft does not rotate. Replace. Shaft rotates draggy. Faulty clutch bearing. Replace. Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Saggy belt.
  • Page 456 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 conditioner unit. The same work is required when gas leakage is found. 1. Add compressor oil Oil amount: 160 cm (0.17 qt) 2.

  • Page 457: Air Conditioner

    TROUBLESHOOTING / Troubleshooting B CHARGE CONDITIONER WITH REFRIGERANT 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. 1.
  • Page 458 TROUBLESHOOTING / Troubleshooting B Purging Procedure Gauge Manifold Low Pressure IMPORTANT: Never mistake the charge hose Valve connections. Low Pressure Charge Hose High Pressure 1. Close the high and low pressure valves on the Valve gauge manifold (Parts Number 4360564). Connect the high-pressure-side charge hose and High Pressure Charge Hose...
  • Page 459 TROUBLESHOOTING / Troubleshooting B IMPORTANT: If the pointer returns to 0, retighten the line connections and perform Close purging again. 3. When the low pressure gauge reading falls below Close -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.
  • Page 460 TROUBLESHOOTING / Troubleshooting B IMPORTANT: Always stop engine when High charging the air conditioner with Pressure refrigerant. Do not position the Gauge refrigerant container upside down Tighten during charging operation. When changing the refrigerant container Open during charging operation, purge air from the charge hose, as shown in step 10.
  • Page 461 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...
  • Page 462 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, Sight Glass causing danger.
  • Page 463 TROUBLESHOOTING / Troubleshooting B Relation between Refrigerant Quantity and Refrigerant Flow in Sight Glass: Refrigerant Flow in Sight Glass Refrigerant (approx. 1 min. after air conditioner Explanation for Refrigerant Flow in Sight Glass Quantity switch is turned ON) Immediately after the air conditioner is turned ON, few (immediately after) (approx.
  • Page 464 TROUBLESHOOTING / Troubleshooting B Warm-Up Operation After charting the air conditioner, carry out warm-up operation five minute 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...
  • Page 465 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.
  • Page 466 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-108...

  • Page 467: Exchange Inspection

    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 and solenoid valves used on this ma- chine identical.
  • Page 468 TROUBLESHOOTING / Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble Applicability 11204-3 Abnormal Pump Delivery Pressure Sensor High Voltage Applicable (Sensor only) 11204-4 Abnormal Pump Delivery Pressure Sensor Low Voltage Applicable (Sensor only) 13312-3 Service Brake Pressure Sensor High Voltage Applicable (Sensor only) 13312-4 Service Brake Pressure Sensor Low Voltage...

  • Page 469: Bleeding Air From Brake (Axle)

    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 hy- draulic oil is replaced, bleed air from in the brake.

  • Page 470: One Part Of Data, "Daily Report

    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.
  • Page 471 TROUBLESHOOTING / Troubleshooting B Controller sending data Inspected Position Generated/Detected Data Position on CAN Internal clock circuit in MC Fuel level sensor Monitor unit Communication line between monitor unit and ICF (CAN line) Circuit calculating fuel used amount in Communication line between ECM and ICF (CAN line) Hour meter circuit in monitor unit Monitor unit...
  • Page 472 TROUBLESHOOTING / Troubleshooting B Daily Report Data Data Input Signal Date Replace ICF Fuel level Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #33, #34 of connector monitor-2 in monitor unit Fuel used amount Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #46, #47 of connector in ECM Machine hour meter Check terminals #C5, #C11 of connector ICF-C in ICF,...
  • Page 473 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-115...
  • Page 474 TROUBLESHOOTING / Troubleshooting B Frequency Distribution Data Data Description Output Shaft Speed Distribution Frequency distribution of output shaft speed Pump Load Distribution Frequency distribution of main pump delivery pressure Axle Oil Temperature Distribution Frequency distribution of axle oil temperature Travel Load Distribution Frequency distribution of travel torque Radiator Coolant Temperature Distribution Frequency distribution of coolant temperature...
  • Page 475 TROUBLESHOOTING / Troubleshooting B Controller sending data on Inspected Position Generated/Detected Data Position Output shaft sensor in torque converter Communication line between MC and ICF (CAN line) Pump delivery pressure sensor Communication line between MC and ICF (CAN line) Axle oil temperature sensor Communication line between MC and ICF (CAN line) •...
  • Page 476 TROUBLESHOOTING / Troubleshooting B Frequency Distribution Data Data Discription Output Shaft Speed Distribution Inspect #C5 and #C11 terminals of connector ICF-C in ICF and #4 and #15 terminals of connector MC-C in MC Pump Load Distribution Inspect #C5 and #C11 terminals of connector ICF-C in ICF and #4 and #15 terminals of connector MC-C in MC Axle Oil Temperature Distribution Inspect #C5 and #C11 terminals of connector ICF-C in ICF and...
  • Page 477 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-119...
  • Page 478 TROUBLESHOOTING / Troubleshooting B Total Operating Hours Data Data Description 1 Hour Meter (ICF) Hour meter’s value accumulated inside ICF 2 Hour Meter (Monitor Unit) Hour meter’s value accumulated in monitor unit 3 Engine Operating Hour Total engine operating hours 4 Traveling Distance Total traveling distance 5 Manual...
  • Page 479 TROUBLESHOOTING / Troubleshooting B Controller sending data Generated/Detected Data Position Inspected Position on CAN Hour meter circuit in ICF Hour meter circuit in monitor unit Monitor unit Communication line between monitor unit and ICF (CAN line) • • Alternator Wiring between alternator and ICF Alternator •...
  • Page 480 TROUBLESHOOTING / Troubleshooting B Total Operating Hours Data Data Description Hour Meter (ICF) Replace ICF Hour Meter (Monitor Check terminals #C5, #C11 of connector ICF-C in ICF, terminals #33, #34 of Unit) connector monitor-2 in monitor unit • Check terminal #8 of connector ICF-C in ICF, terminal L in alternator Engine Operating Hour •...
  • Page 481 TROUBLESHOOTING / Troubleshooting B (Blank) T5-6-123...
  • Page 482 TROUBLESHOOTING / Troubleshooting B Alarm Data Data Description Overheat Alarm Date when the overheat indicator lights Engine Warning Alarm Date when the engine warning indicator lights Engine Oil Pressure Alarm Date when the engine oil pressure indicator lights Alternator Indicator Alarm Date when the alternator indicator lights Air Filter Restriction Alarm Date when the air filter restriction indicator lights...
  • Page 483 TROUBLESHOOTING / Troubleshooting B Controller sending data on Inspected Position Generated/Detected Data Position Monitor unit Communication line between monitor unit and ICF (CAN line) Monitor unit Communication line between monitor unit and ICF (CAN line) Monitor unit Communication line between monitor unit and ICF (CAN line) Alternator Monitor unit...
  • Page 484 TROUBLESHOOTING / Troubleshooting B Alarm Data Data Description Overheat Alarm Inspect #C5 and #C11 terminals of connector ICF-C in ICF and #33 and #34 terminals of monitor-2 connector in monitor unit Engine Warning Alarm Inspect #C5 and #C11 terminals of connector ICF-C in ICF and #33 and #34 terminals of monitor-2 connector in monitor unit Engine Oil Pressure Alarm...

  • Page 485: Troubleshooting C (Trouble Shooting For Monitor) Procedure

    TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLE- SHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators malfunction. • How to Read Troubleshooting Flow Charts YES (OK) After completing the checking and/or measuring procedures in box ・...

  • Page 486: Malfunction Of Indicator Light Check System

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check the wiring connections first. Check power line · Fuse · Disconnect connector 1-A. Check for continuity between To A terminal #2 of harness end and fuse terminal #8 in fuse box A.
  • Page 487 TROUBLESHOOTING / Troubleshooting C (Blank) T5-7-3...

  • Page 488: Malfunction Of Buzzer In Monitor

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER IN MONITOR • Check the wiring connections first. NOTE: * Terminals L in the alternator are wa- ter-resistant type connectors so that it is not practical to measure voltage at these ter- minals. Measure voltage at terminal R in starter relay.
  • Page 489 TROUBLESHOOTING / Troubleshooting C Connector (Harness end of connector viewed from the open end side) Monitor Unit Connector 2-A Starter Relay ＃2 Connector A T183-05-04-013 Less than 12 V or 35 V or higher Faulty regulator or faulty al- ternator. Less than 12 V Open circuit in harness be- or 35 V or higher...

  • Page 490: Gauge

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION COOLANT TEM- PERATURE GAUGE • Check the wiring connections first. Disconnect coolant temperature sensor. Connect harness end terminal Coolant temperature gauge to body. pointer does not move at all. Check if pointer swings to (H) Disconnect connector 2-A side.
  • Page 491 TROUBLESHOOTING / Troubleshooting C Coolant Temperature Gauge Faulty coolant temperature sensor. Open circuit in harness be- tween monitor unit and sen- sor. Faulty monitor unit. T4GB-05-07-005 Coolant Temperature Sensor Coolant Temperature Resistance (kΩ) °C (°F) 25 (77) 7.6±0.76 Faulty coolant temperature 40 (104) 4.0±0.35 sensor.

  • Page 492: Malfunction Of Transmission Oil Temperature Gauge

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TRANSMISSION OIL TEMPERATURE GAUGE • Check the wiring connections first. Disconnect transmission oil temperature sensor. Transmission oil temperature Connect harness end terminal gauge pointer does not move to body. at all. Check if pointer swings to (H) Disconnect connector 2-A side.
  • Page 493 TROUBLESHOOTING / Troubleshooting C Transmission Oil Temperature Gauge Faulty transmission oil tem- perature sensor. Open circuit in harness be- tween monitor unit and sen- sor. Faulty monitor unit. T4GB-05-07-006 Transmission Oil Temperature Sensor Oil Temperature Resistance (kΩ) °C (°F) 25 (77) 7.6±0.76 40 (104) 4.0±0.35...

  • Page 494: Malfunction Of Fuel Gauge

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Check the wiring connections first. Disconnect fuel sensor. Connect terminals #1 to #2 of harness end connector by us- Fuel gauge pointer does not ing a clip. move at all. Check if pointer swings to up- per limit (FULL) side.
  • Page 495 TROUBLESHOOTING / Troubleshooting C Fuel Gauge Upper Limit Faulty fuel sensor. Open circuit in harness be- tween monitor unit and sen- sor. Lower Limit Faulty monitor unit. T4GB-05-07-007 Fuel Sensor Float Upper Limit (FULL) Faulty fuel sensor. R134.5 106 mm Shorted circuit in harness between monitor unit and sensor.

  • Page 496: Malfunction Of Turn Signal Indicators (Left And Right)

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TURN SIGNAL INDI- CATORS (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. Faulty turn signal lever. When hazard light Although turn signal switch is shifted,...

  • Page 497: Malfunction Of Hazard Light Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HAZARD LIGHT INDI- CATOR • The hazard light indicator lights when the excited 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.

  • Page 498: Malfunction Of High Beam Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HIGH BEAM INDICA- • Check the wiring connections first. Faulty high beam relay (AR3). Replace high beam relay (AR3) with horn relay (AR5). Disconnect connector of Check if high beam indi- head light switch. cator lights.
  • Page 499 TROUBLESHOOTING / Troubleshooting C Open circuit in harness be- tween high beam relay (AR3) and head light switch. Open circuit in harness be- Connect the discon- tween high beam relay (AR3) nected connector. and monitor unit. Disconnect connector 2-B in monitor unit. Check for continuity be- Check if voltage at ter- Faulty logic circuit in monitor...

  • Page 500: Malfunction Of Working Light Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF WORKING LIGHT IN- DICATOR • 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.
  • Page 501 TROUBLESHOOTING / Troubleshooting C Faulty working light relay (Front) (AR6). Connect the disconnected connector. YES Faulty working light. Disconnect connector 1-B in monitor unit. Check if voltage at terminal Open circuit in harness Check for continuity #23 of harness end con- between working light between terminal #8 nector is 24 V.

  • Page 502: Malfunction Of Fnr Switch Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FNR SWITCH INDI- CATOR CAUTION: Turn the FNR lever and the FNR switch neutral turn for- ward/reverse selector switch to the ON posi- tion. If not, the indicator does not light and the machine cannot be operated by the FNR switch.
  • Page 503 TROUBLESHOOTING / Troubleshooting C Open circuit in harness between terminal #4 in forward/reverse selector Check for continuity switch and terminal #13 between terminals #2 of connector B in MC. and #4 of switch end in forward/reverse selec- Faulty forward/reverse tor switch. selector switch.

  • Page 504: Malfunction Of Maintenance Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF MAINTENANCE INDI- CATOR • The maintenance indicator lights when the hour meter reaches the set replacement interval for lubrication system and filter. (Refer to the Opera- tion 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.

  • Page 505: Malfunction Of Preheat Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • The preheat system is controlled by ECM. (Refer to SYSTEM / Electrical Circuit.) • In case the preheat system malfunctions, refer to Troubleshooting B. • Check the wiring connections first. Faulty ECM. Preheat indicator Disconnect connec- lights although pre-...

  • Page 506: Malfunction Of Transmission Oil Temperature Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF TRANSMISSION OIL TEMPERATURE INDICATOR • Check the wiring connections first. Disconnect connector of transmission oil temperature sensor. Connect terminal of harness end to body. Connect the discon- Check if indicator nected terminal. lights. Connect terminal #5 of connector 2-A in monitor unit to body.
  • Page 507 TROUBLESHOOTING / Troubleshooting C Transmission Oil Temperature Indicator Faulty transmission oil temperature sensor. Oil Temperature Operation Less than 110 °C Open circuit in harness (230 °F) between monitor unit and 120 °C (248 °F) or transmission oil tempera- higher ture sensor. Faulty monitor unit.

  • Page 508: Malfunction Of Hydraulic Oil Temperature Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION HYDRAULIC TEMPERATURE INDICATOR • 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 CAN and is proceeded in the logic circuit of monitor unit.
  • Page 509 TROUBLESHOOTING / Troubleshooting C (Blank) T5-7-25...

  • Page 510: Malfunction Of Transmission Warning Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION TRANSMISSION WARNING INDICATOR • Although the fault code is not displayed in MC and if the trouble occurs, conduct this remedy. • Check the wiring connections first. Disconnect connector B in MC. Connect terminal #24 of harness end connector Connect the disconnected to body.
  • Page 511 TROUBLESHOOTING / Troubleshooting C Faulty MC. Open circuit in harness between monitor unit and Faulty monitor unit. Faulty monitor unit, or burnt indicator light. Faulty MC. Shorted circuit in harness between monitor unit and Faulty monitor unit. Connector (Harness end of connector viewed from the open end side) Connector B Monitor Unit...

  • Page 512: Malfunction Of Air Filter Restriction Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRIC- TION INDICATOR • Check the wiring connections first. Disconnect air filter re- striction switch at plug receptacle with light green cable. Disconnect connector Connect plug of harness 1-A in monitor unit. end to body.
  • Page 513 TROUBLESHOOTING / Troubleshooting C Air Filter Restriction Switch Operational Resistance: 6.2±0.6 kPa (635±58 mmH Faulty air filter restriction switch. Faulty monitor unit. Open circuit in harness between monitor unit and air filter restriction switch. Connector (Harness end of connector viewed from the Faulty monitor unit, or open end side) burnt indicator light.

  • Page 514: Malfunction Of Engine Oil Pressure Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRES- SURE INDICATOR NOTE: Pressure may remain in the circuit for one • Although the fault code is not displayed in ECM to two minutes after the engine stops. If the and if the trouble occurs, conduct this remedy. engine starts in this condition, the indica- tors may not light.
  • Page 515 TROUBLESHOOTING / Troubleshooting C Faulty engine oil pres- sure relay (BR1). To A Check if voltage at terminal #1 in regulator Faulty fuse or open cir- relay (BR6) is 24V. cuit in harness between fuse and regulator relay Check if voltage at (BR6).

  • Page 516: Faulty Overheat Indicator

    TROUBLESHOOTING / Troubleshooting C FAULTY OVERHEAT INDICATOR • Only when the fault code is not displayed in ECM and this trouble occurs, conduct this remedy. Replace overheat relay (BR2) with horn relay (AR5). Check if warning indicator lights. Check if voltage at terminal #1 in overheat relay (BR2) is 24V.
  • Page 517 TROUBLESHOOTING / Troubleshooting C Faulty overheat relay (BR2). To A Check if voltage at terminal #1 in regulator Faulty fuse, or open relay (BR6) is 24V. circuit in harness be- tween fuse and regula- Check if voltage at tor relay (BR6). Connect terminal #7 of terminal #1 in diode G connector 1-A in...

  • Page 518: Malfunction Of Engine Warning Indicator

    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. Faulty ECM. Disconnect con- nector ECM-B in ECM. Connect terminal #44 of Disconnect Open circuit in harness end con- connector 2-B harness between...

  • Page 519: Malfunction Of Stop Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF STOP INDICATOR • When the following troubles occur, the stop indicator lights in order to announce the trouble to the op- erator, stop the machine and repair the machine. • Although the machine is repaired and if the stop in- dicator does not go out, other indicator on monitor must light.

  • Page 520: Malfunction Of Service Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF SERVICE INDICATOR • When the following troubles occur, the service indi- cator lights in order to announce the trouble to the operator, stop the machine and maintain the ma- chine. • Although the machine is maintained and if the ser- vice indicator does not go out, other indicator on monitor must light.
  • Page 521 TROUBLESHOOTING / Troubleshooting C (Blank) T5-7-37...

  • Page 522: Malfunction Of Parking Brake Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PARKING BRAKE IN- DICATOR • Although the fault code is not displayed in MC and if the trouble occurs, conduct this remedy. Disconnect connector B Although brake switch is in MC. Check if indicator not turned to Parking po- goes out.
  • Page 523 TROUBLESHOOTING / Troubleshooting C Faulty MC. Shorted circuit in harness between monitor unit and Faulty monitor unit. Faulty MC. Open circuit in harness be- Connect the discon- tween monitor unit and MC. nected connector. Connect terminal #17 of connector 1-A in monitor unit to body.

  • Page 524: Malfunction Of Clearance Light Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF CLEARANCE LIGHT INDICATOR • If the light switch 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. •...

  • Page 525: Malfunction Of Brake Low Oil Pressure Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE LOW OIL PRESSURE INDICATOR • When this trouble occurs, the fault code corre- sponding to the service brake pressure switch in monitor unit must be displayed. Refer to Trou- bleshooting A and conduct the remedy for this trouble.

  • Page 526: Malfunction Of Brake Low Oil Level Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE LOW OIL LEVEL INDICATOR • Check the wiring connections first. Disconnect plug of hydraulic oil level switch. Check if indi- cator lights. Disconnect connector · Key switch: ON 1-A in monitor unit. When key switch is Check if indicator Although hydraulic turned to ON posi-...
  • Page 527 TROUBLESHOOTING / Troubleshooting C Faulty hydraulic oil level switch. Shorted circuit in harness between monitor unit and hydraulic oil level switch. Faulty monitor unit. Faulty monitor unit, or burnt indicator light. Faulty hydraulic oil level Connector (Harness end of connector viewed from the switch.

  • Page 528: Malfunction Of Emergency Steering Indicator (Optional)

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION EMERGENCY STEERING INDICATOR (OPTIONAL) • After checking if the fault code is not displayed on Troubleshooting by Dr. ZX, conduct this remedy. Connect connector of To A check switch. Disconnect connector 1-A in monitor unit. Connect terminal #14 of harness end connector to body.
  • Page 529 TROUBLESHOOTING / Troubleshooting C Faulty monitor unit. Disconnect connector 2-A in monitor unit. Connect terminal #11 of With connecting terminal harness end to body. #11 of harness end Check if pump unit is connector 2-A in monitor operated. unit to body, disconnect emergency steering re- Replace emergency lay.

  • Page 530: Malfunction Of Low Steering Oil Pressure Indicator (Optional)

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LOW STEERING OIL PRESSURE INDICATOR (Optional) • When this trouble occurs, the fault code corre- sponding to the emergency steering pressure switch in monitor unit must be displayed. Refer to Troubleshooting A and conduct the remedy. •...
  • Page 531 TROUBLESHOOTING / Troubleshooting C (Blank) T5-7-47...

  • Page 532: Malfunction Of Discharge Warning Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DISCHARGE WARN- ING INDICATOR • Check the wiring connections first. NOTE: *Terminals L in the alternator are wa- ter-resistant type connectors so that it is not practical to measure voltage at these ter- minals. Measure voltage at terminal R in starter relay.
  • Page 533 TROUBLESHOOTING / Troubleshooting C Connector (Harness end of connector viewed from the open end side) Monitor Unit Starter Relay Connector 2-A Connector A T183-05-04-013 Faulty monitor unit. Faulty harness between ter- minal L in alternator and monitor unit. Faulty regulator, or faulty al- ternator.

  • Page 534: Malfunction Of Monitor Display

    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 CAN and is proceeded in the logic circuit of monitor unit.

  • Page 535: Malfunction Of Ride Control Indicator

    TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF RIDE CONTROL INDI- CATOR • Check the wiring connections first. Faulty monitor unit. Disconnect connector 1-A in monitor unit. Connect terminal #10 of harness end to body. Check for continuity. Faulty harness be- tween ride control switch and monitor ·...

  • Page 536: Malfunction Of Engine Coolant Temperature Display

    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.

  • Page 537: Precautions For Inspection And Maintenance

    TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Disconnect the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting.
  • Page 538 TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. When disconnecting the harnesses, grasp Correct Incorrect them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate the connectors, if a lock is provided.

  • Page 539: Instructions For Disconnecting Connectors

    TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS FOR DISCONNECTING CONNECTORS • Pull and Separate Type • Push, Unlock and Separate Type NOTE: The connectors will not be easily separated although the lock is pushed while being pulled. Push the lock first before pulling the connectors.
  • Page 540 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.
  • Page 541 TROUBLESHOOTING / Electrical System Inspection (Blank) T5-8-5...

  • Page 542: Fuse Inspection

    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.
  • Page 543 TROUBLESHOOTING / Electrical System Inspection (Fuse Box A) (Fuse Box B) M178-07-034 M178-07-034 Fuse NO. Capacity Connected to 20 A Option (Seat Heater) 10 A 12V Converter 10 A Option 1 15 A Wiper (Front) Head Light (Right) 10 A Cigar Lighter 10 A Controller Power Source...

  • Page 544: Fusible Link Inspection

    TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION Inspection 1. Open either battery box cover from right of the machine. Disconnect the negative cable from the battery. 2. Open the engine cover on left side of the machine with the front attachment side facing forward. 3.

  • Page 545: Battery Voltage Check

    TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK Ground to Battery Positive vehicle frame. 1. Turn the key switch OFF. Terminal 2. Open the battery box cover on left side of the machine with the front attachment side facing forward. 3.

  • Page 546: Alternator Check

    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.
  • Page 547 TROUBLESHOOTING / Electrical System Inspection (Blank) T5-8-11...

  • Page 548: Continuity Check

    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 Ω = Continuity ∞ Ω = Discontinuity Ω NOTE: When the one end connector is far apart from the other, connect one end of Connect to connector (A) to the machine chassis by...
  • Page 549 TROUBLESHOOTING / Electrical System Inspection Multi-line continuity check First short-circuit 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 ∞...
  • Page 550 TROUBLESHOOTING / Electrical System Inspection VOLTAGE AND CURRENT MEASURE- MENT Turn each 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 loca- tion to be measured from either power source or...
  • Page 551 TROUBLESHOOTING / Electrical System Inspection Head Light Switch Key Switch Fuse Box A B-16 A-27 Load Damp Neutral Relay Relay 2-10 Monitor Unit 1-24 Radio Fuse Box B Air Intake Relay To Fuel Injection Diode Solenoid Valve Timer Diode Intake Air Heater Battery Relay Battery...
  • Page 552 TROUBLESHOOTING / Electrical System Inspection 5V Circuit Signal or Power • Voltage between terminal #1 and the vehicle Ground Source Two Polarities frame With the key switch turned OFF, disconnect the connector. Measure voltage between the terminal of 5V power source on the machine harness end connector and the vehicle frame (ground).

  • Page 553: Check By False Signal

    TROUBLESHOOTING / Electrical System Inspection CHECK BY FALSE SIGNAL Two Polarities Power Turn the key switch OFF and disconnect the sensor Signal Source connector. Turn the key switch ON. Connect the ter- minal of power source and the signal terminal on the machine harness end connector.
  • Page 554 TROUBLESHOOTING / Electrical System Inspection (Blank) T5-8-18...
  • Page 555 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 556 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 557 Hitachi Construction Machinery Co. Ltd Hitachi Ref. No. Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162 SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY: MODEL: PUBLICATION NO.: (Located at the right top corner in the cover page) YOUR NAME: PAGE NO.: DATE: (Located at the bottom center in the page.
  • Page 558 THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) 1. ZW180 ELECTRIC CIRCUIT DIAGRAM 1 ZW180 ELECTRIC CIRCUIT DIAGRAM 2 2. ZW180 LIFT ARM PROXIMITY SWITCH HARNESS ZW180 LIFT ARM ANGLE SENSOR HARNESS (OPTIONAL) 3. ZW180 FRONT LIGHT HARNESS ZW180 FRONT HARNESS 4.

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