PART NO.

TTNEM50-EN-01

ZW250-6
WHEEL LOADER
Technical Manual
Troubleshooting

TECHNICAL MANUAL TROUBLESHOOTING

ZW250-6
Wheel Loader

URL:http://www.hitachi-c-m.com
TTNEM50-EN-01

Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TONEM50-EN
Technical Manual (Troubleshooting) : Vol. No.TTNEM50-EN
PRINTED IN JAPAN (K) 2018, 08 Workshop Manual : Vol. No.WNEM50-EN
SECTION 4

OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 6 Adjustment
Operational Performance Tests....................................... T4-1-1 Rewrite of Aftertreatment Device Serial No............... T4-6-1
Preparation for Performance Tests................................ T4-1-2 Clean DEF Tank..................................................................... T4-6-2
Transmission Learning....................................................... T4-6-3
Group 2 Standard Lift Arm Angle Sensor Learning...................................... T4-6-3
Operational Performance Standard Table.................. T4-2-1 Digging Position Adjustment.......................................... T4-6-3
Main Pump P-Q Diagram................................................T4-2-10
Sensor Activating Range.................................................T4-2-12
Group 3 Engine Test
Engine Speed........................................................................ T4-3-1
Lubricant Consumption.................................................... T4-3-3
Group 4 Machine Performance Test
Travel Speed.......................................................................... T4-4-1
Service Brake Function Check......................................... T4-4-4
Service Brake Wear Amount............................................. T4-4-6
Parking Brake Function Check........................................ T4-4-7
Bucket Stopper Clearance,
Lever (Bell Crank) Stopper Clearance...................... T4-4-8
Hydraulic Cylinder Cycle Time.......................................T4-4-10
Cylinder Drift Check..........................................................T4-4-12
Bucket Levelness................................................................T4-4-13
Control Lever Operating Force......................................T4-4-14
Control Lever Stroke.........................................................T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit)....... T4-5-1
Secondary Pilot Pressure................................................... T4-5-4
Solenoid Valve Set Pressure............................................. T4-5-6
Main Pump Delivery Pressure......................................... T4-5-8
Loading Circuit Main Relief Set Pressure...................T4-5-10
Steering Circuit Relief Set Pressure..............................T4-5-14
Loading Overload Relief Valve Set Pressure.............T4-5-16
Main Pump Flow Rate Measurement.........................T4-5-18
Service Brake Pressure (Front and Rear)....................T4-5-26
Parking Brake Release Pressure....................................T4-5-28
Brake Accumulator Pressure..........................................T4-5-30
Brake Warning Pressure (Pressure-Decreasing)......T4-5-32
Brake Warning Pressure (Pressure-Increasing)........T4-5-34
Transmission Clutch Pressure........................................T4-5-36
Torque Converter Pressure.............................................T4-5-38

TTNEM50-EN-01(20181109) NEM50T-4-1
(Blank)

TTNEM50-EN-01(20181109) NEM50T-4-2
SECTION 5

TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Cab..........................................................................................T5-4-12
Introduction........................................................................... T5-1-1 Engine....................................................................................T5-4-19
Diagnosis Procedure........................................................... T5-1-2 Aftertreatment Device.....................................................T5-4-20
Electric System Inspection................................................ T5-1-5 Fan Valve...............................................................................T5-4-21
Precautions for Inspection and Maintenance............ T5-1-6 Pump Device.......................................................................T5-4-22
Instructions for Disconnecting Connectors............... T5-1-8 Multiple Control Valve......................................................T5-4-22
Fuse Inspection...................................................................T5-1-10 Manifold Valve.....................................................................T5-4-23
Fusible Link Inspection....................................................T5-1-12 Parking Brake Solenoid Valve........................................T5-4-23
Battery Voltage Check......................................................T5-1-13 Brake Charge Valve............................................................T5-4-23
Alternator Check................................................................T5-1-14 2-Spool Solenoid Valve Unit...........................................T5-4-23
Continuity Check...............................................................T5-1-16 Steering Valve Block..........................................................T5-4-24
Voltage and Current Measurement.............................T5-1-18 Emergency Steering Pump............................................T5-4-24
Check by False Signal.......................................................T5-1-25 Flow Regulator Valve........................................................T5-4-24
Test Harness.........................................................................T5-1-26 DEF Tank................................................................................T5-4-25
Surge Voltage and Surge Suppression Diodes........T5-1-28 DEF Supply Module...........................................................T5-4-25
Joystick Steering Hydraulic Component Layout....T5-4-26
Group 2 Monitor Joystick Steering Cab Components............................T5-4-28
Outline..................................................................................... T5-2-1
Operating Procedures of Service Menu....................... T5-2-2 Group 5 Troubleshooting A
Troubleshooting................................................................... T5-2-4 Troubleshooting A (Base Machine Diagnosis By
Monitoring............................................................................. T5-2-6 Using Fault Codes) Procedure.................................... T5-5-1
Controller Version..............................................................T5-2-16 MPDr. Fault Code Reference Table................................. T5-5-3
Issued Warning Record....................................................T5-2-17 MC Fault Code List.............................................................T5-5-10
Communication Terminal Status..................................T5-2-22 Monitor Controller (Monitor) Fault Code List..........T5-5-22
Machine Setting.................................................................T5-2-24 Monitor Controller (Information) Fault Code List...T5-5-23
Aftertreatment Device No..............................................T5-2-33 Column Display Controller Fault Code List...............T5-5-24
Engine Tachometer...........................................................T5-2-34 JCU Fault Code List............................................................T5-5-25
Transmission Oil Temperature Gauge and Communication Terminal Fault Code List.................T5-5-28
DEF Level Gauge...........................................................T5-2-35 Air Conditioner Controller Fault Code List................T5-5-28
Coolant Temperature Gauge.........................................T5-2-36 ECM Fault Code List...........................................................T5-5-29
TCU Fault Code List...........................................................T5-5-59
Group 3 e-Service MC Fault Codes 111000 to 111002..............................T5-5-79
Outline..................................................................................... T5-3-1 MC Fault Code 111003.....................................................T5-5-80
List of Operation Data........................................................ T5-3-2 MC Fault Codes 111006, 111007,
Snapshot Data....................................................................... T5-3-6 111009, 111011.............................................................T5-5-83
Communication System.................................................... T5-3-7 Monitor Controller (Monitor) Fault Codes
Group 4 Component Layout 113002, 113003, 113005, 113012...........................T5-5-83
Main Component (Overview).......................................... T5-4-1 CAN1 Harness Check........................................................T5-5-84
Main Component................................................................. T5-4-2 CAN3 Harness Check........................................................T5-5-88
Electrical System (Overview)........................................... T5-4-4 MC Fault Codes 111008, 111010,
Air Cleaner / Radiator Assembly..................................... T5-4-5 111014, 111025.............................................................T5-5-91
Battery Box............................................................................. T5-4-7 Monitor Controller (Monitor) Fault Codes
Hydraulic Oil Tank................................................................ T5-4-8 113004, 113006, 113007............................................T5-5-91
Fuel Tank................................................................................. T5-4-9 CAN2 Harness Check........................................................T5-5-92
Drive Unit..............................................................................T5-4-10 MC Fault Code 111100.....................................................T5-5-95
Front Axle..............................................................................T5-4-11 MC Fault Codes 111103, 111106, 111107.................T5-5-96

TTNEM50-EN-01(20181109) NEM50T-5-1
 MC Fault Codes 111205, 111207..................................T5-5-97 Charge Air Conditioner with Refrigerant..................T5-7-36
MC Fault Codes 111200, 111202, 111203.................T5-5-98 Hose and Pipe Tightening Torque................................T5-7-44
MC Fault Codes 111217, 111312..................................T5-5-99
MC Fault Code 111204 . ............................................... T5-5-100
MC Fault Codes 111206, 111208............................... T5-5-101
MC Fault Codes 111311, 111313............................... T5-5-102
MC Fault Code 111410.................................................. T5-5-103
MC Fault Code 111411.................................................. T5-5-104
MC Fault Code 111412.................................................. T5-5-105
MC Fault Code 111413.................................................. T5-5-106
MC Fault Code 111422.................................................. T5-5-107
MC Fault Code 111901.................................................. T5-5-108
MC Fault Code 111902.................................................. T5-5-109
Monitor Controller (Information)
Fault Code 113311.................................................... T5-5-110
MC Fault Codes 120000, 120002 to 120005.......... T5-5-111
MC Fault Code 120014.................................................. T5-5-111
Monitor Controller Fault Code 115001................... T5-5-112
JCU Fault Codes 116003, 116004.............................. T5-5-113
JCU Fault Codes 116006, 116007, 116008............. T5-5-114
JCU Fault Code 116118................................................. T5-5-115
JCU Fault Code 116119................................................. T5-5-116
Monitor Controller (Monitor)
Fault Code 120300.................................................... T5-5-117
Monitor Controller (Information)
Fault Codes 120400, 120401................................. T5-5-117
Column Display Controller Fault Codes
120500 to 120504...................................................... T5-5-118
Column Display Controller (Information)
Fault Codes 120505 to 120507............................. T5-5-119
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by
Using Trouble Symptom) Procedure....................... T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts..................................... T5-6-3
Correlation between Trouble Symptoms and
Part Failures....................................................................T5-6-26
Engine System Troubleshooting..................................T5-6-46
All Actuator System Troubleshooting.........................T5-6-52
Front Attachment System Troubleshooting.............T5-6-57
Steering System Troubleshooting...............................T5-6-66
Travel System Troubleshooting....................................T5-6-70
Brake System Troubleshooting.....................................T5-6-79
Other System Troubleshooting.....................................T5-6-83
Exchange Inspection........................................................T5-6-97
Air Bleeding Procedures for Brake (Axle)...................T5-6-99
Group 7 Air Conditioner
Outline..................................................................................... T5-7-1
Functions of Main Parts..................................................... T5-7-4
Troubleshooting................................................................... T5-7-9
Air Conditioner Controller Fault Code List................T5-7-10
Air Conditioner Controller Fault Codes 11 to 22.....T5-7-11
Air Conditioner Controller Fault Codes 43 to 92.....T5-7-12
Work after Replacing Components.............................T5-7-34
Refill Compressor Oil........................................................T5-7-35

TTNEM50-EN-01(20181109) NEM50T-5-2
 INTRODUCTION

To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@hitachi-kenki.com

Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.

Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.

Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:

Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group

Trademark
AdBlue® is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).

TTNEM50-EN-01(20181109) IN-1
 INTRODUCTION

Safety Alert Symbol and Headline Notations

In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential d CAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate fNOTE:
lifting techniques and equipment when lifting heavy Indicates supplementary technical information or know-
parts. how.

Units Used
SI Units (International System of Units) are used in this A table for conversion from SI units to other system units
manual. is shown below for reference purposes.

Quantity To Convert From Into Multiply By

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

TTNEM50-EN-01(20181109) IN-2
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.

TTNEM50-EN-01(20181109) SY-1
 SYMBOL AND ABBREVIATION

Symbol / Name Explanation

Abbreviation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
HRV Hose Rupture Valve Hose rupture valve.
LLC Long Life Coolant Long life coolant.
SCR Selective Catalytic Reduction The urea SCR system injects diesel exhaust fluid to nitrogen
oxide (NOx) exhausted from the engine and purifies NOx.
DCU Dosing Control Unit Urea SCR system controller. DCU controls the diesel exhaust
fluid injection amount according to the machine operating
condition.
S/M Supply Module Diesel exhaust fluid supply module. The diesel exhaust fluid
supply module pumps diesel exhaust fluid to the dosing
module (D/M). Then, it returns diesel exhaust fluid in the
diesel exhaust fluid circuit when the key switch is turned
OFF.
D/M Dosing Module Dosing module. The dosing module (D/M) injects diesel
exhaust fluid into the exhaust piping according to the signal
from DCU.
NOx Nitrogen Oxide Nitrogen oxide.
DEF Diesel Exhaust Fluid Diesel exhaust fluid. The diesel exhaust fluid concentration is
32.5 %, which is specified in ISO22241.

TTNEM50-EN-01(20181109) SY-2
 SAFETY
Recognize Safety Information
 These are the SAFETY ALERT SYMBOLS.

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

manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.

SA-2644

Understand Signal Words

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

 DANGER indicates an imminently hazardous situation

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

 CAUTION also calls attention to safety messages in this

manual.
 To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a SA-1223
situation which, if not avoided, could result in damage to
the machine.

 f NOTE indicates an additional explanation for an

element of information.

TTNEM50-EN-01(20181109) SA-1
 SAFETY
Follow Safety Instructions
 Carefully read and follow all safety signs on the machine
and all safety messages in the operator's manual.

 Safety signs should be installed, maintained and replaced

when necessary.
 If a safety sign or operator's manual is damaged or
missing, order a replacement from your authorized dealer
in the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).

 Learn how to operate the machine and its controls correctly

SA-003
and safely.

 Allow only trained, qualified, authorized personnel to

operate the machine.

 Keep your machine in proper working condition.

 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Never attempt to modify or disassemble the inlet/exhaust
parts and the aftertreatment device. Avoid giving shocks
on the aftertreatment device by striking elements with
other objects or dropping the elements. Failure to do
so may affect the exhaust gas purifying device, possibly
damaging it or lowering its performance.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Carefully read and
follow all instructions for use and safety in the operator's
manual for the attachment. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.

 The safety messages in this SAFETY chapter are intended

to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.

TTNEM50-EN-01(20181109) SA-2
 SAFETY
Prepare for Emergencies
 Be prepared if a fire starts or if an accident occurs.

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

 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your SA-437
telephone.

Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.

You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
SA-438
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.

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

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

 Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones while
operating the machine.

TTNEM50-EN-01(20181109) SA-3
 SAFETY
Protect Against Noise
 Prolonged exposure to loud noise can cause impairment or
loss of hearing.

 Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.

SA-434

Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.

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

described in the “Inspect Machine Daily Before Starting”
section in the operator’s manual.

SA-435

TTNEM50-EN-01(20181109) SA-4
 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.

 Do not leave parts and / or tools lying around the

operator’s seat. Store them in their specified locations.

 Avoid storing transparent bottles in the cab. Do not

attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.

 Refrain from using music headphones or mobile

telephones in the cab while operating the machine.

 Keep all flammable objects and / or explosives away from

the machine.

 After using the ashtray, always cover it to extinguish the

match and / or tobacco.

 Do not leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.

 Use proper floor mat dedicated to the machine.

If another floor mat is used, it may be displaced and
contact with the accelerator or brake pedals during
operation, resulting in serious injury or death.

 Never weld, drill or in any way modify the ROPS without

approval from the manufacturer.

TTNEM50-EN-01(20181109) SA-5
 SAFETY
Use Handrails and Steps
 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.

 Do not use any controls as handholds.

 Do not hold the door handle or lever as a handrail when
getting on and off the machine.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
SA-439
 Never get on and off the machine with tools in your
hands.

Never Ride Attachment

 Never allow anyone to ride attachment or the load. This is
an extremely dangerous practice.

Adjust Operator’s Seat

 A poorly adjusted seat for either the operator or the work
at hand may quickly fatigue the operator leading to
misoperations.

 The seat should be adjusted whenever changing the

operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear SA-462
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.

TTNEM50-EN-01(20181109) SA-6
 SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open / close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the control lever lock switch to the lock ( ) position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.

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

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

Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and / or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.

 Prior to operating the machine, thoroughly examine

webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident. SA-237
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.

TTNEM50-EN-01(20181109) SA-7
 SAFETY
Move and Operate Machine Safely
 Bystanders can be run over.

 Take extra care not to run over bystanders. Be advised

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

Handle Starting Aids Safely

Starting fluid:

 Starting fluid is highly flammable.

 Keep all sparks and flame away when using it.

 Keep starting fluid well away from batteries and cables.
 Remove container from machine if engine does not need
starting fluid.
 To prevent accidental discharge when storing a
pressurized container, keep the cap on the container, and
store it in a cool, well-protected location. SA-293
 Do not incinerate or puncture a starting fluid container.

TTNEM50-EN-01(20181109) SA-8
 SAFETY
Operate Only from Operator’s Seat
 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.

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

 NEVER start the engine while standing on the tire or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-431

Jump Starting
 Battery gas can explode, resulting in serious injury.

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

instructions shown in the “OPERATING ENGINE” chapter in
the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032

TTNEM50-EN-01(20181109) SA-9
 SAFETY
Investigate Job Site Beforehand
 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.

 Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder,
employ a signal person as required. SA-447
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware of the possibility of fire when operating the
machine near flammable objects such as dry grass.

TTNEM50-EN-01(20181109) SA-10
 SAFETY
Equipment of Head Guard, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
Any modification of the ROPS structure will modify its
performances and its certification will be lost.

ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure

SA-521

Provide Signals for Jobs Involving Multiple

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

SA-481

TTNEM50-EN-01(20181109) SA-11
 SAFETY
Keep Riders Off Machine
 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.

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

off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-427

Drive Safely
 Beware of the possibility of slipping and / or turning over
the machine when driving on a slope.

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

(A) 410 to 460 mm (16 to 18 in) above the ground as
illustrated.
 Avoid traveling over any obstacles.
 Drive the machine slowly when driving on rough terrain.
 Avoid quick direction changes. Failure to do so may cause
the machine to turn over.
 If the engine stops while driving, the steering function
becomes inoperative. Immediately stop the machine by
applying the brake to prevent personal accident. SA-448

TTNEM50-EN-01(20181109) SA-12
 SAFETY
Drive Machine Safely (Work Site)
 Before driving the machine, always confirm that the
steering wheel / and forward / reverse lever (switch)
direction corresponds to the direction you wish to drive.

 Be sure to detour around any obstructions.

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

overturn, possibly resulting in serious injury or death.
SA-449
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 450 mm (18 in) (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Before using the downshift switch (DSS) while driving
down a slope, apply the brake to decrease the machine
speed enough.
If the engine overrun alarm indicator turns on with an
alarm sound, immediately depress the brake pedal to
slow down the machine.

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

SA-450
may cause the machine to skid or overturn. If the direction
must be changed, move the machine to level ground, then,
change the direction to ensure safe operation. WRONG

SA-451

TTNEM50-EN-01(20181109) SA-13
 SAFETY
Drive Safely with Bucket Loaded
 If the machine is operated incorrectly while driving with the
bucket loaded, the machine may turn over. Be sure to follow
all of the instructions indicated below.

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

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

Drive on Snow Safely

 Beware of the possibility of slipping or turning over the
machine when driving on frozen snow surfaces.

 The machine may slip more easily than expected on

frozen snow surfaces even if the incline is small. Reduce
speed when driving. Avoid fast starts, stops and quick
turns.
 Road shoulder and / or set-up utilities covered with snow
are difficult to locate. Be sure where they are before
removing snow.
SA-452
 Be sure to use tire chains when driving on snow.
 Avoid applying the brake for quick stops on snow. If a
quick stop is required, lower the bucket to the ground.

TTNEM50-EN-01(20181109) SA-14
 SAFETY
Travel on Public Roads Safely
 This machine is not allowed to drive on public roads with
the bucket loaded.

 Be sure to empty the bucket.

 Hold the bucket at mark (A) 410 to 460 mm (16 to 18 in)
above the road surface as illustrated.

SA-453

Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.

To avoid rollaways:
 Select level ground when possible to park machine.
 Do not park the machine on a grade.
 Lower the bucket to the ground.
 Put the forward / reverse lever (switch) in neutral.
 Run the engine at low idle speed without load for 5
minutes to cool down the engine. SA-457
 Turn the control lever lock switch to the lock ( ) position.
 Turn the parking brake switch ON.
 Stop the engine and remove the key from the key switch.
 Block both tires and lower the bucket to the ground.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.

SA-458

TTNEM50-EN-01(20181109) SA-15
 SAFETY
Avoid Accidents from Backing Up and Turning
 Make sure no one is working under or close to the machine
before backing up or turning the machine to avoid personal
injury and / or death by being run over or entangled in the
machine.

 Keep all personnel away from the machine by sounding

the horn and / or using hand signals. Use extra care to be
sure no one is in from the articulation area before turning
the machine.
 Keep windows, mirrors, and lights in good condition.
 Reduce travel speed when dust, heavy rain, fog, etc.,
reducing the visibility.
 In case good visibility is not obtained, use a signal person SA-383
to guide you.

SA-312

TTNEM50-EN-01(20181109) SA-16
 SAFETY
Avoid Positioning Bucket or Attachment Over
Anyone
 Never allow the bucket or attachment to pass over co-
workers and / or the dump truck operator’s cab. Falling
material from the bucket or contact with bucket or
attachment may cause serious personal accidents and / or
damage to the machine.

 Avoid carrying the bucket or attachment over the co-

workers to ensure safe operation.
SA-518

Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE. MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE, POSSIBLY RESULTING IN SERIOUS
PERSONAL INJURY OR DEATH. IF TIPPING OVER OF THE
MACHINE IS PREDICTED, SECURELY HOLD THE STEERING
WHEEL TO PREVENT YOUR BODY FROM BEING THROWN
OUT OF THE MACHINE.
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
SA-463
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.

To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 5
degrees if crossing the grade is unavoidable.
 Reduce speed as necessary when swinging loads.

 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become

soft and make ground travel unstable.

TTNEM50-EN-01(20181109) SA-17
 SAFETY
Never Undercut a High Bank
 The edges could collapse or a land slide could occur causing
serious injury or death.

SA-519

Dig with Caution

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

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

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

Perform Truck Loading Safely

 Do not operate the machine involuntarily. Unexpected
machine movement may cause personal injury and / or
death.

 Do not lower the bucket with the lift arm control lever
in the FLOAT position. The bucket may free fall, possibly
causing personal injury and / or death.
 Always select a level surface for truck loading.
SA-397

TTNEM50-EN-01(20181109) SA-18
 SAFETY
Avoid Power Lines
Serious injury or death can result from contact with electric
lines.

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

electric line than 3 m (10 ft) plus twice the line insulator
length.

SA-455

Precautions for Operation

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

 Take care to avoid coming in contact with overhead

obstacles with the bucket or arm during operation.

Precautions for Lightning

 Lightning may strike the machine.

If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.

If lightning strikes the machine or near the machine,

check all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is
found, operate the machine only after repairing it.

M4GB-0S-001

TTNEM50-EN-01(20181109) SA-19
 SAFETY
Object Handling
CRANING OPERATION USING THE MACHINE IS NOT
ALLOWED.
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.

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

attachment (fork or grapple for example). They may come
off, causing the load to fall.

SA-132

Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.

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

wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.

SA-432

TTNEM50-EN-01(20181109) SA-20
 SAFETY
Park Machine Safely
To avoid accidents:
 Park the machine on a firm, level surface.
 Lower bucket to the ground.
 Put the forward / reverse lever (switch) in neutral, and
turn the parking brake switch (lever) ON (parking brake)
position.
 Run the engine at low idle speed without load for 3
minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
SA-456
 Turn the control lever lock switch to the lock ( ) position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.

Store Attachments Safely

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.

 Securely store attachments and implements to prevent

falling. Keep children and bystanders away from storage
areas.

SA-034

TTNEM50-EN-01(20181109) SA-21
 SAFETY
Transport Safely
 Be careful because the machine may turn over when
loading or unloading the machine on or off of a truck or
trailer.

 Observe the related regulations and rules for safe

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

Be sure to further follow the details described in the

TRANSPORTING chapter in the operator's manual.

TTNEM50-EN-01(20181109) SA-22
 SAFETY
Handle Fluids Safely−Avoid Fires
 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and / or a fire may occur, possibly resulting in
serious injury or death.

 Do not refuel the machine while smoking or when near

open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.

 All fuels, most lubricants, and some coolants are flammable.

SA-018
 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler caps.

SA-019

TTNEM50-EN-01(20181109) SA-23
 SAFETY
Practice Safe Maintenance
To avoid accidents:
 Understand service procedures before starting work.
 Keep the work area clean and dry.
 Do not spray water or steam inside cab.
 Never lubricate or service the machine while it is moving.
 Keep hands, feet and clothing away from power-driven
parts.

Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Run the engine at low idle speed without load for 3
SA-028
minutes.
4. Turn the key switch to OFF to stop engine. Wait for some
seconds and turn the key switch to ON again.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Turn the control lever lock switch to the LOCK ( )
position.
7. Turn the key switch to OFF, and remove the key from the
key switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Connect the front and rear chassis with articulation
stopper. SA-312

10. Allow the engine to cool.

 Refer to page 7-8 "Preparations for Inspection and

Maintenance" in the operator's manual.
 If a maintenance procedure must be performed with the
engine running, do not leave machine unattended.
 Never work under a machine raised by the lift arm.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of operator's manual.
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
SA-134
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (-) before making
adjustments to electrical systems or before performing
welding on the machine.

SA-527

TTNEM50-EN-01(20181109) SA-24
 SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid,
or window washer fluid may catch fire.

SA-037

Warn Others of Service Work

 Unexpected machine movement can cause serious injury.

 Before performing any work on the machine, attach a “Do

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

ZZDT17389

Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.

 Always lower the attachment to the ground before you

work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.

SA-527

TTNEM50-EN-01(20181109) SA-25
 SAFETY
Stay Clear of Moving Parts
 Entanglement in moving parts can cause serious injury.

 To prevent accidents, care should be taken to ensure that

hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.

SA-026

Support Maintenance Properly

 Explosive separation of a tire and rim parts can cause
serious injury or death.

 Do not attempt to mount a tire unless you have the

proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
 Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
 When inflating tires, use a chip-on chuck and extension
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
if available.
 Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
 Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and
SA-249
may result in tire explosion.

TTNEM50-EN-01(20181109) SA-26
 SAFETY
Prevent Parts from Flying
 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face

away from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then
gradually loosen AIR RELEASE PLUG to release pressure.

SA-344

Prevent Burns
Hot spraying fluids:

 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator
and heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.

 Avoid possible injury from hot spraying water. DO NOT

remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.

Hot fluids and surfaces:

 Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.

 Wait for the oil and components to cool before starting

any maintenance or inspection work.

SA-225

TTNEM50-EN-01(20181109) SA-27
 SAFETY
Replace Rubber Hoses Periodically
 Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and abrasion. It
is very difficult to gauge the extent of deterioration due to
aging, fatigue, and abrasion of rubber hoses by inspection
alone.

 Periodically replace the rubber hoses. (See the page

of “Periodic replacement of parts” in the operator’s
manual.)

 Failure to periodically replace rubber hoses may cause a SA-019

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

Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure
can penetrate the skin or eyes causing serious injury,
blindness or death.

 Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear
a face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
SA-031
type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours, or
gangrene may result.

SA-292

SA-044

TTNEM50-EN-01(20181109) SA-28
 SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler flange
bolts.
 Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
 Do not bend or strike high-pressure lines.
SA-019
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically
even if there is no abnormality in their external
appearance.

Check for Shorts:

 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
 Check before each shift or after eight (8) to ten (10)
hours operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.

Clean up Flammables:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammables immediately. Check and clean high
temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to
catching fire.
 Keep flammables away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the
engine compartment covers to prevent flammables
such as dead leaves from entering. However,
flammables which have passed through the wire screen
may cause fires. Check and clean the machine every day
and immediately remove accumulated flammables.
The temperature around the engine may tend to
become higher with wire screens. Be careful of the
overheat.

TTNEM50-EN-01(20181109) SA-29
 SAFETY
Check Key Switch:
 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at low idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
before operating the machine.

Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or
replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover
is open, splattered oil on the high temperature parts
such as mufflers may cause fire. Always close the engine
cover while operating the machine.

Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:

 Stop the engine by turning the key switch to the OFF

position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 If the cab doors do not open, break them with a
hammer to make an escapeway.

 If the cab door cannot be opened, break the window glass SA-393
with the hammer.

SS-1510

TTNEM50-EN-01(20181109) SA-30
 SAFETY
Beware of Exhaust Fumes
 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.

 If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
 White smoke may be generated during aftertreatment
device regeneration. Do not attempt to do aftertreatment
device manual regeneration in a badly ventilated indoors.

SA-016

Precautions for Welding and Grinding

 Welding may generate gas and / or small fires.

 Be sure to perform welding in a well ventilated and

prepared area. Store flammable objects in a safe place
before starting welding.
 Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.

 Grinding on the machine may create fire hazards. Store

flammable objects in a safe place before starting grinding.

 After finishing welding and grinding, recheck that there are

no abnormalities such as the area surrounding the welded
SA-818
area still smoldering.

Avoid Heating Near Pressurized Fluid Lines

 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..

SA-030

TTNEM50-EN-01(20181109) SA-31
 SAFETY
Avoid Applying Heat to Lines Containing
Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.

Precautions for Handling Accumulator and Gas

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

Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest authorized dealer.

Precautions for Diesel Exhaust Fluid (DEF)

 Diesel exhaust fluid (DEF), commonly referred to as
AdBlue®, is an aqueous urea solution used as a consumable
in selective catalytic reduction (SCR) to lower NOx
concentration in the exhaust emissions from the engine.
It is a non-flammable and non-hazardous solution, and
harmful effects are not expected under normal conditions
of use.

 In case of a fire, DEF/AdBlue® would decompose and

generate ammonia gas when heated to 160 °C (320 °F) or
higher.
Ammonia gas may cause lung injury and potentially is fatal
if inhaled. It is a corrosive gas and the liquefied gas can
cause frostbite and corrosive injury to eyes and skin.
In case of contact, immediately flush skin with plenty of
water at least 15 minutes while removing contaminated
clothing. Get medical attention if symptoms occur.

 DEF/AdBlue® is corrosive to steel, aluminium, copper and

brass, etc. If DEF/AdBlue® is spilled on your vehicle, wipe off
and rinse with water.

 For the handling of DEF/AdBlue®, follow handling

precautions on Material Safety Data Sheet. Have suitable
emergency equipment for fires, spills and leaks readily
available. Practice good housekeeping. Maintain handling
equipment. Comply with applicable regulations.

TTNEM50-EN-01(20181109) SA-32
 SAFETY
Remove Paint Before Welding or Heating
 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.

 Avoid potentially toxic fumes and dust.

 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.

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

Beware of Asbestos and Silicon Dust and Other

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

 Depending on the work site conditions, the risk

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

TTNEM50-EN-01(20181109) SA-33
 SAFETY
Prevent Battery Explosions
 Battery gas can explode.

 Keep sparks, lighted matches, and flame away from the

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

 Battery electrolyte is poisonous. If the battery should

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

Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.

 Refer to the instructions described on the container for

proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.

SA-405

TTNEM50-EN-01(20181109) SA-34
 SAFETY
Handle Chemical Products Safely
 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.

 A Safety Data Sheet (SDS) provides specific details on

chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS before you start any job using a hazardous
chemical. That way you will know exactly what the risks
are and how to do the job safely. Then follow procedures
and use recommended equipment.
 See your authorized dealer for SDS’s (available only in
SA-2579
English) on chemical products used with your machine.

Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with Hitachi equipment includes such items as oil, fuel,
coolant, brake fluid, filters, DEF/AdBlue®, and batteries.

 Use leakproof containers when draining fluids. Do not use

food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants. SA-226
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

TTNEM50-EN-01(20181109) SA-35
 SAFETY
Notes for Aftertreatment Device
Urea SCR System
The aftertreatment device removes particulate matter (PM)
and nitrogen oxide (NOx) from the exhaust gas. Follow the
instructions below to prevent the aftertreatment device
from being damaged.

dWARNING: Exhaust gas from the aftertreatment

device, muffler, exhaust piping and tail piping
becomes hot during and just after engine running and
regeneration of aftertreatment device. Be careful not
to let your skin contact any part of exhaust system or
hot gas from the exhaust piping. Otherwise, it may
cause severe burns.

 White smoke may be generated during the aftertreatment

device regeneration. Do not attempt to do aftertreatment
device manual regeneration in a badly ventilated indoors.
 Do not directly touch water coming out of the
aftertreatment device. The water is mildly-acidic by
oxidation catalyst mounted in the aftertreatment device. If
filter water spills on your skin, immediately flush it out with
clean water.

Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.

Never attempt to disassemble, repair, modify or displace the

communication terminal, antennas or cables. Failure to do so
may result in damage and/or fire to the base machine or to the
communication terminal. (When required to remove or install
the communication terminal, consult your nearest Hitachi
dealer.)

Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause a short or broken circuit that may
result in damage and/or fire to the base machine or to the
communication terminal.

TTNEM50-EN-01(20181109) SA-36
 SAFETY
Precaution for Communication Terminal
Equipment
This machine may have a communication terminal
equipment emitting electrical waves installed in the right
rear corner within the cab.

There is a possibility that a medical device, including an

implantable device such as a cardiac pacemaker, would be
affected and would malfunction by the electrical waves
emitted from the communication terminal equipment.

Any person affixed with a medical device such as the above

should not use this machine, unless the medical device
and the equipment are at least 22 centimeters (8 inches)
apart at all times. If such condition cannot be met, please
contact our company's nearest dealer and have the person
in charge stop the communication terminal equipment from
functioning completely and confirm that it is not emitting
electrical waves.
Machine Front

Specific Absorption Rate ("SAR") (measured by 10 g per unit)

of communication terminal equipment: 90MNEC-01-046

Model A Model B
E-GSM900 0.573 W/Kg 0.12 W/Kg
(914.8 MHz) (897.6 MHz)
DCS-1800 0.130 W/Kg 0.06 W/Kg
(1710.2 MHz) (1748.0 MHz)
WCDMA Band I 0.271 W/Kg 0.05 W/Kg
(1950.0 MHz) (1950.0 MHz)
WCDMA Band VIII - 0.10 W/Kg
(892.6 MHz)

fNOTE: Please contact to your authorized representative

if you want to know which terminal model A or B is installed.

* This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.18 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application
such as a mobile phone.
* In the United States, the SAR limit set by the Federal
Communications Commission is at or below 1.6 watts per
kilogram (W/kg) taken over the volume containing a mass of
1 gram of tissue that is absorbing the most signal.

TTNEM50-EN-01(20181109) SA-37
 SAFETY
Articulation Stopper (Lock Bar)

dWARNING: With articulation stopper in LOCKED

position, machine will not steer; which, while
operating, could cause an accident, injury or death. Do
not lock Articulation Stopper during normal operation.

Articulation stopper locks the front and rear chassis to

prevent them from sudden articulation during inspection or
transportation.

To lock: 1

1. Align the front and rear chassis straight ahead.

2. Remove β-form pin (4) to remove set pin (1) from the
rear chassis hole. 4 2 3
85Z7B-1-143-1
3. Pull out and rotate articulation lock bar (2) to align it with
the front chassis hole (3).

4. Install set pin (1) into the front chassis hole (3) and the
articulation lock bar tip end hole. Install β-form pin (4) to
lock the articulation lock bar (2) in position. (This is the
LOCKED position.)

2 4

85Z7B-1-143-2

Before Returning the Machine to the Customer

 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.

SA-435

TTNEM50-EN-01(20181109) SA-38
 SECTION AND GROUP SECTION 4 OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
TECHNICAL MANUAL Group 5 Component Test
Group 6 Adjustment
(Troubleshooting)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner

All information, illustrations and

specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

COPYRIGHT(C)2018
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved

TTNEM50-EN-01(20181109)
(Blank)

TTNEM50-EN-01(20181109)
SECTION 4

OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 6 Adjustment
Operational Performance Tests....................................... T4-1-1 Rewrite of Aftertreatment Device Serial No............... T4-6-1
Preparation for Performance Tests................................ T4-1-2 Clean DEF Tank..................................................................... T4-6-2
Transmission Learning....................................................... T4-6-3
Group 2 Standard Lift Arm Angle Sensor Learning...................................... T4-6-3
Operational Performance Standard Table.................. T4-2-1 Digging Position Adjustment.......................................... T4-6-3
Main Pump P-Q Diagram................................................T4-2-10
Sensor Activating Range.................................................T4-2-12
Group 3 Engine Test
Engine Speed........................................................................ T4-3-1
Lubricant Consumption.................................................... T4-3-3
Group 4 Machine Performance Test
Travel Speed.......................................................................... T4-4-1
Service Brake Function Check......................................... T4-4-4
Service Brake Wear Amount............................................. T4-4-6
Parking Brake Function Check........................................ T4-4-7
Bucket Stopper Clearance,
Lever (Bell Crank) Stopper Clearance...................... T4-4-8
Hydraulic Cylinder Cycle Time.......................................T4-4-10
Cylinder Drift Check..........................................................T4-4-12
Bucket Levelness................................................................T4-4-13
Control Lever Operating Force......................................T4-4-14
Control Lever Stroke.........................................................T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit)....... T4-5-1
Secondary Pilot Pressure................................................... T4-5-4
Solenoid Valve Set Pressure............................................. T4-5-6
Main Pump Delivery Pressure......................................... T4-5-8
Loading Circuit Main Relief Set Pressure...................T4-5-10
Steering Circuit Relief Set Pressure..............................T4-5-14
Loading Overload Relief Valve Set Pressure.............T4-5-16
Main Pump Flow Rate Measurement.........................T4-5-18
Service Brake Pressure (Front and Rear)....................T4-5-26
Parking Brake Release Pressure....................................T4-5-28
Brake Accumulator Pressure..........................................T4-5-30
Brake Warning Pressure (Pressure-Decreasing)......T4-5-32
Brake Warning Pressure (Pressure-Increasing)........T4-5-34
Transmission Clutch Pressure........................................T4-5-36
Torque Converter Pressure.............................................T4-5-38

TTNEM50-EN-01(20181109) NEM50T-4-1
(Blank)

TTNEM50-EN-01(20181109) NEM50T-4-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction

Operational Performance Tests

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

Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.

Performance Standards
“Performance Standard” is shown in tables to evaluate
the performance test data.

Precautions for Evaluation of Test Data

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

TTNEM50-EN-01(20181109) T4-1-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction

Preparation for Performance Tests

Observe the following rules in order to carry out
performance tests accurately and safely.

THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, before
starting to test.

TEST AREA and TOOL

1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 200 m (656 ft 2 in), and to make
the steering operate.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
4. Prepare the measuring instruments and tools. Use
MPDr. if possible.

PRECAUTIONS
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.

MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance to
obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test data
obtained can be produced repeatedly. Use mean
values of measurements if necessary.

TTNEM50-EN-01(20181109) T4-1-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Operational Performance Standard Table The standard measurement conditions are as followings
unless instructed in each performance test procedure:
The standard Performance values are listed in the table  Accelerator Pedal: Full Stroke
below.  Power Mode Switch: ON
The detailed measurement procedures are explained in  Hydraulic Oil Temperature: 55±5 °C (131±9 °F)
T4-3, T4-4, and T4-5. Refer to the reference page.  The aftertreatment device regeneration control
Values indicated in parentheses [ ] are reference values. should not be activated.

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Engine Speed min-1 Power mode: OFF T4-3-1
Low Idle Speed (without load) 800±50 Value indicated on MPDr.
High Idle Speed (without load) 2210±50 First- speed forward,
Value indicated on MPDr.
High Idle Speed (with torque 2020±100 Second- speed forward,
converter stalled) Value indicated on MPDr.
High Idle Speed (with torque 1680±100 Third- speed forward,
converter stalled and relieved) Value indicated on MPDr.
Engine Speed min-1 Power mode: ON T4-3-1
Low Idle Speed (without load) 800±50 Value indicated on MPDr.
High Idle Speed (without load) 2350±50 First- speed forward,
Value indicated on MPDr.
High Idle Speed (with torque 2150±100 Second- speed forward,
converter stalled) Value indicated on MPDr.
High Idle Speed (with torque 1790±100 Third- speed forward, Value
converter stalled and relieved) indicated on MPDr.
Valve Clearance (In, Ex) mm (in) In: 0.254 (0.010) With the engine cold Refer to
Ex: 0.508 (0.020) Engine Manual
Lubricant Consumption (Rated mL (in3)/h 50 (3) or less Hour meter: 2000 hours T4-3-4
output) or less

TTNEM50-EN-01(20181109) T4-2-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Travel Speed km/h (mph) Power mode: OFF T4-4-1
First Speed (Forward/Reverse) 5.8±0.7/6.1±0.7 Value indicated on MPDr.
(3.6±0.4/3.8±0.4)
Second Speed (Forward/Reverse) 10.5±1.1/10.7±1.1 Value indicated on MPDr.
(6.5±0.6/6.7±0.6)
Third Speed (Forward/Reverse) 15.0±1.6/24.6±2.5 Value indicated on MPDr.
(9.3±1.0/15.3±1.6)
Fourth Speed (Forward) 24.3±2.4 (15.1±1.4) Value indicated on MPDr.
Fifth Speed (Forward) 39.5 +0/-4 (24.5 +0/-2.5)
Travel Speed km/h (mph) Power mode: ON T4-4-1
First Speed (Forward/Reverse) 5.8±0.7/6.1±0.7 Value indicated on MPDr.
(3.6±0.4/3.8±0.4)
Second Speed (Forward/Reverse) 10.8±1.1/11.8±1.2 Value indicated on MPDr.
(6.7±0.6/7.3±0.7)
Third Speed (Forward/Reverse) 16.3±1.6/26.7±2.7 Value indicated on MPDr.
(10.1±1/16.6±1.7)
Fourth Speed (Forward) 25.4±2.5 (15.8±1.5) Value indicated on MPDr.
Fifth Speed (Forward) 39.5 +0/-4 (24.5 +0/-2.5)
Service Brake Function Check m (ft) 12 (39) or less Vehicle speed: 35±3 km/h T4-4-4
(21.7±1.8 mph)
Service Brake Wear Amount mm (in) T4-4-6
Brake Disc 6.2 (0.2) Allowable limit: 5.3 (0.2)
Brake Ring (t=11.9) 11.9 (0.5) Allowable limit: 10.4 (0.4)
Brake Ring (t=6.5) 6.5 (0.3) Allowable limit: 6.0 (0.2)
Brake Ring (t=6.9) 6.9 (0.3) Allowable limit: 6.4 (0.3)
Parking Brake Function Check mm/5 min 0 T4-4-7
Parking Brake Wear Amount mm (in) -
Brake Disc 2.2 (0.1) Allowable limit: 1.9 (0.1)
Brake Pad 6.0 (0.2) Allowable limit: 4.5 (0.2)
Bucket Dump Stopper Clearance mm (in) 5±2 (0.2±0.08) T4-4-8
Bell Crank (Lever) Stopper Clearance mm (in) 0 T4-4-8
Front Pin Wear Amount mm (in) - Allowable limit: -1.0 (-0.03) -
Front Bushing Wear Amount mm (in) - Allowable limit: -1.5 (-0.05) -
Clearance Between Front Pin and mm (in) 0.3 (0.01) -
Bushing

TTNEM50-EN-01(20181109) T4-2-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Hydraulic Cylinder Cycle Time sec Power mode: OFF T4-4-10
Lift Arm Raise 5.8±0.3
Lift Arm Lower (Float) 3.5±0.4
Bucket Dump 1.6±0.3
Steering (engine: low idle speed) 3.1±0.3
Steering (engine: high idle speed) 2.7±0.4
Hydraulic Cylinder Cycle Time sec Power mode: ON T4-4-10
Lift Arm Raise 5.3±0.3
Lift Arm Lower (Float) 3.5±0.4
Bucket Dump 1.5±0.3
Steering (engine: low idle speed) 3.1±0.3
Steering (engine: high idle speed) 2.7±0.4
Cylinder Drift Check mm (in)/15 min T4-4-12
Lift Arm Cylinder 10 (0.4) or less
Bucket Cylinder 10 (0.4) or less
Bucket Bottom 50 (1.97) or less
Bucket Levelness mm (in) 10 (0.4) or less T4-4-13

TTNEM50-EN-01(20181109) T4-2-3
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Control Lever Operating Force N (kgf ) Two-lever T4-4-14
Lift Arm Raise 10 (1.0) or less
Lift Arm Raise (Detent) 16 (1.6) or less
Lift Arm Raise (Detent Release) 36 (3.6) or less
Lift Arm Lower 10 (1.0) or less
Lift Arm Lower (Float) 16 (1.6) or less
Lift Arm Lower (Float Release) 36 (3.6) or less
Bucket Control Lever Roll Back 11 (1.1) or less
Bucket Control Lever Roll Back 16 (1.6) or less
(Detent)
Bucket Control Lever Roll Back 36 (3.6) or less
(Detent Release)
Bucket Control Lever Dump 16 (1.6) or less
Steering 16 (1.6) or less
Forward/Reverse Lever 8±1 (1.8±0.2)
Accelerator Pedal 40±2 (4.0±0.2)
Brake Pedal (Right) 313±34 (31.3±3.4)
Declutch Pedal (Left) 313±34 (31.3±3.4)

TTNEM50-EN-01(20181109) T4-2-4
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Control Lever Operating Force N (kgf ) MF (Joystick type) lever T4-4-14
Lift Arm Raise 20 (2.0) or less
Lift Arm Raise (Detent) 40 (4.0) or less
Lift Arm Raise (Detent Release) 50 (5.0) or less
Lift Arm Lower 20 (2.0) or less
Lift Arm Lower (Float) 40 (4.0) or less
Lift Arm Lower (Float Release) 50 (5.0) or less
Bucket Control Lever Roll Back 20 (2.0) or less
Bucket Control Lever Roll Back 40 (4.0) or less
(Detent)
Bucket Control Lever Roll Back 50 (5.0) or less
(Detent Release)
Bucket Control Lever Dump 30 (3.0) or less
Steering 16 (1.6) or less
Forward/Reverse Lever 8±1 (1.8±0.2)
Accelerator Pedal 40±2 (4.0±0.2)
Brake Pedal (Right) 313±34 (31.3±3.4)
Declutch Pedal (Left) 313±34 (31.3±3.4)

fNOTE: MF: Multi-Function

TTNEM50-EN-01(20181109) T4-2-5
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

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

fNOTE: MF: Multi-Function

TTNEM50-EN-01(20181109) T4-2-6
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Pedal Depressing Angle deg. (without play) T4-4-16
Accelerator Pedal 18±1
Brake Pedal (Right) 17.2±1.5
Declutch Pedal (Left) 17.2±1.5
Electrolyte Density 1.26 Allowable limit: 1.16 -
(Specification at 20°C (68°F))
Tire Inflation kPa (PSI) -
Bias Tire 375 (54.4) 23.5-25-16PR
343~441 (50~64) 26.5-25-20PR
Radial Tire 350 (50.8) 23.5R25
392~490 (57~71) 26.5R25

TTNEM50-EN-01(20181109) T4-2-7
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Performance Test Designation Unit Performance Remarks Reference

Standard Page
Primary Pilot Pressure MPa (PSI) 4.8±0.3 (696±43) T4-5-1
Secondary Pilot Pressure MPa (PSI) 3.7+0.5/-0.3 (537+73/-43) T4-5-4
Solenoid Valve Set Pressure MPa (PSI) T4-5-6
Solenoid Valve Unit Set Pressure (Value indicated Value indicated on MPDr.
on MPDr.)±0.2 (29)
Main Pump Delivery Pressure MPa (PSI) 2.0+1.0/-0.5 In neutral, T4-5-8
(290+145/-73) Value indicated on MPDr.
Main Relief Set Pressure MPa (PSI) T4-5-10
Relief Operation of Lift Arm 29.4 to 31.3 Value indicated on MPDr.
(4264 to 4540)
Relief Operation of Bucket 29.4 to 31.3 Value indicated on MPDr.
(4264 to 4540)
Steering Relief Pressure MPa (PSI) 29.4 to 31.3 Value indicated on MPDr. T4-5-14
(4264 to 4540)
Overload Relief Pressure MPa (PSI) Reference values at 50 L T4-5-16
(13.2 gal)/min
Lift Arm Raise 36.3 to 37.3
(5265 to 5410)
Bucket 32.3 to 33.3
(4685 to 4830)
Main Pump Flow Rate Measurement L/min - Refer to T4-2-10, 11 T4-5-18
Service Brake Pressure (Front/Rear) MPa (PSI) 4.6 to 5.4 at brake pedal (right) T4-5-26
(667 to 783)
Parking Brake Pressure MPa (PSI) 10.8 to 17.0 (110 T4-5-28
to 173)
Brake Accumulator Pressure MPa (PSI) T4-5-30
Service Brake 16±1.0 (2321±145)
Parking Brake 16±1.0 (2321±145)
Brake Warning Pressure (Pressure- MPa (PSI) 8±0.5 (1160±73) T4-5-32
Decreasing)
Brake Warning Pressure (Pressure- MPa (PSI) 10±0.5 (1450±73) T4-5-34
Increasing)
Transmission Clutch Pressure MPa (PSI) 1.6 to 1.8 T4-5-36
(232 to 261)
Lock-up Clutch Pressure MPa (PSI) 1.2 to 1.4 T4-5-36
(174 to 203)
Torque Converter Pressure MPa (PSI) T4-5-38
Inlet Pressure 1.1 to 1.3
(160 to 189)
Outlet Pressure 0.43 to 0.73
(62.4 to 105.9)

TTNEM50-EN-01(20181109) T4-2-8
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

(Blank)

TTNEM50-EN-01(20181109) T4-2-9
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Main Pump P-Q Diagram

 P-Q Control (Torque Control) Points on P-Q Line
(Reference: Measured at Test Stand) Delivery Pressure (P) Flow Rate (Q)
 Rated Pump Speed: 2200 min-1 (rpm) MPa (PSI) L (gal)/min
 Hydraulic Oil Temperature: 55±5 °C (131±9 °F)
A 4.9 (711) 275±3 (72.6±0.8)
B 21.6 (3133) 275±5 (72.6±1.3)
fNOTE: Refer to T4-5-16.
C 25.5 (3698) 260±6 (68.7±1.6)
D 29.4 (4264) 220±6 (58.1±1.6)

L/min A B

MPa (kgf/cm2) P

T4GB-04-02-001

TTNEM50-EN-01(20181109) T4-2-10
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

 P-Q Control by Pump Control Pilot Pressure Signal

(Reference: Measured at Test Stand)
Points on Pi-Q Line
Pump Control Pressure (Pi) Flow Rate (Q)
 Rated Pump Speed: 2200 min-1 (rpm) MPa (PSI) L (gal)/min
 Hydraulic Oil Temperature: 55±5 °C (131±9 °F) A 0.39+0.1/-0.2 (56.6+14.5/-29) 275±3 (72.6±0.8)
f NOTE: Refer to T4-5-18. B 1.25±0.05 (181.3±7.25) 70±2 (18.5±0.53)
C 1.96+0.2/-0 (284.3+29/-0) 40±2 (10.6±0.53)

Q
L/min
A

MPa (kgf/cm2) Pi

T4GB-04-02-002

TTNEM50-EN-01(20181109) T4-2-11
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard

Sensor Activating Range

1. Checking Method
 Hydraulic Oil Temperature: 55±5 °C (131±9 °F)
 Unless specified:

Engine Speed Power Mode

Switch
High Idle Speed ON

• Monitor each sensor by using MPDr.

2. Sensor Activating Range

Item Operation Specification

Pump Delivery Pressure Neutral 1.5 to 3.0 MPa (218 to 435 PSI)
Relieved 29.4 to 31.3 MPa (4264 to 4540 PSI)
Main Relief Pressure Neutral 1.5 to 3.0 MPa (218 to 435 PSI)
Control Lever: Relieved 29.4 to 31.3 MPa (4264 to 4540 PSI)
Parking Brake Pressure Parking Brake Switch: ON 0 to 0.1 MPa (0 to 14.5 PSI)
Parking Brake Switch: OFF 10.8 to 17.0 MPa (1566 to 2466 PSI)
Service Brake Pressure Brake Pedal: Neutral 0 to 0.1 MPa (0 to 14.5 PSI)
Brake Pedal: Fully Depressed 4.6 to 5.4 MPa (667 to 783 PSI)

TTNEM50-EN-01(20181109) T4-2-12
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test

Engine Speed

Summary:
1. Measure the engine speed by using the monitor
unit or MPDr.
2. Measure the engine speeds in each mode.

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

other performance data will be unreliable. Consequently,
measure the engine speed before performing all other
tests in order to check that the engine speed meets
specification.

Preparation:
1. Select the service menu of monitor (In case of
MPDr., install MPDr. first).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, hydraulic oil
temperature is 55±5 °C (131±9 °F), and transmission
oil temperature is 85±5 °C (185±9 °F).

TTNEM50-EN-01(20181109) T4-3-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test

Measurement:
1. Measure the items as shown in the table below.
2. When measuring, set the switch and test condition
as shown in the table below in response to the
engine speed to be measured.

Forward/Reverse Accelerator Pedal Parking Brake Switch Power Mode

Lever, Shift Switch
Low Idle Speed N No depression ON ON/OFF
(with no load)
High Idle Speed First speed forward Full stroke ON ON/OFF
(with no load)
High Idle Speed Second speed Full stroke OFF ON/OFF
(with torque converter forward
stalled)
High Idle Speed Third speed forward Full stroke OFF ON/OFF
(with torque converter
stalled and relieved)

Declutch Cut Position Brake Pedal Control Lever

Switch (Bucket)
Low Idle Speed OFF - Transporting
(with no load) position, No control
lever operation
High Idle Speed OFF Full stroke Transporting
(with no load) position, No control
lever operation
High Idle Speed OFF Full stroke Transporting
(with torque converter position, No control
stalled) lever operation
High Idle Speed OFF Full stroke Transporting
(with torque converter position, Bucket
stalled and relieved) is rolled back and
relieved.

Evaluation:
Refer to Operational Performance Standard (p.T4-2-1).

Remedy:
Refer to Troubleshooting B.
f NOTE: Engine System Troubleshooting (T5-6-27).

TTNEM50-EN-01(20181109) T4-3-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test

Lubricant Consumption

Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level gauge.
4. Operate the machine for at least 100 hours or until
the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in step
1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.

fNOTE: When measuring, use a high-precision

measuring cylinder or the like.
8. Determine lubricant consumption from the
following equation: Oil replenishing volume (C)
[mL] / Operating hours (B-A) [hr]

Evaluation:
50 mL/h (3 in3/h) or less

TTNEM50-EN-01(20181109) T4-3-3
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test

(Blank)

TTNEM50-EN-01(20181109) T4-3-4
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Travel Speed
Summary:
Measure the time required for the machine to travel
a 50 m (164 ft) test track and check the performance
of the travel drive system (torque converter to
transmission).

Preparation:
1. Adjust air pressure of the tires in advance.
 Bias Tire
(23.5-25-16PR): 375 kPa (54.4 PSI)
(26.5-25-20PR): 343~441 kPa (50~64 PSI)
 Radial Tire
(23.5R25): 350 kPa (50.8 PSI)
(26.5R25): 392~490 kPa (57~71 PSI)

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

length, with extra length of 70 m (229 ft) on both
ends for machine acceleration and deceleration.
(For measurement at fifth speed, a 300 m (984 ft) a
acceleration zone is needed.)
3. Empty the bucket and hold the lift arm with it c b c
floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the d e
ground. T4GB-04-04-001

4. Maintain the hydraulic oil temperature at 55±5°C a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 c- Acceleration/Deceleration

(131±9°F). Warm the axle oil satisfactorily by in) Zone
repeating travel operation and brake operation. b- Test Track d- End
Make a warm up operation so that the indicators of e- Start
the coolant temperature monitor and the torque
converter oil temperature monitor should rise
above the horizontal position.

TTNEM50-EN-01(20181109) T4-4-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Measurement:

dCAUTION: Do not perform measurement in

reverse travel to avoid accident.

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

2. Select the switches as follows.
Shift Switch Parking Brake Accelerator Pedal Power Mode
Switch
First Speed First Speed OFF Full Stroke ON/OFF
Second Speed Second Speed OFF Full Stroke ON/OFF
Third Speed Third Speed OFF Full Stroke ON/OFF
Fourth Speed Fourth Speed OFF Full Stroke ON/OFF
Fifth Speed Fifth Speed OFF Full Stroke ON/OFF

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

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

Evaluation:
1
Refer to Operational Performance Standard (p.T4-2-2).
TNEK-01-02-014
Remedy:
Refer to Troubleshooting B. 1- Machine Speed Sensor
f NOTE: Travel System Troubleshooting (p.T5-6-38)

TTNEM50-EN-01(20181109) T4-4-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

(Blank)

TTNEM50-EN-01(20181109) T4-4-3
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Service Brake Function Check

Summary:
1. Check the performance of the service brake.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance
test.

Preparation:
1. Adjust air pressure of the tires evenly in advance.
 Bias Tire
(23.5-25-16PR): 375 kPa (54.4 PSI)
(26.5-25-20PR): 343~441 kPa (50~64 PSI)
 Radial Tire
(23.5R25): 350 kPa (50.8 PSI)
a
(26.5R25): 392~490 kPa (57~71 PSI)
c b
2. On a paved dry road, prepare a 150 m (492
c d
ft) straight travel course (a 100 m (328 ft) of
T4GB-04-04-002
acceleration zone and a 50 m (164 ft) of test track)
and set the brake starting point. a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 c- Stop Position
in) d- Brake Starting Point
3. Empty the bucket and hold the lift arm with it b- Braking Distance
floated 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 in) above the
ground.
4. Maintain the hydraulic oil temperature at 55±5°C
(131±9°F). Warm the axle oil satisfactorily by
repeating travel operation and brake operation.
Make a warm up operation so that the indicators of
the coolant temperature monitor and the torque
converter oil temperature monitor should rise
above the horizontal position.

TTNEM50-EN-01(20181109) T4-4-4
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Measurement:

dCAUTION: Do not perform measurement in

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

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

position. Start traveling the machine in the
acceleration zone with the accelerator pedal
depressed to the stroke end and travel at 35 km/h
(22 mph).
4. Release the accelerator pedal and step on the right
service brake pedal at the brake starting point.
Completely stop the machine.
5. Measure the distance from the brake starting point
to the point where the front tire is contacting.
6. Repeat the measurement three times and calculate
the mean values. Add traveling distance 0.97 m (3 ft
2 in) to the mean value. This is stopping distance.

Evaluation:
Stopping distance: 12 m (13 yard) or less

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-4-5
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Service Brake Wear Amount

Summary: 1

Check the extent of wear of the brake disc at the

service brake of the axle by using a wear gauge or
thickness gauge (5.3 mm) (0.2 in).

Preparation:
1. Clean around inspection plug (1) of the axle and
loosen it.
2. In case of the rear axle, inspection plug (1) is located
below the center line of the differential. Loosen
inspection plug (1) after draining axle oil.
T4GB-04-04-004

Measurement:
1. Operate the service brake by stepping on the brake
7 2
pedal.
2. Insert wear gauge (2) into inspection port (7) until it
contacts brake disc (6) between brake ring (3) and
brake ring (4).

Evaluation:
1. In case wear gauge (2) has entered between brake
rings (3, 4) and the model scale of wear gauge
(2) and housing surface (5) have coincided, the
wear amount of brake disc (6) does not reach the
maximum allowable limit of use. In case wear gauge T4GB-04-04-005
(2) has not entered between brake rings (3, 4) and
the model scale is sticking above housing surface
(5), brake disc (6) is worn in excess of the maximum
5
allowable limit of use.
2
2. In the method above, in case the wear amount is
beyond the maximum allowable limit of use or in
case the service brake portion has been assembled,
refer to Operational Performance Standard in T4-2.
L
 Distance (L) between Housing Surface (5) and Brake
Disc (6): 54 mm (2.13 in)

IMPORTANT: One kind of brake ring (4) and two

kinds of brake ring (3) are available. Thickness of
6
them are different as below.
In addition, combination patterns of brake rings
(3, 4) may be different depending on serial No.
3
 Brake ring (4) thickness (new):
11.9 mm (0.47 in) 4
T4GB-04-04-006
 Brake ring (3) thickness (new):
6.5 mm (0.26 in), 6.9 mm (0.27 in)

TTNEM50-EN-01(20181109) T4-4-6
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Parking Brake Function Check

Summary:
1. Measure the parking brake function on a specified
slope.
2. The braking capability of the brake is an item of
safety control. Be sure to conduct the performance
test.

Preparation:
1. Measure on a 1/5 slope (approx. 11.3°).
2. Empty the bucket and hold the bucket with it
floated at the specified height (a) from the ground.
3. Maintain the hydraulic oil temperature at 55±5°C
(131±9°F). Warm the axle oil satisfactorily by
repeating travel operation and brake operation. a
Make a warm up operation so that the indicators of
the coolant temperature monitor and the torque
converter oil temperature monitor should rise b
above the horizontal position.
T4GB-04-04-003

Measurement:
a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8 b- 11.3° (20%)
1. Climb the slope and set the parking brake switch to in)
the ON position.
2. Stop the engine.
3. Put a mark (white line) on each tire and the road
surface respectively.
4. After five minutes, measure the amount of
movement between white lines of tire and road
surface.
5. Repeat the measurement three times and calculate
the mean values.

Evaluation:
No movement.

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-4-7
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Bucket Stopper Clearance, Lever (Bell Crank)

Stopper Clearance
Summary:
Measure wear and deformation conditions of the
bucket roll back stopper and bucket dump stopper,
and the clearance between bucket dump stopper and
lift arm.

Preparation:
1. Stop the machine on a plane road surface and apply
the parking brake.
a
Measurement:
b
 Bucket Dump Stoppers (a, b)
1. Raise the lift arm to the highest lifting position and
stop the engine.
2. Dump the bucket calmly with the engine stopped
until cross pipe dump stopper (b) contacts the cross
pipe.
At this time, measure strokes (A and B) of the bucket
cylinder and the lift arm and dump angle (C) of the
bucket. In addition, measure the clearance between
bucket dump stopper (a) and the lift arm.
3. At the same time, measure the contact condition of
bucket dump stopper (a) (left and right).
 Bucket Roll Back Stopper (c)
1. Raise the lift arm until lift arm cylinder stroke (E) T4GB-04-04-008
becomes the length of the standard dimension.
a- Bucket Dump Stopper b- Cross Pipe Dump Stopper
2. Set the engine at idling speed and roll back the
bucket calmly until it contacts bucket roll back
stopper (c).
3. At this time, measure strokes (D and E) of the bucket
cylinder and the lift arm cylinder and roll back angle
(F) of the bucket. In addition, measure height (G)
c
from the ground to the center of bucket hinge pin.
4. At the same time, measure the contact condition of
bucket roll back stopper (c) (left and right).

90T4GB-04-04-10

c- Bucket Roll Back Stopper

TTNEM50-EN-01(20181109) T4-4-8
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Evaluation:
1. Bucket Dump Stopper 2. Bucket Roll Back Stopper
 Cylinder Stroke (A)(B) (For reference)  Cylinder Stroke (D)(E) (For reference)
Bucket Cylinder (A) Lift Arm Cylinder (B) (mm Bucket Cylinder (D) Lift Arm Cylinder (E) (mm
(mm (in)) (in)) (mm (in)) (in))
390±2 (15.4±0.08) 1185±2 (46.7±0.08) 725±2 (28.5±0.08) 272±2 (10.7±0.08)

 Bucket Dump Angle (C)

 Bucket Roll Back Angle (F)
C (deg.)
F (deg.)
46.5 to 49.5
41 to 43

 Clearance between Cross Pipe and Cross Pipe Dump

Stopper (b)  Height from Ground to Bucket Hinge Center (G)
Clearance between Stopper and Pipe (With 23.5-25-16 tires)
Standard 0 (Even contact both sides) G (mm (in))
290 (11.4)
 Clearance between Lift Arm and Bucket Dump
Stopper (a)
 Clearance between Lift Arm and Bucket Roll Back
Clearance between Stopper and Lift Stopper (c)
Arm
Clearance between Stopper and Lift
Standard 5±2 (0.2±0.08)
Arm
Standard 0 (Even contact both sides)

fNOTE:
 Standard dimensions indicate those with new tires
(standard) at the specified air pressure.
 When installing roll-back stoppers, the stoppers must
have a smooth radius and must contact lift arm on
both sides. The bucket cylinder must retain 3~5 mm of
rod with in the cylinders so the piston does not hit the
cylinder head.

TTNEM50-EN-01(20181109) T4-4-9
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Hydraulic Cylinder Cycle Time Lift Arm Cylinder:

(Raising)
Summary:
1. Measure the operating time of cylinders for
the lift arm, bucket, and steering and check the
performance of the cylinder drive system (main
pump to each cylinder).
2. The bucket should be empty.

T4GB-04-04-016
Preparation:
1. Measurement is made for the following positions.
(Lowering)
 Measurement of Lift Arm Cylinder (Raising)
Fully roll back the bucket and lower the lift arm.
 Measurement of Lift Arm Cylinder (Lowering)
Lower the lift arm until the bucket bottom surface
touches the ground horizontally.
 Measurement of Bucket Cylinder
Lift the lift arm to the highest position.
 Measurement of Steering Cylinder
Empty the bucket and take the travel forward T487-04-03-005
position.
2. Maintain the hydraulic oil temperature at 55±5°C
(131±9°F). Bucket Cylinder:

dCAUTION: Select ground filled with sand or

something so that the bucket contacts the ground
with buffer.

T487-04-03-006

Travel Position

M4GB-04-001

a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8
in)

TTNEM50-EN-01(20181109) T4-4-10
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Measurement:
1. Set the pedal, switches, and forward/reverse lever as
follows.
Accelerator Pedal Parking Brake Forward/ Power Mode
Switch Reverse Lever
Lift Arm (Raising) Full stroke (engine: high idle speed) ON F1 ON/OFF
Lift Arm (Lowering) Full stroke (engine: high idle speed) ON F1 ON/OFF
Bucket Full stroke (engine: high idle speed) ON F1 ON/OFF
Steering Full stroke (engine: high idle speed) OFF N ON/OFF

dCAUTION: Prevent personal injury. Always make

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

Evaluation:
Refer to Operational Performance Standard (p.T4-2-3).

Remedy:
Refer to Troubleshooting B.
f NOTE: Front Attachment System Troubleshooting (p.T5-
6-32)

TTNEM50-EN-01(20181109) T4-4-11
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Cylinder Drift Check

Summary:
1. Measure cylinder natural drift, which can be caused
by oil leakage in lift arm cylinder, bucket cylinder,
and the control valve, with the bucket loaded.
2. Measure in the standard front condition (standard
bucket).
3. In case measurement is made immediately after the
cylinder replacement, bleed air from the cylinder
before measurement by operating the cylinders
slowly to the stroke end several times.

Preparation:
1. Load the bucket with either soil or a weight
equivalent to the weight standard: 6120 kg (13490
lb)

dCAUTION: Never allow any personnel to be

under the bucket.
1

2. In the front position, extend the lift arm to the

maximum reach and hold the bucket at an angle of
about 5 degrees declined forward from full tilting
(rolling back).
3. Maintain the hydraulic oil temperature at 55±5°C
(131±9°F).

2
Measurement: a

1. Stop the engine.

2. In 15 minutes after the engine has been stopped,
measure the change in position of lift arm cylinder
(2) (b), bucket cylinder (1) (b), and bottom of the
bucket (a). T4GB-04-04-014

3. Repeat the measurement three times and calculate a- Bucket Bottom Drift Amount
the mean values.

Evaluation:
Drift amount:
Lift Arm Cylinder: 10 mm (0.4 in) or less
Bucket Cylinder: 10 mm (0.4 in) or less
Bucket Bottom (a): 50 mm (1.97 in) or less
b
Remedy:
TNEE-04-04-001
Refer to Troubleshooting B.
f NOTE: Front Attachment System Troubleshooting (p.T5- b- Cylinder Drift Amount
6-32)

TTNEM50-EN-01(20181109) T4-4-12
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Bucket Levelness
Summary:
1. Check left and right inclinations of the bucket.

Preparation:
1. Place the unloaded machine on a level platen on
the ground. (In case a platen is not available, place
it on a horizontal flat concrete on the ground. Deal
with the measurement values as guide lines.)
2. Adjust the tire air pressure to the designated value
all evenly.
3. Lower the bucket onto the ground in the horizontal
position.
1

Measurement:
T4GB-04-04-011
dCAUTION: Never put hands, feet, and measuring
instruments under the bucket.
1. Float the bucket bottom slightly above the platen.
2. Measure the vertical distance from the platen and
the bottom surface of cutting edge (1) on the left
and right ends, and confirm the difference.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Drift amount: 10 mm (0.4 in) or less

TTNEM50-EN-01(20181109) T4-4-13
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Control Lever Operating Force

Summary:
1. Measure a play and operating condition of each
control lever, pedal, and steering wheel, and
measure operating force of them.

2. Measure maximum operating force of each control Travel Position

lever, pedal, and steering wheel.

3. Measure at the grip center of each control lever.

Measure at 10 mm (0.4 in) from the end of forward/
reverse lever.
Measure at 150 mm (6 in) from the pedal support of
each pedal.

Preparation: M4GB-04-001

1. In the front position, empty the bucket in advance.

a- 0.4 to 0.5 m (1 ft 4 in to 1 ft 8
in)
2. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

TTNEM50-EN-01(20181109) T4-4-14
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Measurement:
1. Measure for each control lever, pedal, and steering
wheel.
2. Set the pedal, switches, and forward/reverse lever as
follows.
Accelerator Pedal Parking Brake Forward/Reverse
Switch Lever
Neutral (engine: low ON N
idle speed)

dCAUTION: Prevent personal injury. Always make

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

Evaluation:
Refer to Operational Performance Standard.
 Two-lever: p.T4-2-4
 MF (Joystick type) lever: p.T4-2-5

TTNEM50-EN-01(20181109) T4-4-15
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test

Control Lever Stroke

Summary:
1. Measure a play and operating condition of each
control lever, pedal, and steering wheel, and
measure the stroke.
2. Measure at the grip tip of each control lever.
Measure at the pedal top of each pedal.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both side
lever strokes.

Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Measure as follows.
 Measurement of Control Lever
 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure each lever stroke from neutral to the stroke
end of each control lever of lift arm, bucket, and
forward/reverse at the grip top center.
 Measurement of Pedal
 Lower the bucket bottom onto the ground.
 Stop the engine.
 Measure the stroke from neutral to the stroke end of
the pedal at the pedal top.
 Measurement of Steering Wheel
 Start the engine. (Low idle)
 Float the bucket slightly above the ground.
 Measure the number of times of rotation required
for movement of the steering wheel from the right
to the left stroke end and from the left to the right
stroke end.

2. Measure the chord length from neutral to the stroke

end.

3. Repeat the measurement three times and calculate

the mean values.

Evaluation:
Refer to Operational Performance Standard (p.T4-2-6).

TTNEM50-EN-01(20181109) T4-4-16
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Primary Pilot Pressure (Including Brake

Circuit)

dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system after
removing and installing the brake piping and
replacing hydraulic oil. (Refer to Troubleshooting
1
B.)

IMPORTANT: The primary pilot pressure circuit

delivers pressure oil from pilot pump (1) to the
brake circuit when the pressure in service brake
accumulator (4) decreases, and accumulates
the pressure in service brake accumulator (4).
Therefore, the brake circuit pressure (15.5 MPa,
2248 PSI or higher) is higher than the pilot
circuit pressure. Use a pressure gauge capable of
measuring over 15.5 MPa (2248 PSI).

Preparation: 4 2

1. Stop the engine.

TNED-04-05-001
2. Push the air bleed valve on top of the hydraulic oil 3
tank and bleed air.
3. Disconnect hose (3) from the pilot filter (2) inlet or
outlet port. Install the adapter (13/16-16UNF), a
nipple, a pressure gauge, and a coupling between
pilot filter (2) and hose (3).

j : 22 mm, 24 mm, 27 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

T1F3-04-05-001

TTNEM50-EN-01(20181109) T4-5-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.
Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever
Full stroke ON ON N

2. Read pressures on the pressure gauge with no load.

3. Repeat the measurement three times and calculate
the mean values.

fNOTE: When the pressure in the service brake

accumulator decreases during measurement of primary
pilot pressure, the measured value increases to 15.5 MPa
(2248 PSI) for several seconds.

Evaluation:
Standard. 4.8±0.3 MPa (696±43 PSI)

TTNEM50-EN-01(20181109) T4-5-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Primary Pilot Pressure Adjustment Procedure

Adjustment: 1

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

j : 36 mm A A

2. Install the estimated number of shims (2).

fNOTE: Total thickness of shim (2) should be less than

1.5 mm.
3. After the adjustment, tighten plug (1).

m : 98.0±9.8 N·m (72±7.2 lbf·ft)

5. After the adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference)

Shim (2) Thickness Change in Pressure
mm (in) kPa (PSI)
0.2 (0.008) 61.8 (9.0)
0.5 (0.020) 154.5 (22.4)

TNED-03-07-008

Section A-A

TNED-03-07-018

1- Plug
2- Shim

TTNEM50-EN-01(20181109) T4-5-3
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Secondary Pilot Pressure

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Measure the pressure between pilot valve and
control valve. Disconnect pilot hose (1) from the
circuit to be measured. Install a tee and a pressure
gauge.

j : 17 mm, 19 mm, 22 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

Measurement:
1. Select the following conditions.
1 TNED-04-05-002
Accelerator Power Mode Parking Brake Forward/
Pedal Switch Switch Reverse Lever
Full stroke ON ON N

2. Measure the pilot pressure by using a pressure

gauge with the lift arm and bucket control levers
operated to full stroke.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 3.7+0.5/-0.3 MPa (537+73/-43 PSI)

Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.

fNOTE:
All Actuator System Troubleshooting (p.T5-6-29)
Front Attachment System Troubleshooting (p.T5-6-32)
Steering System Troubleshooting (p.T5-6-36)
Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-4
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

(Blank)

TTNEM50-EN-01(20181109) T4-5-5
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Solenoid Valve Set Pressure

Summary:
Use MPDr. and pressure gauge (2) at the same time. 1

2
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil 6
tank and bleed air.
3. Disconnect the hose from the solenoid valve to be
measured. Install tee (4) (ST 6451), hose (5) (Parts
Number: 4216453), adapter (3) (ST 6461), adapter 5 4 3
(6) (ST 6069), and pressure gauge (2) (ST 6942).

j : 17 mm, 19 mm, 22 mm T157-05-04-002

1- Solenoid Valve Unit 4- Tee
4. Connect MPDr. and select the monitoring function. 2- Pressure Gauge 5- Hose
5. Start the engine. Confirm that no oil leakage is 3- Adapter 6- Adapter
observed at the pressure gauge connection.
6. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

Measurement:
1. Select the following conditions.
SZ SJ
Accelerator Pedal Power Mode Switch
Full stroke ON

2. Perform the following procedures for the solenoid

valve to be measured.
 Solenoid Valve (SJ):
Turn the ride control switch ON/OFF and check
vibration of the front attachment while traveling.
 Solenoid Valve (SZ):
Performs combined operation of lift arm raise and
bucket tilt.
3. Read the values on both MPDr. and the pressure
gauge. TDAA-03-07-002

4. Repeat the measurement three times and calculate

the mean values.

Evaluation:
(Value indicated on MPDr.)±0.2 MPa (29 PSI)

TTNEM50-EN-01(20181109) T4-5-6
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Solenoid Valve Adjustment Procedure

7 9
IMPORTANT: As O-ring (9) is damaged and oil
leakage may cause, do not loosen adjusting screw
(8) excessively. 8

Do not loosen adjusting screw (8) more than 2

turns from fully tightened position.

1. Loosen lock nut (7). Turn adjusting screw (8) and

adjust the set pressure.
2. After the adjustment, tighten lock nut (7).
a
j : 13 mm
b TDAA-04-05-013
m : 5 N·m (3.69 lbf·ft)
a - 0.7 mm (0.028 in) b - 2.0 mm (0.079 in)
l : 3 mm
3. After the adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference)

Adjusting Screw (8) Turns 1/4 1/2 3/4 1
7
Change in kPa 111 222 333 444
Pressure (PSI) (16.1) (32.2) (48.3) (64.4)
8

TDAA-04-05-012

7 8

c d

W107-02-05-129

c - Pressure Increase d - Pressure Decrease

7- Lock Nut 9- O-Ring

8- Adjusting Screw

TTNEM50-EN-01(20181109) T4-5-7
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Main Pump Delivery Pressure

The main pump delivery pressure can be also measured
by using MPDr.
ST 6941

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure
check port (1) of the main pump.
Install the adapter, hose, and pressure gauge to the
port as shown.

j : 19 mm

l : 6 mm 1

4. Connect MPDr. and select the monitoring function. ST 6069

Start the engine. Confirm that no oil leakage is ST 6943
observed at the pressure gauge connection. T4GB-04-05-008

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

(131±9 °F). 1- Pump 1 Delivery Pressure
Check Port

Measurement:
1. Select the following conditions. fNOTE: ST xxxx is tool number.
ST 6069: Adapter
Accelerator Power Mode Parking Forward/ ST 6943: Hose
Pedal Switch Brake Switch Reverse ST 6941: Pressure gauge
Lever
Full stroke ON ON N

2. Measure the pressure with the control levers in

neutral without load.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard (neutral): 2.0+1.0/-0.5 MPa (290+145/-73 PSI)

Remedy:
Refer to Troubleshooting A for any accompanied error
code.
Refer to Troubleshooting B for observed phenomena.
f NOTE:
All Actuator System Troubleshooting (p.T5-6-29)
Front Attachment System Troubleshooting (p.T5-6-32)
Steering System Troubleshooting (p.T5-6-36)

TTNEM50-EN-01(20181109) T4-5-8
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

(Blank)

TTNEM50-EN-01(20181109) T4-5-9
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Loading Circuit Main Relief Set Pressure

Summary:
Measure the main relief valve set pressure at the ST 6941
delivery port in main pump.
The main relief set pressure can be also measured by
using MPDr.

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure
check port (1) of the main pump.
Install the adapter, hose, and pressure gauge to the
port as shown. 1

j : 19 mm ST 6069
ST 6943
l : 6 mm T4GB-04-05-008

4. Connect MPDr. and select the monitoring function.

Start the engine. Confirm that no oil leakage is 1- Pump 1 Delivery Pressure
observed at the pressure gauge connection. Check Port

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

(131±9 °F). fNOTE: ST xxxx is tool number.
ST 6069: Adapter
ST 6943: Hose
ST 6941: Pressure gauge

TTNEM50-EN-01(20181109) T4-5-10
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever

Full stroke ON ON N

2. Slowly operate each control lever of bucket and

lift arm. Operate each cylinder to the stroke end
(extend, retract) and relieve the main relief valve.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard (relief operation):
29.4 to 31.3 MPa (4264 to 4540 PSI)

TTNEM50-EN-01(20181109) T4-5-11
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Main Relief Valve Pressure Adjustment Procedure

1. While holding lock nut (1), remove nut (3).

j : 17 mm
2. While holding screw (2), loosen lock nut (1).

j : 17 mm
3. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
3
4. While holding screw (2), tighten lock nut (1).

m : 19.5 N·m (14.4 lbf·ft)

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

fNOTE: Standard Change in Pressure (Reference)

Adjusting Screw (2) 1/4 1/2 3/4 1
2
Turns
Change in MPa 2.79 5.59 8.36 11.2
Pressure (PSI) (405) (811) (1213) (1624)

a b

T105-06-05-002

a - Pressure Increase b - Pressure Decrease

TTNEM50-EN-01(20181109) T4-5-12
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

(Blank)

TTNEM50-EN-01(20181109) T4-5-13
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Steering Circuit Relief Set Pressure

Summary:
1. Measure the steering relief valve set pressure at the ST 6941
delivery port in the main pump. The steering relief
set pressure can be also measured by using MPDr.

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure
check port (1) of the main pump to be measured.
Install the adapter, hose, and pressure gauge to the
1
port (1) as shown.
ST 6069
j : 19 mm ST 6943
T4GB-04-05-008
l : 6 mm
4. Connect MPDr. and select the monitoring function. 1- Pump 1 Delivery Pressure
Start the engine. Confirm that no oil leakage is Check Port
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
fNOTE: ST xxxx is tool number.
ST 6069: Adapter
ST 6943: Hose
ST 6941: Pressure gauge
Measurement:
1. Select the following conditions.

Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever

Full stroke ON ON N

2. Install the articulation lock bar.

Slowly operate the steering wheel and relieve the
steering.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 29.4 to 31.3 MPa (4264 to 4540 PSI)

TTNEM50-EN-01(20181109) T4-5-14
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Steering Relief Valve Pressure Adjustment

4
Procedure
1. While holding lock nut (1), remove nut (3).

j : 24 mm
2. While holding screw (2), loosen lock nut (1).

j : 24 mm
3. Turn adjusting screw (2) and adjust the relief
pressure to the specification.
4. While holding screw (2), tighten lock nut (1).

m : 37 N·m (27.3 lbf·ft)

T4GB-04-05-012
5. While holding lock nut (1), tighten nut (3).
3 1
m : 37 N·m (27.3 lbf·ft)
6. Check the relief set pressures.

fNOTE: Standard Change in Pressure (Reference)

Adjusting Screw (2) 1/4 1/2 3/4 1
Turns
Change in MPa 3.8 7.5 11.3 15.0
Pressure (PSI) (551) (1088) (1639) (2176)
2
T4GB-04-05-013

a b

T105-06-05-002

a - Pressure Increase b - Pressure Decrease

TTNEM50-EN-01(20181109) T4-5-15
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Loading Overload Relief Valve Set Pressure Measurement:

1. Select the following conditions.
Summary:
1. The circuit pressure must be increased by applying Accelerator Power Mode Parking Forward/
an external force while blocking the return circuit of Pedal Switch Brake Switch Reverse
the control valve. However, this measuring method Lever
is hazardous and the results obtained with this Full stroke ON ON N
method are unreliable.
2. Accordingly, the overload relief valve assembly 2. Slowly operate the bucket or lift arm control lever.
should be removed from the machine and checked Operate each cylinder to the stroke end (extend,
on a specified test stand at a correct oil flow rate. retract) and relieve the relief valve.
3. Measure the pressure on the machine is not 3. Read the pressure on the pressure gauge at this
recommended because of above mentioned time.
reasons. If the measurement on the machine is
4. Perform the measurement for the bucket and lift
required, please substitute the measurement of the
arm in sequence.
main relief set pressure.
5. Repeat the measurement three times and calculate
fNOTE: The main relief set pressure can be also the mean values.
measured by using MPDr.

ST 6941
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug (G1/4) from delivery pressure
check port (1) of the main pump to be measured.
Install the adapter, hose, and pressure gauge to the
port as shown.
1
j : 19 mm
ST 6069
l : 6 mm ST 6943

4. Connect MPDr. and select the monitoring function. T4GB-04-05-008

Start the engine. Confirm that no oil leakage is
1- Pump 1 Delivery Pressure Check Port
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
fNOTE: ST xxxx is tool number.
ST 6069: Adapter
ST 6943: Hose
ST 6941: Pressure gauge

Evaluation:
The overload relief valves are normal when each main
relief set pressure in the measured circuits (bucket and
lift arm) is within the specified value range.

Reference values at 50 L (13.2 gal)/min:

Lift arm raise: 36.3 to 37.3 MPa (5265 to 5410 PSI)
Bucket: 32.3 to 33.3 MPa (4685 to 4830 PSI)

TTNEM50-EN-01(20181109) T4-5-16
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Overload Relief Valve Pressure Adjustment

Procedure (Reference)
IMPORTANT: Adjust the overload relief valve 1
pressure on a test stand.
2
Loosen lock nut (1) and adjust the set pressure of the
overload relief valve by using adjusting screw (2).

1. Loosen lock nut (1).

TNED-04-05-003
j : 22 mm
2. Turn adjusting screw (2) and adjust the set pressure. 1- Lock Nut 2- Adjusting Screw

l : 6 mm
3. Tighten lock nut (1).

j : 22 mm
4. After the adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference) 1 2

Adjusting Screw (2) 1/4 1/2 3/4 1
Turns
Change in MPa 5.2 10.6 15.9 21.1 a b
Pressure (PSI) (754) (1537) (2306) (3060)

W107-02-05-129

a - Pressure Increase b - Pressure Decrease

TTNEM50-EN-01(20181109) T4-5-17
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Main Pump Flow Rate Measurement

 P-Q Control (Torque Control)
Summary:
Install hydraulic tester (5) to the delivery port of the 6. Remove the vacuum pump. Loosen plug (12) on top
main pump to be measured. Main pump performance of the pump casing. Bleed air from the casing until
is checked by measuring the pump flow rate. Use MPDr. oil comes out.
and a pressure gauge at the same time.
j : 41 mm
IMPORTANT: This measurement procedure is a 7. Fully open the loading valve of hydraulic tester (5).
simple method. In order to measure accurately,
8. Start the engine. Confirm that no oil leakage
disconnect the return circuit from the control
is observed at the pressure gauge connection.
valve and connect it to the hydraulic oil tank.
Connect MPDr. and select the monitoring function.

Preparation:
Measurement:
1. Stop the engine. Push the air bleed valve on top the
1. Maintain the hydraulic oil temperature at 55±5 °C
hydraulic oil tank and bleed air. Connect a vacuum
(131±9 °F).
pump to the oil filler port.
2. Measure the maximum flow rate.
fNOTE: Operate the vacuum pump while connecting the
3. Select the following conditions.
pump flow rate test line.
2. Disconnect delivery hose (7) from the main pump Accelerator Power Mode Parking Forward/
to be measured. Connect test hose (3) to the main Pedal Brake Switch Reverse
pump delivery port. Lever
j : 41 mm Full stroke ON ON N

3. Install test hose (3) to hydraulic tester (5) by using

adapter (4). Install adapter (6) and delivery hose (7) 4. Slowly restrict the loading valve of hydraulic tester
to hydraulic tester (5). (5) while relieving pressure in the bucket tilt circuit.
Measure the flow rate and engine speeds at each
j : 41 mm pressure point specified in the P-Q curve. (Refer to
4. Install a pressure gauge to the main pump to be T4-2-10.)
measured. (Refer to Main Relief Set Pressure.) 5. Repeat the measurement three times and calculate
the mean values.
l : 6 mm
5. Disconnect hose (14) of port ST (13) from the
regulator. Install the plug (G1/4) to the removed
hose (14) and port ST (13).

j : 17 mm

TTNEM50-EN-01(20181109) T4-5-18
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formula:
Qc = Ns×Q/Ne

Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Engine Speed: 2200 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
2. Standard Flow Rate
Refer to Operational Performance Standard.

3 4 5 6 7

TNED-04-05-005

12

14 13
TNED-04-05-004

3- Test Hose (1-7/16-12UN) 5- Hydraulic Tester (ST 6299) 7- Delivery Hose 14- Hose
4- Adapter 1-7/16-12UN×G1- 6- Adapter 1-7/16-12UN×G1- 12- Plug
1/2 1/2 13- Port ST

TTNEM50-EN-01(20181109) T4-5-19
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

 Pilot Characteristics

Summary:
Install hydraulic tester (5) to the delivery port of the 7. Remove the vacuum pump. Loosen plug (12) on top
main pump to be measured. Main pump performance of the pump casing. Bleed air from the casing until
is checked by measuring the pump flow rate. Use MPDr. oil comes out.
and pressure gauge (18) at the same time.
j : 41 mm
IMPORTANT: This measurement procedure is a 8. Fully open the loading valve of hydraulic tester (5).
simple method. In order to measure accurately,
disconnect the return circuit from the control 9. Start the engine. Confirm that no oil leakage is
valve and connect it to the hydraulic oil tank. observed at the pipe connection.

Preparation:
1. While referring to steps 1 to step 3 on T4-5-18,
install hydraulic tester (5) to the main pump to be
measured.
2. Disconnect the hose from regulator port Pi1 (21)
of the pump to be measured. Install the plug
(UNF9/16) to the removed hose.

j : 19 mm
3. Connect regulator port Pi2 (8) and port VQ (2) to the
hydraulic oil tank.

j : 19 mm
4. Install adapter (15) and adapters (13) (2 used)
to reducing valve (16). Remove plug (23) from
manifold valve (1). Install adapter (13) and hose (14).
Connect hose (14) to port P1 of reducing valve (16).

l : 8 mm

j : 19 mm
5. Install tee (17) to port P2 of reducing valve (16).
Connect pressure gauge (18) and hose (14) to tee
(17). Connect hose (14) to the regulator.

j : 19 mm
6. Connect hose (19) and tee (20) to port T of reducing
valve (16). Disconnect hose (10) from return pipe
(22). Install tee (20) to return pipe (22). Connect
hoses (10, 19) to tee (20).

j : 22 mm, 27 mm

TTNEM50-EN-01(20181109) T4-5-20
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

3 4 5 6 7

TNED-04-05-005

21 10
8 12

23 1
2

TNED-04-05-007

22
Reducing Valve Port Position
16

T
10
20
d

P1 P2
18
19

24 15

T
c b
P2 P1

85TNEK-04-05-001
14 17 13 16 13 14 13

b- To Manifold Valve c- To Regulator Port Pi1 (21) d- To Manifold Valve Port DR4

1- Manifold Valve 10- Hose UNF3/4×UNF3/4 15- Adapter 19- Hose UNF3/4×UNF3/4
2- Port VQ (4313437) G3/8×UNF3/4(A852134) (4313154)
3- Test Hose (1-7/16-12UN) 12- Plug (Regulator) 16- Reducing Valve (4325439) 20- Tee G1/2×UNF3/4×UNF3/4
4- Adapter 1-7/16-12UN×G1-1/2 13- Adapter UNF9/16×G3/8 17- Tee (A852444)
5- Hydraulic Tester (ST 6299) (A852133) NF9/16×UNF9/16×G1/4(ST 21- Port Pi
6- Adapter 1-7/16-12UN×G1-1/2 14- Hose UNF9/16×UNF9/16 6450) 22- Return Pipe
7- Delivery Hose (4334307) 18- Pressure Gauge (ST 6934) 23- Plug G3/8
8- Port Pi2 24- Adapter (ST 6069)

TTNEM50-EN-01(20181109) T4-5-21
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
2. Measure pump flow rate in response to the external
command pilot pressure.
3. Select the following conditions.

Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever

Full stroke ON ON N

4. Adjust the reducing valve set pressure to each

pressure point specified along the main pump
P-Q curve. (Pilot Characteristics) (Refer to T4-2-11.)
Measure the flow rate and engine speed at the
pressure points specified in the P-Q curve.
5. Repeat the measurement three times and calculate
the mean values.

Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formula:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
Ns : Specified Engine Speed: 2200 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
2. Standard Flow Rate
Refer to Operational Performance Standard.

TTNEM50-EN-01(20181109) T4-5-22
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

3 4 5 6 7

TNED-04-05-005

21 10
8 12

23 1
2

TNED-04-05-007

22
Reducing Valve Port Position
16

T
10
20
d

P1 P2
18
19

24 15

T
c b
P2 P1

85TNEK-04-05-001
14 17 13 16 13 14 13

b- To Manifold Valve c- To Regulator Port Pi1 (21) d- To Manifold Valve Port DR4

1- Manifold Valve 10- Hose UNF3/4×UNF3/4 15- Adapter 19- Hose UNF3/4×UNF3/4
2- Port VQ (4313437) G3/8×UNF3/4(A852134) (4313154)
3- Test Hose (1-7/16-12UN) 12- Plug (Regulator) 16- Reducing Valve (4325439) 20- Tee G1/2×UNF3/4×UNF3/4
4- Adapter 1-7/16-12UN×G1-1/2 13- Adapter UNF9/16×G3/8 17- Tee (A852444)
5- Hydraulic Tester (ST 6299) (A852133) NF9/16×UNF9/16×G1/4(ST 21- Port Pi
6- Adapter 1-7/16-12UN×G1-1/2 14- Hose UNF9/16×UNF9/16 6450) 22- Return Pipe
7- Delivery Hose (4334307) 18- Pressure Gauge (ST 6934) 23- Plug G3/8
8- Port Pi2 24- Adapter (ST 6069)

TTNEM50-EN-01(20181109) T4-5-23
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Regulator Adjustment

6 5 1

7
8
4

9 10

TNED-03-01-025

1- Lock Nut (For Minimum Flow 3- Lock Nut (For Maximum Flow 5- Lock Nut (For Pilot Pressure 8- Adjusting Screw (For P-Q
Rate) Rate) Characteristic) Control)
2- Adjusting Screw (For Minimum 4- Adjusting Screw (For 6- Adjusting Screw (For Pilot 9- Lock Nut (For P-Q Control)
Flow Rate) Maximum Flow Rate) Pressure Characteristic) 10- Adjusting Screw (For P-Q
7- Lock Nut (For P-Q Control) Control)

Adjustment Item Adjustment Procedure Remark

1. Maximum Flow Rate Loosen lock nut (3) and adjust the Do not turn adjusting screw (4) more
maximum pump flow rate by using than 2 turns.
Q
adjusting screw (4). Do not increase the maximum flow
Turning adjusting screw (4) 1/4 turn rate. In other words, do not turn the
clockwise decreases the maximum adjusting screw counterclockwise.
pump flow rate by 12.58 cm3/rev. Securely tighten lock nut (3) after
j : 22 mm adjustment.
m : 20 N·m (14.8 lbf·ft)

TDAA-04-05-004

TTNEM50-EN-01(20181109) T4-5-24
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Adjustment Item Adjustment Procedure Remark

2. Pilot Pressure Characteristics Loosen lock nut (1) and adjust the Do not turn adjusting screw (2) more
pump flow rate of pilot pressure than one turn.
Q
characteristics by using adjusting Securely tighten lock nut (1) after
screw (2). adjustment.
Turning adjusting screw (2) 1/4 turn
clockwise decreases the pump flow
rate by 9.22 cm3/rev.
j : 17 mm
m : 20 N·m (14.8 lbf·ft)
Pi

TNED-04-5-008
3. P-Q Control (Torque Adjustment) Loosen lock nut (7) and adjust the Do not turn adjusting screw (8) more
pump flow rate of P-Q control by using than one turn.
Q
adjusting screw (8). Rotate the adjusting screws watching
Turning adjusting screw (8) 1/4 turn the engine performance.
clockwise increases the pump flow rate Securely tighten lock nut (7) after
by 15.5 cm3/rev. adjustment.
j : 30 mm
m : 30 N·m (22.1 lbf·ft)
Pd

TDAA-04-05-006
4. P-Q Control (Torque Adjustment) Loosen lock nut (9) and adjust the Do not turn adjusting screw (10) more
Q
pump flow rate of P-Q control by using than one turn.
adjusting screw (10). Rotate the adjusting screws watching
Turning adjusting screw (10) 1/4 turn the engine performance.
clockwise increases the pump flow rate Securely tighten lock nut (9) after
by 4.2 cm3/rev. adjustment.
j : 13 mm
m : 10 N·m (7.38 lbf·ft)
Pd

TDAA-04-05-007

TTNEM50-EN-01(20181109) T4-5-25
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Service Brake Pressure (Front and Rear)

dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)

Summary:
Measure the service brake pressure at the outlet port of
brake valve (5) white brake pedal (2) is depressed.

Preparation:

dCAUTION: Set blocks (1) onto the front and rear

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

2. Push the air bleed valve on top of the hydraulic oil 1

tank and bleed air.
2
3. Depress brake pedal (2) at least 50 strokes in order
to decrease the accumulated pressure left in the
brake circuit.
4. Install a pressure gauge to the front and rear wheel
brake circuits.
 Front wheel brake circuit pressure: Disconnect hose
(3) from brake valve (5). Install the tee (9/16-18UNF)
and a pressure gauge between brake valve (5) and
hose (3).
j : 22 mm
3
 Rear wheel brake circuit pressure: Disconnect hose
(4) from brake valve (5). Install the tee (9/16-18UNF)
and a pressure gauge between brake valve (5) and
hose (4).
j : 22 mm
5. Start the engine. Confirm that no oil leakage is 5
observed at the pressure gauge connection. 4
TNED-04-05-010
6. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

TTNEM50-EN-01(20181109) T4-5-26
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever

Full stroke ON ON N

2. Measure the pressure when fully depressing the

brake pedal at left side to the floor.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 4.6 to 5.4 MPa (667 to 783 PSI)

Remedy:
Refer to Troubleshooting B.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-27
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Parking Brake Release Pressure

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

Preparation:

dCAUTION: Set blocks (1) onto the front and rear

tires in order not to move the machine. Keep away
from the machine.
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Disconnect brake hose (2) from the parking brake
side. Install a pressure gauge to the removed hose.

j : 19 mm
T4GB-04-05-017
IMPORTANT: When the parking brake disc is dirty
with hydraulic oil, the parking brake function is 1
reduced. Clean hydraulic oil off the parking brake
disc. 2
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).

M4GB-06-004

TTNEM50-EN-01(20181109) T4-5-28
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Accelerator Pedal Brake Pedal Forward/Reverse Lever

Neutral Full stroke N

2. Release the parking brake and measure the pressure

at this time.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 10.8 to 17.0 MPa (110 to 173 PSI)

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-29
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Brake Accumulator Pressure

dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)

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

Preparation:

dCAUTION: Set blocks (1) onto the front and rear

tires in order not to move the machine. Keep away T4GB-04-05-017
from the machine.
1
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
a
tank and bleed air.
3. Depress the brake pedal at least 50 strokes in
order to decrease the accumulated pressure left in
accumulator (5) of the brake circuit.
4. Disconnect hoses (3, 4) from brake charge valve (2).
Install the tee (7/16-20UNF) and a pressure gauge
between brake charge valve (2) and hoses (3, 4).

j : 19 mm 2
5. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
3
6. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F). 5

TNED-04-05-009

a- To Brake Valve

TTNEM50-EN-01(20181109) T4-5-30
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Accelerator Pedal Power Mode Parking Brake Switch Forward/Reverse Lever

Full stroke ON ON N

2. Measure the maximum pressure when depressing

the brake pedal slowly several times.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 16±1.0 MPa (2321±145 PSI)

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-31
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Brake Warning Pressure (Pressure-

Decreasing)

dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)

Summary:
Measure the brake warning pressure (pressure
decreasing) at the accumulator output port when the
alarm sounds while decreasing the accumulated brake
pressure.

Preparation:

dCAUTION: Set blocks (1) onto the front and rear

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

1
from the machine.
1. Stop the engine.
a
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Depress the brake pedal at least 50 strokes in
order to decrease the accumulated pressure left in
accumulator (5) of the brake circuit.
4. Disconnect hoses (3, 4) from brake charge valve (2).
Install the tee (7/16-20UNF) and a pressure gauge
between brake charge valve (2) and hoses (3, 4).
2
j : 19 mm
5. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection. 3
6. Maintain the hydraulic oil temperature at 55±5 °C 5
(131±9 °F).

TNED-04-05-009

a- To Brake Valve

TTNEM50-EN-01(20181109) T4-5-32
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Forward/Reverse Lever Parking Brake Switch

N ON

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

position.
3. Depress the brake pedal several times. Measure the
pressure when the buzzer sounds.
4. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 8±0.5 MPa (1160±73 PSI)

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-33
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Brake Warning Pressure (Pressure-

Increasing)

dCAUTION: If air is mixed in the brake system,

the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil. (Refer to Troubleshooting
B.)

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

Preparation:

dCAUTION: Set blocks (1) onto the front and rear

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

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

j : 19 mm
5. Start the engine. Confirm that no oil leakage is 3
observed at the pressure gauge connection.
5
6. Maintain the hydraulic oil temperature at 55±5 °C
(131±9 °F).
4

TNED-04-05-009

a- To Brake Valve

TTNEM50-EN-01(20181109) T4-5-34
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Measurement:
1. Select the following conditions.

Forward/Reverse Lever Parking Brake Switch

N ON

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

position.
3. Depress the brake pedal several times. Sound the
buzzer.
4. Start the engine. Measure the pressure when the
buzzer stops sounding. Notice that it is difficult to
read the gauge as the pressure increases rapidly.
5. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Standard: 10±0.5 MPa (1450±73 PSI)

Remedy:
Refer to Troubleshooting B.
f NOTE: Brake System Troubleshooting (p.T5-6-41)

TTNEM50-EN-01(20181109) T4-5-35
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Transmission Clutch Pressure

Summary:
Measure each operating pressure of the transmission
clutch at each check port of the transmission control
valve.

Preparation:
1. Stop the engine.
2. Remove the plug from the check port. Install a hose,
an adapter, and a pressure gauge.

l : 5 mm

m : 6 N·m (4.4 lbf·ft)

fNOTE: Although the pressure can be measured by using

one pressure gauge, all pressures can be measured by
using six pressure gauges at the same time.
3. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
4. Maintain the torque converter oil temperature at
85±5°C (185±41°F).

Measurement:
T4GB-04-05-017
dCAUTION: Set blocks (1) onto the front and rear
tires in order not to move the machine. Keep away 1
from the machine.
1. Select the following conditions.

Accelerator Pedal Brake Pedal Power Mode Declutch Position Parking Brake
Switch Switch
Full stroke Full stroke ON OFF OFF

2. Operate the forward/reverse lever and the shift

switch. Measure each clutch pressure. (As for the
combination of clutch pack, refer to the following
page.)
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Transmission Clutch: 1.6 to 1.8 MPa (232 to 261 PSI)
Lock-up Clutch: 1.2 to 1.4 MPa (174 to 203 PSI)

TTNEM50-EN-01(20181109) T4-5-36
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

1 4

2 5

3 6

7
85Z7BTT04-05-02

1- Second Speed 5- Reverse

2- Low-Speed Forward 6- First Speed
3- Third Speed 7- Lock-Up
4- High-Speed Forward

Transmission Clutch Pack Combination

Directional Control Clutch Pack Speed Control Clutch Pack

Selected Speed Low-Speed High-Speed Reverse (5) First Speed (6) Second Third Speed Lock-Up (7)
Shift Forward (2) Forward (4) Speed (1) (3)
First Speed
Forward (F1)
* *
Second Speed
Forward (F2)
* *
F2 Lock-Up * * *
Third Speed
Forward (F3)
* *
F3 Lock-Up * * *
Fourth Speed
Forward (F4)
* *
F4 Lock-Up * * *
Fifth Speed
Forward (F5)
* *
F5 Lock-Up * * *
First Speed
Reverse (R1)
* *
Second Speed
Reverse (R2)
* *
R2 Lock-Up * * *
Third Speed
Reverse (R3)
* *
R3 Lock-Up * * *

fNOTE: The operating pressure is applied to the clutch with an asterisk mark (*) when
setting the forward/reverse lever and the shift switch to each selected speed shift.

TTNEM50-EN-01(20181109) T4-5-37
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

Torque Converter Pressure

Summary:
Measure the torque converter pressure (inlet) at the
check port of torque converter housing.
f NOTE: Measuring inlet port pressure maybe enough for
the performance test. The outlet port pressure should be
confirmed when abnormality, such as decreased traction
force, is observed.

Preparation:
1. Stop the engine.
2. Remove plug (3) from the check port of
transmission control valve (2). Install a hose, an
adapter, and a pressure gauge to the open part.

l : 5 mm

m : 6 N·m (4.4 lbf·ft)

3. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
4. Maintain the torque converter oil temperature at
85±5°C (185±41°F).

Measurement:
T4GB-04-05-017

d CAUTION: Set blocks (1) onto the front and rear

tires in order not to move the machine. Keep away
1
from the machine.
1. Select the following conditions.

Accelerator Pedal Brake Pedal Power Mode Declutch Position Parking Brake
Switch Switch
Full stroke Full stroke ON OFF OFF

2. Set the forward/reverse lever to F (Forward) and the

shift switch to 5 (Fifth Speed). Measure the pressure.
3. Repeat the measurement three times and calculate
the mean values.

Evaluation:
Input Pressure: 1.1 to 1.3 MPa (160 to 189 PSI)

Reference:
Output Pressure: 0.43 to 0.73 MPa (62.4 to 105.9 PSI)

TTNEM50-EN-01(20181109) T4-5-38
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

85Z7BTT04-05-02

TNEK-01-02-015

1- Transmission Control Valve 2- Torque Converter Input 3- Torque Converter Output

Pressure Test Port Pressure Test Port

fNOTE: Torque converter output pressure test port is the

torque converter oil temperature sensor port.

TTNEM50-EN-01(20181109) T4-5-39
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test

(Blank)

TTNEM50-EN-01(20181109) T4-5-40
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment

Rewrite of Aftertreatment Device Serial No.

After replacing the aftertreatment device (DOC/SCR), 5. After inputting, select Set.
rewrite their serial Nos. and upload the data to e-Service.
IMPORTANT: After finishing Aftertreatment Device
1. Connect the Maintenance Pro Dr. (MPDr.)
Serial No. input, upload the data to e-Service.

2. Set the key switch to the ON position. fNOTE: When the input data is uploaded to e-Service,
the M-Find product specification and history will be
updated.
3. Select Functions - Engine - Aftertreatment Device
No.

4. Input the following items of Oxidation Catalyst

(DOC) and SCR.
 ASM
 SUB
 Serial No.

90Z7B-04-06-01

TTNEM50-EN-01(20181109) T4-6-1
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment

Clean DEF Tank

When contamination or liquid other than DEF is mixed
in the DEF tank, fault code 3362-31 (Aftertreatment 1
Diesel Exhaust Fluid Dosing Unit Input Lines), 3364-X
(Aftertreatment Diesel Exhaust Fluid Quality), 4334-X
(Aftertreatment 1 Diesel Exhaust Fluid Pressure Sensor)
will be displayed. When one of the above errors is
displayed, the DEF tank must be cleaned. Clean the DEF
tank as follows.

Procedure

Procedure Detail
1 Set the machine position so that you can access to the bottom
part of the DEF tank. Park the machine.
2 Remove bolt (a). Remove cover (b).
3 Place a container to receive DEF under drain plug (c). Slowly
loosen and remove drain plug (c). Drain DEF from the DEF tank.
4 Insert a hose in the filler port and clean the DEF tank by using
DEF.
5 Secure cover (b) with bolt (a).
6 Add new DEF.

85Z7B-7-129-1 85Z7B-7-129-2

TTNEM50-EN-01(20181109) T4-6-2
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment

Transmission Learning
When transmission or transmission control valve has been
repaired/replaced, and TCU has been replaced, perform
transmission learning.
Refer to p. T5-2-26 for the details.

Lift Arm Angle Sensor Learning

When lift arm angle sensor has been replaced, perform lift
arm angle sensor learning.
Refer to p. T5-2-29 for the lift arm angle sensor learning.

Digging Position Adjustment

When lift arm angle sensor has been replaced, perform
the digging position adjustment after performing the lift
arm angle sensor learning.
Refer to p. T5-2-31 for the digging position adjustment.

TTNEM50-EN-01(20181109) T4-6-3
 SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment

(Blank)

TTNEM50-EN-01(20181109) T4-6-4
MEMO

TTNEM50-EN-01(20181109)
MEMO

TTNEM50-EN-01(20181109)
SECTION 5

TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Cab..........................................................................................T5-4-12
Introduction........................................................................... T5-1-1 Engine....................................................................................T5-4-19
Diagnosis Procedure........................................................... T5-1-2 Aftertreatment Device.....................................................T5-4-20
Electric System Inspection................................................ T5-1-5 Fan Valve...............................................................................T5-4-21
Precautions for Inspection and Maintenance............ T5-1-6 Pump Device.......................................................................T5-4-22
Instructions for Disconnecting Connectors............... T5-1-8 Multiple Control Valve......................................................T5-4-22
Fuse Inspection...................................................................T5-1-10 Manifold Valve.....................................................................T5-4-23
Fusible Link Inspection....................................................T5-1-12 Parking Brake Solenoid Valve........................................T5-4-23
Battery Voltage Check......................................................T5-1-13 Brake Charge Valve............................................................T5-4-23
Alternator Check................................................................T5-1-14 2-Spool Solenoid Valve Unit...........................................T5-4-23
Continuity Check...............................................................T5-1-16 Steering Valve Block..........................................................T5-4-24
Voltage and Current Measurement.............................T5-1-18 Emergency Steering Pump............................................T5-4-24
Check by False Signal.......................................................T5-1-25 Flow Regulator Valve........................................................T5-4-24
Test Harness.........................................................................T5-1-26 DEF Tank................................................................................T5-4-25
Surge Voltage and Surge Suppression Diodes........T5-1-28 DEF Supply Module...........................................................T5-4-25
Joystick Steering Hydraulic Component Layout....T5-4-26
Group 2 Monitor Joystick Steering Cab Components............................T5-4-28
Outline..................................................................................... T5-2-1
Operating Procedures of Service Menu....................... T5-2-2 Group 5 Troubleshooting A
Troubleshooting................................................................... T5-2-4 Troubleshooting A (Base Machine Diagnosis By
Monitoring............................................................................. T5-2-6 Using Fault Codes) Procedure.................................... T5-5-1
Controller Version..............................................................T5-2-16 MPDr. Fault Code Reference Table................................. T5-5-3
Issued Warning Record....................................................T5-2-17 MC Fault Code List.............................................................T5-5-10
Communication Terminal Status..................................T5-2-22 Monitor Controller (Monitor) Fault Code List..........T5-5-22
Machine Setting.................................................................T5-2-24 Monitor Controller (Information) Fault Code List...T5-5-23
Aftertreatment Device No..............................................T5-2-33 Column Display Controller Fault Code List...............T5-5-24
Engine Tachometer...........................................................T5-2-34 JCU Fault Code List............................................................T5-5-25
Transmission Oil Temperature Gauge and Communication Terminal Fault Code List.................T5-5-28
DEF Level Gauge...........................................................T5-2-35 Air Conditioner Controller Fault Code List................T5-5-28
Coolant Temperature Gauge.........................................T5-2-36 ECM Fault Code List...........................................................T5-5-29
TCU Fault Code List...........................................................T5-5-59
Group 3 e-Service MC Fault Codes 111000 to 111002..............................T5-5-79
Outline..................................................................................... T5-3-1 MC Fault Code 111003.....................................................T5-5-80
List of Operation Data........................................................ T5-3-2 MC Fault Codes 111006, 111007,
Snapshot Data....................................................................... T5-3-6 111009, 111011.............................................................T5-5-83
Communication System.................................................... T5-3-7 Monitor Controller (Monitor) Fault Codes
Group 4 Component Layout 113002, 113003, 113005, 113012...........................T5-5-83
Main Component (Overview).......................................... T5-4-1 CAN1 Harness Check........................................................T5-5-84
Main Component................................................................. T5-4-2 CAN3 Harness Check........................................................T5-5-88
Electrical System (Overview)........................................... T5-4-4 MC Fault Codes 111008, 111010,
Air Cleaner / Radiator Assembly..................................... T5-4-5 111014, 111025.............................................................T5-5-91
Battery Box............................................................................. T5-4-7 Monitor Controller (Monitor) Fault Codes
Hydraulic Oil Tank................................................................ T5-4-8 113004, 113006, 113007............................................T5-5-91
Fuel Tank................................................................................. T5-4-9 CAN2 Harness Check........................................................T5-5-92
Drive Unit..............................................................................T5-4-10 MC Fault Code 111100.....................................................T5-5-95
Front Axle..............................................................................T5-4-11 MC Fault Codes 111103, 111106, 111107.................T5-5-96

TTNEM50-EN-01(20181109) NEM50T-5-1
 MC Fault Codes 111205, 111207..................................T5-5-97 Charge Air Conditioner with Refrigerant..................T5-7-36
MC Fault Codes 111200, 111202, 111203.................T5-5-98 Hose and Pipe Tightening Torque................................T5-7-44
MC Fault Codes 111217, 111312..................................T5-5-99
MC Fault Code 111204 . ............................................... T5-5-100
MC Fault Codes 111206, 111208............................... T5-5-101
MC Fault Codes 111311, 111313............................... T5-5-102
MC Fault Code 111410.................................................. T5-5-103
MC Fault Code 111411.................................................. T5-5-104
MC Fault Code 111412.................................................. T5-5-105
MC Fault Code 111413.................................................. T5-5-106
MC Fault Code 111422.................................................. T5-5-107
MC Fault Code 111901.................................................. T5-5-108
MC Fault Code 111902.................................................. T5-5-109
Monitor Controller (Information)
Fault Code 113311.................................................... T5-5-110
MC Fault Codes 120000, 120002 to 120005.......... T5-5-111
MC Fault Code 120014.................................................. T5-5-111
Monitor Controller Fault Code 115001................... T5-5-112
JCU Fault Codes 116003, 116004.............................. T5-5-113
JCU Fault Codes 116006, 116007, 116008............. T5-5-114
JCU Fault Code 116118................................................. T5-5-115
JCU Fault Code 116119................................................. T5-5-116
Monitor Controller (Monitor)
Fault Code 120300.................................................... T5-5-117
Monitor Controller (Information)
Fault Codes 120400, 120401................................. T5-5-117
Column Display Controller Fault Codes
120500 to 120504...................................................... T5-5-118
Column Display Controller (Information)
Fault Codes 120505 to 120507............................. T5-5-119
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by
Using Trouble Symptom) Procedure....................... T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts..................................... T5-6-3
Correlation between Trouble Symptoms and
Part Failures....................................................................T5-6-26
Engine System Troubleshooting..................................T5-6-46
All Actuator System Troubleshooting.........................T5-6-52
Front Attachment System Troubleshooting.............T5-6-57
Steering System Troubleshooting...............................T5-6-66
Travel System Troubleshooting....................................T5-6-70
Brake System Troubleshooting.....................................T5-6-79
Other System Troubleshooting.....................................T5-6-83
Exchange Inspection........................................................T5-6-97
Air Bleeding Procedures for Brake (Axle)...................T5-6-99
Group 7 Air Conditioner
Outline..................................................................................... T5-7-1
Functions of Main Parts..................................................... T5-7-4
Troubleshooting................................................................... T5-7-9
Air Conditioner Controller Fault Code List................T5-7-10
Air Conditioner Controller Fault Codes 11 to 22.....T5-7-11
Air Conditioner Controller Fault Codes 43 to 92.....T5-7-12
Work after Replacing Components.............................T5-7-34
Refill Compressor Oil........................................................T5-7-35

TTNEM50-EN-01(20181109) NEM50T-5-2
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to quickly find the cause of
the machine trouble and solution.

The troubleshooting section in this manual consists of

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

 Diagnosing Procedure  Troubleshooting A (Base Machine Diagnosis By Using

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

Example: Even if accelerator pedal is operated,

engine speed does not change.

 Air Conditioner
This group contains system of the air conditioner,
troubleshooting, and procedures for charging air
conditioner with refrigerant.

TTNEM50-EN-01(20181109) T5-1-1
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Diagnosis Procedure
These six basic steps are essential for efficient
troubleshooting:

1. Study the system

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

TTNEM50-EN-01(20181109) T5-1-2
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

5. Perform troubleshooting

dCAUTION: Do not disconnect harnesses or

hydraulic lines while the engine is running. The
machine may malfunction or pressurized oil may
spout, possibly resulting in personal injury. Stop
the engine before disconnecting harnesses or
hydraulic lines.
Perform diagnosis by connecting MPDr. to the machine
or by using the service menu of monitor.
In case any fault code has been displayed by diagnosis
by using MPDr. (the service menu of monitor),
check the cause of the trouble by referring to
Troubleshooting A in this section. In case any fault
code has been displayed by diagnosis by using MPDr.
(the service menu of monitor), write the fault code.
TNED-05-01-001
Delete the fault code once and retry self-diagnosis
again. If the fault code is displayed again, check the
cause of the trouble by referring to Troubleshooting
A in this section. After the machine trouble has been
corrected, the fault code (displayed by the service
menu of monitor) will be deleted. Therefore, in case
the problems which are not easily re-predicable are
encountered, check the fault code by using MPDr.
In case the fault code is not displayed, check operating
condition of each component by referring to
Troubleshooting B in this section and by using MPDr.
(the service menu of monitor).

fNOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The controller
stores even temporary electrical malfunctions, such as
a drop in battery output voltage or disconnection of the
switches, sensors, etc., for inspections. For this reason,
the "RETRIAL" is required to erase the accumulated fault
codes from the controller memory and to confirm if any
fault codes are indicated after the "RETRIAL".

TTNEM50-EN-01(20181109) T5-1-3
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

6. Trace possible causes

Before reaching a conclusion, check the most
suspect causes again.
Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.

T4GB-05-01-006

TTNEM50-EN-01(20181109) T5-1-4
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Electric System Inspection

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

 Precautions for Inspection and Maintenance

 Instructions for Disconnecting Connectors
 Fuse Inspection
 Fusible Link Inspection
 Battery Voltage Check
 Alternator Check
 Continuity Check
 Voltage and Current Measurement
 Check by False Signal
 Test Harness

TTNEM50-EN-01(20181109) T5-1-5
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Precautions for Inspection and Maintenance

1. Disconnect the power source.
Disconnect the harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some cases,
cause fire due to short circuit.
In addition, even when the key switch is turned OFF,
the controller may be operated for a specified time.
Therefore, disconnect the harness from the negative
terminal side in battery after setting the key switch
to the OFF position and waiting five minutes or
more.

2. Color coding of wire harnesses.

As for the color codes of wire harnesses in the
electrical system, refer to the table.
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for base
color, while the right initial stands for marking color.

Code R W L G Y B O Lg Br P Gr V Sb
Color Red White Blue Green Yellow Black Orange Light Brown Pink Gray Violet Sky
green blue

fNOTE:
 Code BW indicates a black base wire with white fine-
line marking.
 Wires with longitudinal stripes printed on them are
not color coded. Do not confuse them with color
coded wires.

TTNEM50-EN-01(20181109) T5-1-6
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

3. Precautions for connecting and disconnecting

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

4. Precaution for using a circuit tester.

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

TTNEM50-EN-01(20181109) T5-1-7
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Instructions for Disconnecting Connectors

 Push Lock, Pull, and Separate Type

 Push the lock, and pull the connector.
 Connectors will not be easily separated even if the
lock is pushed while being pulled.
 The lock is located on female side connector (harness
end side).

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

TTNEM50-EN-01(20181109) T5-1-8
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

 Pull Lock and Switch the Lever Type

TDAA-05-08-005

 Unlock, Move the Lever, Pull, and Separate Type

f NOTE: Securely unlock with one hand and slowly pull
the lever with the other hand. Then, the connector will be
separated.

T4GB-05-06-001

T4GB-05-06-002

 Rotate Lock, Pull, and Separate Type

f NOTE: Pick up the harness end connector with fingers
and rotate it counterclockwise while pushing the
projection part. Then, the connector will be separated.

T4GB-05-06-007

TTNEM50-EN-01(20181109) T5-1-9
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Fuse Inspection
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a circuit tester
in order to correctly inspect fuse continuity. Use a circuit
tester in order to correctly inspect fuse continuity by
following the instructions described below.

1. Set the key switch to the ON position. When the

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

M178-07-034

d- Terminals connected to the e- Terminals connected to loads

power source (accessories)

a, b

10 20
9 19
b 8 18
a
7 17
6 16

5 15
4 14
3 13
2 12
Front c 1 11

90MNEC-01-47

a- Fuse Box A c- Relay Box M178-07-034

b- Fuse Box B

TTNEM50-EN-01(20181109) T5-1-10
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Fuse Box A Fuse Box B

Fuse No. Capacity Connected to Fuse No. Capacity Connected to

1 5A Fuel Pump 1 5A Radio (EU, JPN)
DC-DC Converter IGN (USA)
2 5A Head Lamp (Right) 2 10 A Lighting SW
3 20 A 24 V Socket 3 20 A Dome Lamp
12 V Socket (EU, JPN) DC-DC Converter (USA)
DC-DC Converter (EU, JPN) 12 V Socket (USA)
Radio (EU, JPN)
4 15 A Front Wiper, Washer 4 (15 A) OPT1 (Battery) (Option)
5 20 A Working Lamp (Front) 5 5A Optional Control Unit (Option)
6 5A Head Lamp (Left) 6 10 A Horn
7 5A Backup Lamp/Alarm 7 10 A Flasher Unit
8 5A Stop Lamp 8 10 A MC, DSZ, Monitor (Power)
Load Dump Relay
ECM Timer Relay
9 10 A Air Conditioner Unit 1 9 10 A TCU
10 5A Parking Brake 10 30 A ECM
11 10 A Radio (US) 11 5A Position 1
(Tail Lamp LH, Front Width Lamp RH)
12 (20 A) OPT2 (ACC1) (Option) 12 5A Position 2
(Tail Lamp RH, Front Width Lamp LH)
13 15 A Seat Heater 13 10 A Power ON
14 10 A Starter Key Switch 14 10 A Parking Brake Relay, TCU Power
15 20 A Air Conditioner Unit 2 15 10 A MC (Solenoid Power)
16 10 A DEF/SCR Sensor 16 5A Bucket Leveler
Loading Lever Safety Lock
Lift Arm (Boom) Kickout
Hydraulic Coupler SW
17 15 A DEF Supply Module 17 20 A Working Lamp (Rear)
18 15 A DEF Line Heater 18 10 A Rear Wiper, Washer
19 (15 A) OPT3 (ACC2) (Option) 19 10 A High Beam
20 (5 A) OPT4 (JSS) (Option) 20 5A Emergency (Secondary) Steering

TTNEM50-EN-01(20181109) T5-1-11
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Fusible Link Inspection

Inspection
1. Visually inspect fusible links (1, 2).

Replacement
1. Disconnect the negative cable from the battery.
2. To replace a fusible link, remove 2 bolts and pull it
up.
3. Connect the negative cable to the battery.

1 2
85Z7B-1-126-1

3 4

90Z7-05-01-01

1- Fusible Link (70 A, 140 A) 3- Cover

2- Fusible Link (70 A, 120 A) 4- Fuse Element

TTNEM50-EN-01(20181109) T5-1-12
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Battery Voltage Check

1. Turn the key switch OFF. Check voltage between the
battery positive terminal and the body (ground).
A
Normal Voltage: 24 V

fNOTE: If voltage is abnormal, recharge or replace the

battery.

2. Start the engine. Check voltage between the

battery positive terminal and the body (ground).
Normal Voltage: 26 to 28 V
TNED-05-01-002

fNOTE: If voltage is abnormal, check the charging A- Machine Front

system.

TTNEM50-EN-01(20181109) T5-1-13
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Alternator Check
Generally, if the alternator has generated electricity,
alternator alarm (1) will disappear. If discharge warning
indicator (1) is displayed while the engine is running, the
alternator might be defective.

How to Check Alternator

1. Set the key switch to the ON position. Confirm that
discharge warning indicator (1) is displayed.
2. Measure voltage between terminals B and E of the 1
alternator. If the measured voltage is around 24 V,
the alternator circuit can be considered normal. MNEC-01-073
If the measured voltage is low, a shortage in battery
capacity or looseness of the wire connectors
of alternator circuit might be the cause of the
malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if the
ground line is disconnected.
3. Next, start the engine and measure voltage
generated while the alternator rotates.
As described above, measure voltage between B
terminals B and E on the alternator side.
If voltage is around 28 V, the alternator is operating
normally.
If the rated voltage is not being generated (around
24 V), there is some trouble with the alternator or
the regulator.

T157-07-06-003

TTNEM50-EN-01(20181109) T5-1-14
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

R
I B

90Z7B-05-01-05

B
2

(B) I (L)

(L)

(F)
4 1

(E)

E (G)
90Z7B-05-01-06

1- Battery 3- Alternator
2- Battery Relay 4- Regulator

TTNEM50-EN-01(20181109) T5-1-15
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Continuity Check
IMPORTANT: Before continuity check, set the key
switch to the OFF position. A a

 Single-line continuity check

Disconnect both end connectors of the harness and
check continuity between both ends:
 If the ohm-meter reading is: ∞ Ω = Discontinuity
 0 Ω = Continuity
A a

 When the one end connector is far apart from the

other, connect one end of connector (A) to the chassis
ground by using a clip. Then, check continuity of the
harness through the chassis ground as illustrated.
 If the ohm-meter reading is: ∞ Ω = Discontinuity
 0 Ω = Continuity
A a

 Single-line short-circuit check

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

TTNEM50-EN-01(20181109) T5-1-16
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

 Multi-line continuity check

Disconnect both end connectors of the harness,
and short-circuit two terminals, (A) and (B), at one A a
end connector, as illustrated. Then, check continuity B b
between terminals (a) and (b) at the other connector. C c
If the ohm-meter reading is ∞ Ω, either line (A) - (a), or
(B) - (b) is in discontinuity.
To find out which line is discontinued, conduct the
single line continuity check on both lines individually,
or, after changing the short-circuit terminals from (A)
- (B) to (A) - (C), check continuity once more between
T107-07-05-004
terminals (a) and (c).
By conducting the multi-line continuity check twice, it
is possible to find out which line is discontinued.
With terminals (A) and (C) short-circuited, check
continuity between terminals (a) and (c).
 0 Ω = Line (B) - (b) has discontinuity. A a
 ∞ Ω = Line (A) - (a) has discontinuity. B b
C c

 Multi-line short-circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
 0 Ω = Short-circuit exists between the lines.
 ∞ Ω = No short-circuit exists between the lines.
T107-07-05-005

TTNEM50-EN-01(20181109) T5-1-17
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Voltage and Current Measurement

Turn key switch ON so that the specified voltage (current)
is supplied to the location to be measured. Judge if the
circuit is normal by evaluating whether the measured
voltage (current) matches the specification.

24-Volt Circuit
Start checking the circuit in order up to the location to
be measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
 Black (negative) probe terminal of circuit tester:
To ground to the body
 Red (Positive) probe terminal of circuit tester:
To touch the location to be measured

Engine Key Switch Location to be Measured Specification

Electric Power Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link (70 A) 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current *1 20 mA or less
Preheating Circuit
Stopped ON or START Between (11) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug (Air Heater) *2 20 to 25 V
Charging Circuit
Fast Speed ON Between (9) and Ground: Alternator (B)/Generating Voltage 26 to 30 V
Fast Speed ON Between (8) and Ground: Battery Relay/Generating Voltage 26 to 30 V
Fast Speed ON Between (17) and Ground: Fusible Link (70 A)/Generating 26 to 30 V
Voltage
Fast Speed ON Between (14) and Ground: Monitor Controller (A15) 26 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (9) and Ground: Alternator (B) 26 to 30 V
Idle Speed ON Between (13) and Ground: Key Switch ON Cut Relay 26 to 30 V
Idle Speed ON Between (10) and Ground: Load Dump Relay 26 to 30 V
Idle Speed ON Between (6) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (12) and Ground: ACC Cut Relay 20 to 25 V
Stopped ON Between (15) and Ground: Monitor Controller, Switch Panel, Air 20 to 25 V
Conditioner Unit
Stopped ON Between (18) and Ground: Radio 20 to 25 V
Stopped ON Between (19) and Ground: Fusible Link (120 A) 20 to 25 V
Stopped ON Between (6) and Ground: Battery Relay 20 to 25 V

*1 Before measurement, disconnect the negative cable from the battery. Disconnect the GSM/GPS connector, if provided.
*2 The preheating circuit is operated for the preheating time according to the coolant temperature.

TTNEM50-EN-01(20181109) T5-1-18
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

5 c 3 2 1
12V 12V
70A

h
12 a J-E
MCZ(C12)

Key Switch (g)

J-E
B M ACC G1 G2 ST
J-E
Preheat
J-C
OFF i
ACC 13
ON
Start J-E
10 f
B5 DSZ(D08)

11
4 6
FB13
g G1 M J-C
10A
B ACC
G2 ST 15
J-C d
FA16 j
8
FA14

FA17
10A

FB1
5A

FA18 ES
M
J-A
18
FB2 B E
C
FB3 DSZ(A17)
C1 B C
B6
S E
FB4
14 3A
FB5

FB6
m 17
I E
R
FB7
70A B

b
140A
120A

FB8 9 HR

19
BR
7 e
E

FB9

FB10

B 85Z7BTT05-01-01

a- Battery e- Glow Plug i- Key Switch ON Cut Relay

b- Alternator f- Load Dump Relay j- Fuse Box B
c- Fusible Link (70A) g- Key Switch m- Fusible Link (120 A)
d- Battery Relay h- ACC Cut Relay

TTNEM50-EN-01(20181109) T5-1-19
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Engine Key Switch Location to be Measured Specification

Starting Circuit
Started START Between (20) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (21) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (22) and Ground: Starter (B) 20 to 25 V
Started START Between (23) and Ground: Starter Relay (S) 20 to 25 V
Started START Between (24) and Ground: Starter Relay (C) 20 to 25 V
Started START Between (25) and Ground: Starter Cut Relay 20 to 25 V
Started START Between (26) and Ground: Fuse Box B 20 to 25 V
Started START Between (27) and Ground: Key Switch 20 to 25 V
Started START Between (28) and Ground: Neutral Relay 20 to 25 V
Started START Between (29) and Ground: Monitor Controller (A17) (Key SW Start) 20 to 25 V
Started START Between (30) and Ground: Main Controller (MC) (E4) (Key ON) 20 to 25 V
Started START Between (31) and Ground: ECM (J2-83) 20 to 25 V
Started START Between (32) and Ground: ECM Main Relay 20 to 25 V
Started START Between (33) and Ground ECM Main Relay 20 to 25 V
Started START Between (34) and Ground ECM Timer Relay 20 to 25 V
Started START Between (35) and Ground: ECM Timer Relay 20 to 25 V

TTNEM50-EN-01(20181109) T5-1-20
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

f
26 e 20
c

21
j g 27
30
d a
22

b
29
24
k 28 25 23

32
33

d
31
35 h

m 34
i

85Z7BTT05-01-02

a- Starter d- Starter Cut Relay g- Monitor Controller (DSZ) j- Main Controller (MC)
b- Starter Relay e- Key Switch h- ECM Main Relay k- Neutral Relay
c- Battery Relay f- Fuse Box B i- ECM m- ECM Timer Relay

TTNEM50-EN-01(20181109) T5-1-21
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Engine Key Switch Location to be Measured Specification

Neutral Engine Start
Circuit *
Stopped ON Between (36) and Ground: Key Switch 20 to 25 V
Stopped ON Between (37) and Ground: Key Switch ON Cut Relay 20 to 25 V
Stopped ON Between (38) and Ground: Neutral Relay (Coil) 20 to 25 V
Stopped ON Between (39) and Ground: Neutral Relay (Switch) 0V
* Before measurement, set the forward/ reverse lever to the neutral position.

TTNEM50-EN-01(20181109) T5-1-22
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Key Switch (g)

Preheat
OFF
ACC b
ON
Start

37

36

38 c

39

TCU
85Z7BTT05-01-03

a- Key Switch b- Key Switch ON Cut Relay c- Neutral Relay

TTNEM50-EN-01(20181109) T5-1-23
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

5-Volt Circuit
 Voltage between terminal #1 and the body Two Polarities
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the body 1 2
harness end connector and the body (ground).

 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
ground to the body
 Red (Positive) probe terminal of circuit tester: To
terminal #1

Evaluation: If the measuring voltage is within 5 ± 0.5 volts, T107-07-05-006
the circuit up to terminal #1 is normal.
Three Polarities

1 2 3

T107-07-05-007

 Voltage between terminal #1 and the ground terminal

Turn OFF the key switch, and disconnect the sensor Two Polarities
connector. Measure the voltage between terminal #1
(5 V power supply) on the body harness end connector 1 2
and the ground terminal (terminal #2 for two-polarities
or terminal #3 for three-polarities connector) under the
following conditions.

 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
ground terminal (Terminal #2 or #3)
 Red (Positive) probe terminal of circuit tester: To
T107-07-05-008
terminal #1

Evaluation: If the measuring voltage is within 5 ± 0.5
volts, the circuit up to terminal #1 or the ground terminal Three Polarities
(terminal #2 or #3) is normal.
1 2 3

T107-07-05-009

TTNEM50-EN-01(20181109) T5-1-24
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Check by False Signal

Two Polarities
Turn the key switch OFF. Disconnect the sensor connector.
1 2
Turn the key switch ON. Connect terminal #1 (power
source) of the body harness end connector to terminal #2
(signal). (Power voltage is used as a false signal.)
Check this state by using the monitor function of MPDr.
When the maximum value is displayed, MC and the circuit
up to the body harness end connector are normal. If "ON"
is displayed, the pressure switch circuits are normal.

IMPORTANT: Do not connect terminal #1 or #2 T107-07-05-010

to terminal #3 or to the body (ground) when
checking a three-polarity connector.
Three Polarities

1 2 3
fNOTE: Some kinds of sensors can be monitored by the
service menu of the monitor.

T107-07-05-011

TTNEM50-EN-01(20181109) T5-1-25
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Test Harness

Prepare appropriate tools as shown.

Install a test harness between connectors.

Check the circuit condition depending on whether the
test harness lamp lights or extinguishes during operation.
Check Lamp
 Check Lamp

Use in order to check a single-line (discontinuity and/ -

+
or voltage). -

 During Operation: Light is ON.

+ GND

T107-07-05-012

 Solenoid Check Lamp Solenoid Check Lamp

Use in order to check the solenoid valve unit circuits.

 When the corresponding control lever or switch is

operated: Light is ON.

To Solenoid
Connector 90Z7B-05-01-04

TTNEM50-EN-01(20181109) T5-1-26
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

 Pressure Sensor Test Harness

Connect a test harness to the harness end connector of

pressure sensor. Check the state of pressure sensor circuit.

Pressure Sensor Test Harness (Example)

2 1 3
TDAA-05-06-003

1- Test Harness (Ground, Output, 5 V Lines) 3- Harness Connector for Sensor Connection
2- Dummy Connector

1. Connect the male end connector of test harness (1)

to harness end connector (3).

2. Connect a dummy sensor (2) to the female end

connector of test harness (1).

3. Check the output voltage.

TTNEM50-EN-01(20181109) T5-1-27
 SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure

Surge Voltage and Surge Suppression Diodes

Electromagnetic field forms
when switch closes.
Some electrical parts such as solenoid valves are
equipped with a coil.
Coil

Current direction
Voltage
When a coil is energized, an electromagnetic field is

Battery
Current
formed.

Voltage [V]
Current [A]
Time [sec]

Load
95Z7BTT05-01-07

When the switch opens,

the field collapses across
When the solenoid coil is de-energized, the field collapses the coil windings.
across the coil. The collapse of this electromagnetic field
Voltage
across the solenoid coil generates an unregulated voltage
Battery

surge. Current

Voltage [V]
Current [A]
This can damage transistors, contacts, and other
Coil
electronic parts. (See connection diagram.) ON OFF

Surge voltage
Load Time [sec]

95Z7BTT05-01-08

When the surge voltage was generated, it causes to

increase wear on the switch points. Surge suppression
diode
During the coil is being activated by the transistor, when
the excruciating high voltage is loaded on the transistor, Coil
the transistor may be broken.

In order to absorb this surge voltage, connect the diode

parallel to the coil in the reverse direction against the
Switch or
power supply. transistor

When the switch is off, the same amount of electric

current, that was flown till now, flows through the diode. 95Z7BTT05-01-09

This electric current is attenuated gradually and finally it

reaches zero. That means no surge voltage is generated in
the circuit.
This diode is called as flywheel diode.

TTNEM50-EN-01(20181109) T5-1-28
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Outline
Basic Screen

20 1 2 3

4
19

18

17

6
16

15 14 21 12 13 11 10 9 8 7
85TNEK-05-02-001

1- Engine Tachometer 7- Ride Control Indicator 12- Power Mode Indicator 17- Shift HOLD Display
2- Economy (ECO) Indicator 8- Seat Belt Indicator 13- Auto Shut-Down (Idling-Stop) 18- Transmission Auto-shifting
3- Speedometer 9- Forward/Reverse Selector Indicator Indicator
4- Transmission Oil Temperature Switch Indicator 14- Dual Lift Arm Auto Leveler 19- F-N-R/Shift Position Indicator
Gauge 10- Declutch Indicator Indicator 20- Torque Converter Lock-up
5- DEF Level Gauge 11- Aftertreatment Device 15- Clock, Hour Meter, Odometer Indicator
6- Air Conditioner Display Indicator 16- Fan Reverse Rotation Indicator 21- Joystick Steering Indicator

TTNEM50-EN-01(20181109) T5-2-1
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Operating Procedures of Service Menu

IMPORTANT: The service menu is provided only for
maintenance activity. Do not explain this function
to your customers.

The following items can be displayed on the monitor

without using Maintenance Pro Dr. (MPDr.)

 Troubleshooting:
Fault code is displayed.

 Monitoring:
A part of monitor items for MPDr. is displayed.

 Controller Version:
The controller version is displayed.

 Issued Warning Record:

Ten alarms which were issued recently are displayed.

 Communication Terminal Status:

Information of the communication terminal is
displayed.

 Machine Setting:
The learning and adjustment are performed.

 Aftertreatment Device No.:

The manufacture number of aftertreatment device
(DOC/SCR) is displayed.

TTNEM50-EN-01(20181109) T5-2-2
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

How to display service menu 1 2

1. Push rotating select / confirm knob (3) while

pushing return to previous screen switch (1) when
the basic screen is displayed with the key switch set
in the ON position or the engine running. 3
Then, Service Menu (4) is added to the Main Menu
screen.
2. Turn select / confirm knob (3) and select Service
Menu (4).

MNEC-01-006

3. Push select / confirm knob (3). The Service Menu TNED-05-02-014EN

screen appears.

4. When pushing return to previous screen switch (1), 90Z7B-05-02-10E

the previous screen appears.
5. When pushing return to basic screen switch (2), the
basic screen appears.

fNOTE: When the basic screen has appeared by using

return to previous screen switch (1) or return to basic
screen switch (2), Service Menu (4) on the Main Menu
screen is deleted. In order to display Service Menu (4),
perform step 1 again.

TTNEM50-EN-01(20181109) T5-2-3
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Troubleshooting
1 2
1. Turn select / confirm knob (3) and select
Troubleshooting (4) on Service Menu.

TNED-05-02-002

2. When pushing select / confirm knob (3), the

Troubleshooting screen appears.
4

90Z7B-05-02-10E
3. Turn select / confirm knob (3) and select the
controller.

fNOTE: The number in parentheses to the right of menu 5

name indicates the number of listed fault codes for the
menu.

90TNED-05-02-24EN
4. When pushing select / confirm knob (3), the self-
diagnostic result of selected controller (fault code) is
displayed.
The past fault codes as well as the current ones are
displayed at this time.
6
fNOTE: Main (T/M) (5) is selected as an example here.

90TNED-05-02-25EN

5. Turn select / confirm knob (3), select CLEAR (6), and

push select / confirm knob (3).
The past fault codes are deleted and only the
current fault codes can be displayed.

TNED-05-02-054EN

TTNEM50-EN-01(20181109) T5-2-4
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

6. When pushing return to previous screen switch (1),

the previous screen appears.
7. When pushing return to basic screen switch (2), the
basic screen appears.

TTNEM50-EN-01(20181109) T5-2-5
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Monitoring
1 2
1. Turn select / confirm knob (3) and select Monitoring
(4) on Service Menu.

TNED-05-02-002

2. When pushing select / confirm knob (3), the 90Z7B-05-02-10E

Monitoring screen appears.
3. Turn select / confirm knob (3) and select the
controller for monitoring.
4. When pushing select / confirm knob (3), the
monitoring items for selected controller are
displayed.

fNOTE: Engine is selected as an example here.

90TNED-05-02-15EN

5. Turn select / confirm knob (3), select the item for

monitoring, and push select / confirm knob (3). (Up 5
to 8 items can be selected.)

fNOTE: Actual Engine Speed (5) is selected as an

example here.

90TNED-05-02-16EN
6. Push return to previous screen switch (1) and the
Monitoring screen appears.
7. Turn select / confirm knob (3), select START (6), and
push select / confirm knob (3).
6
f NOTE: START (6) and CLEAR (7) are displayed only when
one or more monitoring items are selected. START (6) 7
and CLEAR (7) are not displayed when no monitoring
item is selected.
90TNED-05-02-17EN

TTNEM50-EN-01(20181109) T5-2-6
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

8. The selected monitoring item is started monitoring.

fNOTE: Actual Engine Speed and Actual Vehicle Speed

are selected as an example here.

TNED-05-02-019EN

1 2

9. When pushing select / confirm knob (3) while

monitoring, PAUSE (8) is displayed and the
monitoring value can pause (be held).
3

10. When pushing select / confirm knob (3) again,

pausing is stopped. TNED-05-02-002

8
f NOTE: Even if the key switch is set to OFF position, the
selected monitoring item has been stored. In order to
release the selected monitoring item, select CLEAR (7) on
the Monitoring screen and push select / confirm knob (3)
for a while until START (6) and CLEAR (7) disappear.

TNED-05-02-018EN
11. When pushing return to previous screen switch (1),
the previous screen appears.

12. When pushing return to basic screen switch (2), the

6
basic screen appears.

TNED-05-02-017EN

TTNEM50-EN-01(20181109) T5-2-7
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

List of Monitoring Item

Engine Controller (ECM)
Item Unit Data
Fuel Filter Restriction Switch OFF/ON Clogged fuel filter status
Load Dump Relay Output OFF/ON Load dump relay ON/OFF status
Actual Engine Percent Torque % Input signal from ECM
Engine Speed min-1 Input signal from crank speed sensor and cam angle sensor
Engine Turbocharger Speed min-1 Input signal from turbocharger speed sensor
Engine Demand Percent Torque % Input signal from ECM
Engine EGR Mass Flow Rate kg/h Input signal from EGR differential pressure sensor
NOx Concentration (before DOC) ppm Input signal from NOx sensor (DOC inlet)
NOx Concentration (after SCR) ppm Input signal from NOx sensor (SCR outlet)
DOC Outlet Exhaust Temperature °C Input signal from the exhaust temperature sensor (DOC outlet)
Regeneration Lamp Command - -
Regeneration Status - -
Manual Regeneration Status - -
SCR Inlet Exhaust Temperature °C Input signal from the exhaust temperature sensor (SCR inlet)
SCR Outlet Exhaust Temperature °C Input signal from the exhaust temperature sensor (SCR outlet)
DEF/AdBlue Level % Input signal from ECM
DEF/AdBlue Tank Temperature °C Input signal from ECM
DEF/AdBlue Residual Alarm Level - -
Aftertreatment Device Alarm Level - -
Boost Temperature (after CAC) °C Input signal from Boost temperature sensro (after CAC)
DEF/AdBlue Concentration % Input signal from ECM
Engine Output Restriction Suspend - -
Remaining Number of Times
Engine Turbo Compressor Inlet Temp °C Input signal from TBAP sensor
Total Fuel Used L Input signal from ECM
Engine Coolant Temperature °C Input signal from coolant temperature sensor
Engine Oil Pressure kPa Input signal from engine oil pressure switch
Crankcase Pressure kPa Input signal from crankcase pressure sensor
Coolant Level % Input signal from coolant level sensor
Intake Manifold 1 Pressure kPa Input signal from boost pressure sensor
Intake Manifold 1 Temperature °C Input signal from boost temperature sensor
Battery Potential V Input signal from battery
DOC Intake Gas Temperature °C Input signal from the exhaust temperature sensor (DOC inlet)
Exh Sys High Temp Lamp Command - Input signal from ECM
Wait To Start Lamp OFF/ON Input signal from ECM
Water In Fuel Indicator OFF/ON Water separator filter clog monitoring switch ON/OFF status

TTNEM50-EN-01(20181109) T5-2-8
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

(Blank)

TTNEM50-EN-01(20181109) T5-2-9
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Main Controller (MC)

Item Unit Data
Demand Engine Speed min-1 Command value of engine speed from MC to ECM.
Actual Engine Speed min-1 Input signal from ECM
Accelerator Pedal 1 V Input signal from accelerator pedal sensor 1
Hydraulic Oil Temperature °C Input signal from hydraulic oil temperature sensor
Axle Oil Temperature °C Input signal from axle oil temperature sensor
Target Hydraulic Fan Speed min-1 Calculated signal from actual engine speed and control signal
to fan control valve
Pump Delivery Pressure MPa Input signal from pump delivery pressure sensor
Vehicle Speed (For Speedometer) km/h Converted signal from vehicle speed sensor into speed per hour
Actual Vehicle Speed km/h Input signal from TCU
Parking Brake Pressure MPa Input signal from pressure sensor (parking brake)
Service Brake Primary Pressure MPa Input signal from pressure sensor (brake primary pressure)
Service Brake Secondary Pressure (For MPa Input signal from pressure sensor (brake secondary pressure)
Declutch)
Torque Converter Speed Ratio % Input signal from TCU
Vehicle Speed Pulse pulse Input signal from TCU
Warning Buzzer 0: OFF Auto shut-down (idling stop) alarm ON/OFF status
1: ON
2: ON
3: ON

TTNEM50-EN-01(20181109) T5-2-10
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Item Unit Data

Lift Arm Angle Sensor V Input signal from lift arm angle sensor
Bucket Tilt Pilot Pressure MPa Input signal from pressure sensor (bucket roll back)
Bucket Dump Pilot Pressure MPa Input signal from pressure sensor (bucket dump)
Lift Arm Raise Pilot Pressure MPa Input signal from pressure sensor (lift arm raise)
Pilot Primary Pressure MPa Input signal from pressure sensor (primary pilot pressure)
Hydraulic Fan Circuit Pressure MPa Input signal from fan pump delivery pressure sensor
Emergency Steering Pump Delivery MPa Input signal from emergency (secondary) steering pump
Pressure delivery pressure sensor
Air Conditioner Refrigerant Pressure MPa Input signal from pressure sensor (refrigerant pressure)
Pump Swash Angle P/S Output MPa Control signal to torque control solenoid valve
Parallel/Tandem Control P/S Output MPa Control signal to 2-spool solenoid valve unit (SZ)
Ride Control P/S Output mA Control signal to 2-spool solenoid valve unit (SJ)
Hyd Fan Reverse Rotation P/S Output mA Control signal to fan reverse control solenoid valve
Hyd Fan Speed Control P/S Output mA Control signal to fan speed control solenoid valve
Lift Arm Speed Multiplication P/S Output mA Control signal to lift arm speed multiplication solenoid valve
Pump Swash Angle P/S Output FB mA Feedback from torque control solenoid valve output
Parallel/Tandem Control P/S Output FB mA Feedback from 2-spool solenoid valve unit (SZ)
Ride Control P/S Output FB mA Feedback from 2-spool solenoid valve unit (SJ)
Hyd Fan Reverse Rotation P/S Output FB mA Feedback from fan reverse control solenoid valve output
Hyd Fan Speed Control P/S Output FB mA Feedback from fan speed control solenoid valve output
Lift Arm Speed Multiplication P/S Output mA Feedback from lift arm speed multiplication solenoid valve
FB
Aftertreatment Device Regeneration ON/OFF Aftertreatment device manual regeneration switch ON/OFF
Switch status

TTNEM50-EN-01(20181109) T5-2-11
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Main Controller (MC)

Item Unit Data
Quick Power Switch OFF/ON Quick power switch ON/OFF status
Power Mode Switch OFF/ON Power mode switch ON/OFF status
Steering Pressure Switch OFF/ON Steering pressure switch ON/OFF status
Emergency Steering Check Switch OFF/ON Emergency (secondary) steering operation check switch ON/
OFF status
Fan Reverse Switch OFF/ON Fan reverse switch ON/OFF status
Fan Reverse Switch (Auto) OFF/ON Fan reverse auto switch ON/OFF status
Ride Control Switch (Auto) OFF/ON Ride control auto switch ON/OFF status
Declutch Position Switch 0: OFF Declutch mode status
1: N Mode
2: D Mode
Travel Mode Selector Switch 0: Manual Auto-shift mode status
Mode
1: AUTO_1
2: AUTO_2
Emergency Steering Pump Relay OFF/ON Emergency steering pump relay ON/OFF status
Parking Brake Indicator OFF/ON Parking brake indicator ON/OFF status
Low Steering Oil Pressure Indicator OFF/ON Steering pressure warning indicator ON/OFF status
Low Brake Oil Pressure Indicator OFF/ON Service brake warning indicator ON/OFF status
Lift Arm Auto Leveler Lower Kickout OFF/ON Lower kickout detent ON/OFF status
Lift Arm Auto Leveler Height Kickout OFF/ON Height kickout detent ON/OFF status
Accelerator Pedal 2 V Input signal from accelerator pedal sensor 2
Auto Shut-Down Relay OFF/ON Auto shut-down (idling stop) relay ON/OFF status
Bucket Angle Switch ON/OFF Bucket angle position detection switch ON/OFF status
Axle Oil Cooler Relay ON/OFF Axle oil cooler relay ON/OFF status
Lift Arm Bottom Pressure MPa Input signal from pressure sensor (lift arm bottom pressure)
Lift Arm Rod Pressure MPa Input signal from pressure sensor (lift arm rod pressure)

TTNEM50-EN-01(20181109) T5-2-12
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Transmission Controller (TCU)

Item Unit Data
Torque Converter Oil Temperature °C Input signal from hydraulic oil temperature sensor
Actual Engine Speed min-1 Input signal from torque converter input speed
sensor
Torque Converter Output Speed min-1 Input signal from torque converter output speed
sensor
Transmission Output Speed min-1 Input signal from machine speed sensor
Forward/Reverse Lever (N) OFF/ON Forward/reverse lever selection (neutral) status
Forward/Reverse Lever (F) OFF/ON Forward/reverse lever selection (forward) status
Forward/Reverse Lever (R) OFF/ON Forward/reverse lever selection (reverse) status
Option Forward/Reverse Switch (N) OFF/ON Forward/reverse switch selection (neutral) status
Option Forward/Reverse Switch (F) OFF/ON Forward/reverse switch selection (forward) status
Option Forward/Reverse Switch (R) OFF/ON Forward/reverse switch selection (reverse) status
Shift Switch 1st/2nd/3rd/4th/5th Selected speed shift
Current Gear R3/R2/R1/N/F1/F2/F3/F4/ Operated speed shift
F5
DSS Switch OFF/ON Downshift switch (DSS) ON/OFF status
Gear Hold Switch OFF/ON Hold switch ON/OFF status
Forward/Reverse Select Switch OFF/ON Forward/reverse selector switch ON/OFF status
USS Switch OFF/ON Upshift switch (USS) ON/OFF status
Torque Converter Lockup Engage 0/1 0: Shift is not in process
1: Shift in process

TTNEM50-EN-01(20181109) T5-2-13
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Column Display Controller

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

TTNEM50-EN-01(20181109) T5-2-14
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Air Conditioner Unit

Item Unit Data
Compressor Operation OFF/ON Compressor operating status
Outdoor Air Temperature °C Input signal from outside temperature sensor
Indoor Air Temperature °C Input signal from air circulation sensor
Amount of Insolation W/m2 Input signal from solar radiation sensor

TTNEM50-EN-01(20181109) T5-2-15
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Controller Version
1 2
1. Turn select / confirm knob (3) and select Controller
Version (4) on Service Menu.

TNED-05-02-002

90Z7B-05-02-10E

2. When pushing select / confirm knob (3), the version

of each controller appears.

TNED-05-02-009EN

3. When pushing return to previous screen switch (1),

the previous screen appears.
4. When pushing return to basic screen switch (2), the
basic screen appears.

TTNEM50-EN-01(20181109) T5-2-16
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Issued Warning Record

1 2
1. Turn select / confirm knob (3) and select Issued
Warning Record (4) on Service Menu.

TNED-05-02-002

90Z7B-05-02-10E

2. When pushing select / confirm knob (3), the Issued

Warning Record screen appears.
The symbol and trouble of maximum ten alarms
which occurred and reported recently are displayed.
(Refer To List of Alarm.)

90Z7B-05-02-21E

3. Turn select / confirm knob (3) and select the

displayed alarm. When pushing select / confirm
knob (3), the time (ON / OFF) when the selected
alarm has occurred / solved are displayed.

90Z7B-05-02-22E

4. In case of currently occurring alarms, the resolving

time (OFF) of the alarm is dashed (---).

fNOTE: The display of date and time depends on the

setting. (Refer to the operator’s manual.)

90Z7B-05-02-23E

5. When pushing return to previous screen switch (1),

the previous screen appears.
6. When pushing return to basic screen switch (2), the
basic screen appears.

TTNEM50-EN-01(20181109) T5-2-17
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

List of Alarm

Symbol Alarm Monitor Message Remedy

Brake Oil Pressure Brake Oil Pressure Is Low. Refer to
Alarm Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Check Hydraulic Oil Level And Brake System For Damages A.
And Leaks
M4GB-01-013
Steering Oil Pressure Steering Oil Pressure Is Low. Refer to
Alarm Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Check Hydraulic Oil Level And Auto-Brake System For A.
M4GB-01-016
Damages And Leaks.
Emergency Steering Safely Park The Machine And Stop The Engine Immediately. Refer to
Alarm Check Hydraulic Oil Level And Emergency Steering System Troubleshooting
(Blinking) For Damages And Leaks. A.

M4GB-01-015
Hydraulic Oil Level Hydraulic Oil Level Is Low. Refer to
Alarm Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Check Hydraulic Oil Level And System For Damages And A.
Leaks.
M4GF-01-004
Aftertreatment Device Aftertreatment Device Is Abnormal. Immediately Set The Follow Trouble
Alarm Machine In The Safe Position And Stop The Engine. Contact Screen on the
(Blinking) (Red) Your Nearest Authorized Dealer. monitor.
MDAA-01-025
Aftertreatment Device Aftertreatment Device Regeneration System Is Abnormal. Refer to
Regeneration System Contact Your Nearest Authorized Dealer. Troubleshooting
Failure A.
MDAA-01-071
* Aftertreatment Device Aftertreatment Device Regeneration Is Needed Follow Trouble
Regeneration Request immediately. Screen on the
(Blinking) (Yellow) If Regeneration Is Not Performed, The Filter May Be monitor.
Damaged. Set The Machine In A Regeneration Condition,
MDAA-01-026 Turn The Regeneration Switch To The Manual Regeneration
Position.
* Aftertreatment Device The Regeneration Inhibition Has Been Set. Move The Follow Trouble
Regeneration Inhibit Machine To A Safe Area. Screen on the
Alarm monitor.
(Lighting) (Yellow)
MDAA-01-027
* Aftertreatment Device As The Regeneration Inhibition Has Been Set, Auto Follow Trouble
Auto Regeneration Regeneration Cannot Be Performed. Screen on the
Inhibit Alarm monitor.
(Lighting) (Yellow)
MDAA-01-027

fNOTE: *: These alarms are not displayed on the Issued

Warning Record screen.

TTNEM50-EN-01(20181109) T5-2-18
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Symbol Alarm Monitor Message Remedy

Urea SCR Alarm DEF/AdBlue Level Is Low Or Urea SCR System Is Abnormal. Refer to
Refill DEF/AdBlue If Level Is Low. Troubleshooting
Contact Your Nearest Authorized Dealer For System A.
MDC1-01-528 Malfunction.
Engine Output Engine Output Is Restricted. Refer to
Restriction Troubleshooting
A.
MDC1-01-527
Overheat Alarm Coolant Temperature Is Abnormally High. Follow Trouble
Stop Operation. Screen on the
Run The Engine At Slow Idle To Cool Coolant Temperature. monitor.

MDAA-01-067
Hydraulic Oil Overheat Hydraulic Oil Temperature Is Abnormally High. Refer to
Alarm Stop Machine Operation. Troubleshooting
Run The Engine At Slow Idle Speed To Lower The Oil A.
Temperature.
MDAA-01-068
Axle Oil Temperature Axle Oil Temperature Is Abnormally High. Follow Trouble
Alarm Check If The Service Brake Is Daggled. Screen on the
If The Brake Pedal Is Continuously Stepped On, An Increase monitor.
Of The Axle Oil Temperature May Result.
M4GF-01-005
Transmission Oil Transmission Oil Temperature Is Abnormally High. Refer to
Overheat Alarm Stop Machine Operation. Troubleshooting
Run The Engine At Slow Idle Speed To Lower The Oil A.
Temperature.
M4GB-01-027
Engine Warning Alarm Engine or Engine Related Parts Are Abnormal. Contact Your Follow Trouble
(Yellow) Nearest Authorized Dealer. Screen on the
monitor.

TNEK-05-02-002
Transmission Warning Transmission Or accessory Is Abnormal. Refer to
Alarm Safely Park The Machine And Stop The Engine Immediately. Troubleshooting
Contact Your Nearest Authorized Dealer. A.

M4GB-01-024
Engine Oil Pressure Engine Oil Pressure Is Low. Refer to
Alarm Immediately Stop The Engine. Troubleshooting
Check The Engine Oil System And Oil Level. A.
M4GB-01-021

fNOTE: *: These alarms are not displayed on the Issued

Warning Record screen.

TTNEM50-EN-01(20181109) T5-2-19
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Symbol Alarm Monitor Message Remedy

Main Pump Oil Pressure Main Pump Oil Pressure Is Too Low. Refer to
Alarm Safely Park The Machine. Troubleshooting
Check For Leaks Especially At Front Attachment Piping. A.
MNEC-01-009
Urea System Alarm Aftertreatment Device Is Abnormal. Contact Your Nearest Refer to
Authorized Dealer. Troubleshooting
A.
MDAA-01-071
Battery Charge Alarm Electrical System Is Abnormal. Refer to
Safely Park The Machine And Stop The Engine. Troubleshooting
Check Alternator And Battery Systems. A.
M183-01-071
Contact Your Nearest Authorized Dealer.

TTNEM50-EN-01(20181109) T5-2-20
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Symbol Alarm Monitor Message Remedy

Air Cleaner Clogging Air Cleaner Elements Are Clogged. Follow Trouble
Clean Or Replace Air Cleaner Element Following The Screen on the
Instruction In The Operator's Manual. monitor.
Serious Engine Damage Will Occur If Ignored.
M183-01-067
Water Separator Alarm Water Separator Is Full. Follow Trouble
Drain Water. Screen on the
monitor.

MNEC-01-010
System Failure Alarm Machine Network System Is Abnormal. Refer to
Contact Your Nearest Authorized Dealer. Troubleshooting
A.

MDDA-01-034

TTNEM50-EN-01(20181109) T5-2-21
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Communication Terminal Status

1 2
1. Turn select / set switch (3) and select
Communication Terminal Status (4) on Service
Menu.
3

TNED-05-02-002

2. When pushing select / set switch (3), the

Communication Terminal Status screen appears. TNED-05-02-010EN

3. Each data of the communication terminals is

displayed. (Refer To List of Communication Terminal
Status.)

4. When pushing back switch (1), the previous screen TNED-05-02-034EN

appears.
5. When pushing return to basic screen switch (2), the
basic screen appears.

TTNEM50-EN-01(20181109) T5-2-22
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

List of Communication Terminal Status

Item Unit Data

Portable Terminal Satellite Terminal
GPS Status 0 to 2 0: Uncoupled Connection 0: Uncoupled Connection
1: Incomplete Positioning 1: Incomplete Positioning
2: Positioning State 2: Positioning State
Radio Wave Intensity 0 to 3, 250, 254 0: Reception Level: 0 0: Communication not
available
1: Reception Level: 1 1: Communication available
2: Reception Level: 2
3: Reception Level: 3
250: Out of range
254: Not detected
Talking Status 0, 1 0: Uncoupled Connection -
1: Connection
Comm Module Status 0, 1 0: Correct -
1: Incorrect
Portable Antenna Signal 0 to 31, 99 0 to 1: Out of range -
2 to 8: Reception Level: 0
9 to 12: Reception Level: 1
13 to 17: Reception Level: 2
18 to 31: Reception Level: 3
99: Not detected
GPRS Ntwk Conn Status 0, 1 0: Failure -
1: Success
Frequency Band 0 to 3 0 to 3 -

fNOTE: The detail data of radio wave intensity are displayed for Antenna Signal.

TTNEM50-EN-01(20181109) T5-2-23
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Machine Setting
1 2
 Learning/Adjustment

1. Turn select / confirm knob (3) and select Machine

Setting (4) on Service Menu. 3

TNED-05-02-002

90Z7B-05-02-11E

2. When pushing select / confirm knob (3), the

Machine Setting screen appears. (Refer to List of
Machine Setting Item.)

fNOTE: Items of learning/adjustment are as follows.

 Transmission Learning
 Lift Arm Angle Sensor Learning TNED-05-02-061EN
 Digging Position Adjustment

TTNEM50-EN-01(20181109) T5-2-24
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

List of Machine Setting Item

Item Unit Overview

Transmission Learning - Performance of learning (calibration)
Lift Arm Angle Sensor Learning - Performance of learning (sensor calibration)
Digging Position Adjustment - Adjustment of digging position

TTNEM50-EN-01(20181109) T5-2-25
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Transmission Learning
IMPORTANT: When transmission or transmission
control valve has been repaired/replaced, and
Main Controller (MC) has been replaced, perform
transmission learning.

Preparation:
1. Start the engine.
2. Select Service Menu screen on the monitor and
Machine Setting/Transmission Learning screen
appears. (Refer to Monitor Operation)
3. Stall the transmission with the following machine
conditions.

Stall Condition:
 Declutch Position Switch: OFF
 Travel Mode: Manual Mode
 Shift Switch: 5th
 Parking Brake Switch: OFF
 Brake Pedal: Fully Applied
 Accelerator Pedal: Fully Applied
 Forward/Reverse Lever: Forward Position

4. Raise torque converter oil temperature (7) 70°C

(158°F) to 90°C (194°F) but not to exceed 100°C
(212°F) by operating the accelerator pedal
moderately.
5. When torque converter oil temperature (7) reaches
90°C (194°F), stop transmission stalling, and set the
machine in the following conditions.

Learning Start Condition:

 Accelerator Pedal: Not Applied
 Forward/Reverse Lever: Neutral Position
 Parking Brake Switch: ON
 Brake Pedal: Not Applied

TTNEM50-EN-01(20181109) T5-2-26
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Monitor Operation:
1 2
IMPORTANT: Do not operate control levers and other
switches when learning is performed.

1. Turn select / confirm knob (3) and select Machine 3

Setting (4) on Service Menu.

TNED-05-02-002

90Z7B-05-02-11E

2. When pushing select / confirm knob (3), the

5
Machine Setting screen appears.
3. Turn select / confirm knob (3) and select
Transmission Learning (5).

TNED-05-02-061EN

TTNEM50-EN-01(20181109) T5-2-27
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

4. When pushing select / confirm knob (3), 6 7

Transmission Learning screen appears.

5. When torque converter oil temperature (7) is 70°C

(158°F) to 90°C (194°F), push select / confirm knob
(3) to select "Start" (6) and start learning.

TNED-05-02-071EN

6. When learning is completed, the Learning End

screen appears.

7. Set the key switch to the OFF position, and finish

the learning.

fNOTE: When the learning is performed, input signal TNED-05-02-083EN

to previous screen switch (1) and return to basic screen
switch (2) is invalid.
fNOTE: When the machine is in deactivation condition
while learning, learning is stopped. And the basic screen
appears. Perform the learning again.

TTNEM50-EN-01(20181109) T5-2-28
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Lift Arm Angle Sensor Learning

1
IMPORTANT: When lift arm angle sensor has been
replaced, perform lift arm angle sensor learning.

Preparation:

1. Start the engine.

2. Set front control lever lock switch (1) to UNLOCK

Position (3).

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

MNEC-01-041
operation.

4. Set front control lever lock switch (1) to LOCK

Position (2). 2 1

5. Set the key switch to the OFF position.

MNEC-01-015

2- LOCK 3- UNLOCK

TTNEM50-EN-01(20181109) T5-2-29
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Monitor Operation:
1 2
IMPORTANT: The learning can not be performed
when the value of lift arm angle sensor is out of
range from 3.3 V to 4.3 V.
3
1. Set the key switch to the ON position.
2. Turn select / confirm knob (3) and select Machine
Setting (4) on Service Menu. TNED-05-02-002

90Z7B-05-02-11E
3. When pushing select / confirm knob (3), the
Machine Setting screen appears.
4. Turn select / confirm knob (3) and select Lift Arm 5
Angle Sensor Learning (5).

TNED-05-02-061EN

5. When pushing select / confirm knob (3), the Lift

Arm Angle Sensor Learning (5) screen appears.
6. When pushing select / confirm knob (3), the
learning starts.

TNED-05-02-072EN

7. When learning is completed, the Learning End

screen appears.
8. Set the key switch to the OFF position, and finish
the learning.

fNOTE: When the learning is performed, input signal to

return to previous screen switch (1) and return to basic
screen switch (2) is invalid.
90TNED-05-02-84EN

TTNEM50-EN-01(20181109) T5-2-30
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Digging Position Adjustment

1
IMPORTANT: When lift arm angle sensor has
been replaced, perform the digging position
adjustment after performing the lift arm angle
sensor learning.

Preparation:

1. Start the engine.

MNEC-01-041

2. Set front control lever lock switch (1) to UNLOCK

Position (3). 2 1

MNEC-01-015

2- LOCK 3- UNLOCK

3. Lower the lift arms and set the bucket on the

ground horizontally.

85Z7B-4-16-1

TTNEM50-EN-01(20181109) T5-2-31
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Monitor Operation:
1 2
1. Turn select / confirm knob (3) and select Machine
Setting - Digging Position Adjustment (7) menu.

3
2. When pushing select / confirm knob (3), the
Digging Position Adjustment screen appears.

TNED-05-02-002
3. Turn select / confirm knob (3) and select the check
mark.
When pushing select / confirm knob (3), the setting
has been completed.

7
4. When the digging position has been changed, the
digging position and lift arm angle position settings
are changed.
TNED-05-02-061EN

5. When pushing return to previous screen switch (1),

the previous screen appears.

6. When pushing return to basic screen switch (2), the

basic screen appears.

TNED-05-02-073EN

TNED-05-02-085EN

TTNEM50-EN-01(20181109) T5-2-32
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Aftertreatment Device No.

1 2
1. Turn select / confirm knob (3) and select
Aftertreatment Device No. (4) on Service Menu.

TNED-05-02-002

90Z7B-05-02-11E

2. When pushing select / confirm knob (3), the

Aftertreatment Device screen appears.
3. The manufacturing number (S/N) of aftertreatment
device (DOC, SCR) is displayed.

90Z7B-05-02-56E

4. When pushing return to previous screen switch (1),

the previous screen appears.
5. When pushing return to basic screen switch (2), the
basic screen appears.

TTNEM50-EN-01(20181109) T5-2-33
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Engine Tachometer

Engine Tachometer No. Engine Engine Speed

Tachometer (Unit: min-1)
Scale
- 0 Less than 600
A 1 More than 600, less than 830
(Low Idle: 800)
C B 2 More than 830, less than 1030
- 3 More than 1030, less than 1200
- 4 More than 1200, less than 1400
B - 5 More than 1400, less than 1600
A - 6 More than 1600, less than 1800
- 7 More than 1800, less than 2000
- 8 More than 2000, less than 2200
C 9 More than 2200, less than 2400
TNED-02-05-080 - 10 More than 2400, less than 2600
(High Idle: 2440)
- 11 More than 2600, less than 2800

fNOTE: Engine tachometer scales are 200 min-1 step.

TTNEM50-EN-01(20181109) T5-2-34
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Transmission Oil Temperature Gauge and

DEF Level Gauge

Transmission Oil Temperature Gauge No. Gauge Torque Converter Oil Temperature
Scale (Unit: °C (°F) )
- 0 Less than 40 (104)
E A 1 More than 40 (104), less than 45 (113)
D
- 2 More than 45 (113), less than 50 (122)
C
B - 3 More than 50 (122), less than 55 (131)
- 4 More than 55 (131), less than 60 (140)
- 5 More than 60 (140), less than 80 (176)
- 6 More than 80 (176), less than 100 (212)
B 7 More than 100 (212), less than 115 (239)
C 8 More than 115 (239), less than 120 (248)
A D 9 More than 120 (248), less than 125 (257)
TNED-02-05-081
E 10 More than 125 (257)

fNOTE: When the oil temperature is more than scale "D",

the alarm mark and the service indicator appear on the
basic screen.

DEF Level Gauge No. Gauge Gauge DEF Remaining Level (Unit: %)
Scale Color
D 10 Green 90 or more
D - 9 Green More than 80, less than 90
- 8 Green More than 70, less than 80
- 7 Green More than 60, less than 70
- 6 Green More than 50, less than 60
C
C 5 Green More than 40, less than 50
- 4 Green More than 30, less than 40
B - 3 Green More than 20, less than 30
B 2 Green More than 10, less than 20
A A 1 Yellow More than 5.2, less than 10
90Z7B-05-02-DEF A 1 Red More than 2.8, less than 5.2
A 0 Red (Frame) Less than 2.8

fNOTE: When the DEF amount becomes level "A", the

alarm mark and the service indicator appear on the
basic screen.

TTNEM50-EN-01(20181109) T5-2-35
 SECTION 5 TROUBLESHOOTING
Group 2 Monitor

Coolant Temperature Gauge

Coolant Temperature Gauge No. Coolant Temperature (°C (°F))

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

A
TNED-05-02-003

1- Coolant Temperature Gauge

TNED-05-02-004

TTNEM50-EN-01(20181109) T5-2-36
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

Outline
Controller saves the input signals from various sensors
and switches of the machine as data. Various input signals
are recorded as Operation Data and Snapshot Data in
monitor controller.

The recorded data is able to be downloaded to the

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

TTNEM50-EN-01(20181109) T5-3-1
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

List of Operation Data

List of Daily Report Data

Item Details
Date Date of daily report data.
Time Last time when the engine is operated during a day.
Fuel Level The value of the final remained fuel during a day. (Value is recorded by fuel
sensor data from monitor controller.)
Fuel Usage Amount The value of fuel used during a day. (Value is calculated and recorded by
accumulated fuel usage amount from ECM.)
Machine Hour Meter Hour meter cumulative hours. (Hours are recorded by hour meter from monitor
controller.)
Machine Travel Distance Travel distance during a day.
Engine Power Mode OFF Total hours of power mode (OFF) with engine running during a day. (Hours are
Operating Hours recorded by power mode switch information from MC.)
Hours Power Mode ON Hours Total hours of power mode (ON) with engine running during a day. (Hours are
recorded by power mode switch information from MC.)
Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode) during a day. (Hours are
Operating Traveling Hours recorded by travel mode switch information from MC.)
Hours AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode) during a day. (Hours are
Traveling Hours recorded by travel mode switch information from MC.)
Manual Mode Total operating hours of travel mode (Manual mode) during a day. (Hours are
Traveling Hours recorded by travel mode switch information from MC.)

TTNEM50-EN-01(20181109) T5-3-2
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

Item Details
Engine Operating Hour Distribution Engine operating hour distribution during a day. (Engine ON state is recorded
Data when engine is running for more than 5 minutes at each range of engine
operating hour distribution.)
Latitude Signal from GPS antenna.
Longitude Signal from GPS antenna.

fNOTE: The daily operation in this table is equivalent

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

TTNEM50-EN-01(20181109) T5-3-3
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

List of Frequency Distribution Data

Item Details
Pump Load Frequency distribution of main pump delivery pressure
Radiator Coolant Temperature (79 °C Total hours when coolant temperature is less than 80 °C (176 °F) during a day.
or less)
Radiator Coolant Temperature (80 to Total hours when coolant temperature is 80 °C (176 °F) or more and less than 94
93 °C) °C (201.2 °F) during a day.
Radiator Coolant Temperature (94 to Total hours when coolant temperature is 94 °C (201.2 °F) or more and less than
104 °C) 105 °C (221 °F) during a day.
Radiator Coolant Temperature (105 °C Total hours when coolant temperature is 105 °C (221 °F) or more during a day.
or more)
Hydraulic Oil Temperature (49 °C or Total hours when hydraulic oil temperature is less than 50 °C (122 °F) during a
less) day.
Hydraulic Oil Temperature (50 to 89 Total hours when hydraulic oil temperature is 50 °C (122 °F) or more and less
°C) than 90 °C (194 °F) during a day.
Hydraulic Oil Temperature (90 to 99 Total hours when hydraulic oil temperature is 90 °C (194 °F) or more and less
°C) than 100 °C (212 °F) during a day.
Hydraulic Oil Temperature (100 °C or Total hours when hydraulic oil temperature is 100 °C (212 °F) or more during a
more) day.
Torque Converter Oil Temperature (49 Total hours when torque converter oil temperature is less than 50 °C during a
°C or less) day.
Torque Converter Oil Temperature (50 Total hours when torque converter oil temperature is 50 °C (122 °F) or more and
to 89 °C) less than 90 °C (194 °F) during a day.
Torque Converter Oil Temperature (90 Total hours when torque converter oil temperature is 90 °C (194 °F) or more and
to 109 °C) less than 110 °C (230 °F) during a day.
Torque Converter Oil Temperature Total hours when torque converter oil temperature is 110 °C (230 °F) or more
(110 °C or more) during a day.

TTNEM50-EN-01(20181109) T5-3-4
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

List of Total Operating Hours

Item Details
Hour Meter End Hour meter’s value accumulated in machine’s monitor
Travel Distance Odometer’s value accumulated in machine’s monitor
Engine Power Mode OFF Total engine operating hours selecting power mode (OFF)
Operating Hours
Hours Power Mode ON Hours Total engine operating hours selecting power mode (ON)
Travel AUTO 1 Mode Total operating hours of travel mode (AUTO 1 mode)
Operating Traveling Hours
Hour AUTO 2 Mode Total operating hours of travel mode (AUTO 2 mode)
Traveling Hours
Manual Mode Total operating hours of travel mode (Manual mode)
Traveling Hours
MC Communication Error Time Total hours of MC communication error
ECM Communication Time Out Time Total hours of ECM communication time out

TTNEM50-EN-01(20181109) T5-3-5
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

Snapshot Data

Item Details
Serial No. - Machine serial no.
Snapshot Model 1 Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and
wheel loader
Model 2 Detail difference on model 1
DTC Code Fault code and frequency of occurrence
Priority -
Hour Meter Machine’s hour meter at a time when trouble occurred
Occurrence: Year Year at a time when trouble occurred
Occurrence: Date Date at a time when trouble occurred
Occurrence: Time Time at a time when trouble occurred
SA -
SPN Version 001: Version 1
010: Version 2
011: Version 3
100: Version 4
111: Missing version

fNOTE: The data on machine body system including

MC are downloaded as for Snapshot Data Download
(Hitachi). The data on engine system including ECM are
downloaded as for Snapshot Data Download (Isuzu).

TTNEM50-EN-01(20181109) T5-3-6
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

Communication System
The communication system is used for maintenance of
the machine, “e-Service” by transmitting various data of
the machine regularly via the communication terminal.

fNOTE: Depending on the circumstances of the machine

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

The communication system consists of communication

terminal, GPS antenna and communication antenna.
The functions of each equipment are as follows.

 Communication Terminal:
Receives the data from monitor controller and GPS
antenna, and sends the data to the communication
antenna.

 GPS Antenna:
Receives location information of the machine.

 Communication Antenna:
Communicates the data.

TTNEM50-EN-01(20181109) T5-3-7
 SECTION 5 TROUBLESHOOTING
Group 3 e-Service

(Blank)

TTNEM50-EN-01(20181109) T5-3-8
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Main Component (Overview)

14 13
8
7

6 12
5

9
1
15

10
11

85Z7BT01-02-28

1- Bucket 6- Horn (2 Used) 12- Rear Combination Light (Turn Signal

2- Bucket Link 7- Front Work Light (2 Used) Light, Hazard Light, Tail Light, Brake
3- Bell Crank (Lever) 8- Cab (Refer to T5-4-13.) Light, Backup Light) (2 Used)
4- Bucket Cylinder 9- DEF Tank Box 13- Rear Work Light (2 Used)
5- Front Combination Light (Headlight, 10- Lift Arm Cylinder (2 Used) 14- Rain Cap/Pre-Cleaner
Turn Signal Light, Clearance Light, 11- Lift Arm 15- Rear Full Fender
Hazard Light) (2 Used)

TTNEM50-EN-01(20181109) T5-4-1
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Main Component

6
26
7 24
5

17

2 9

22

10

15
12
4

13 14
23
16
21

20
11
19
18 25
1
85Z7BT01-02-29

1- Engine (Refer to T5-4-18.) 7- Steering Pilot Valve 13- Service Brake Accumulator 20- Fan Control Valve (Refer to
2- Air Cleaner, Radiator 8- Multiple Control Valve (Refer (2 Used) T5-4-20.)
Assembly (Refer to T5-4-5.) to T5-4-21.) 14- Flow Regulator Valve (Refer 21- Fan Motor
3- Aftertreatment Device (Refer 9- 2-Spool Solenoid Valve Unit to T5-4-23.) 22- DEF Supply Module (Refer to
to T5-4-19.) (Refer to T5-4-22.) 15- Pilot Valve T5-4-24.)
4- Parking Brake Solenoid Valve 10- Ride Control Accumulator 16- Stop Valve 23- DEF Tank (Refer to T5-4-24.)
(Refer to T5-4-22.) 11- Brake Charge Valve (Unloader 17- Hydraulic Oil Tank (Refer to 24- Steering Valve
5- Manifold Valve (Refer to Valve) (Refer to T5-4-22.) T5-4-8.) 25- Battery Box (Refer to T5-4-7.)
T5-4-22.) 12- Pilot Filter 18- Fuel Prefilter 26- Joystick Steering
6- Brake Valve 19- Fuel Tank

TTNEM50-EN-01(20181109) T5-4-2
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

3 4

3
2

7 10
85Z7BT01-02-03

1- Front Axle (Refer to T5-4-11.) 5- Drive Unit (Refer to T5-4-10.) 9- Rear Axle Support (Front)
2- Steering Cylinder (2 Used) 6- Front (2nd) Propeller Shaft 10- Rear Axle Support (Rear)
3- Steering Accumulator (2 Used) 7- Rear (3rd) Propeller Shaft
4- Pump Device (Refer to T5-4-21.) 8- Rear Axle

TTNEM50-EN-01(20181109) T5-4-3
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Electrical System (Overview)

6 1
2

3 9

5
8

10

85Z7BT01-02-04

1- Engine (Refer to T5-4-18.) 3- Cab (Refer to T5-4-12.) 6- Battery Box (Refer to T5-4-8.) 9- Backup Alarm
2- Hydraulic Oil Tank (Refer to 4- Bucket Proximity Switch 7- Fuel Tank (Refer to T5-4-9.) 10- DEF Supply Module (Refer to
T5-4-8.) 5- Lift Arm Angle Sensor 8- DEF Tank (Refer to T5-4-24.) T5-4-24.)

TTNEM50-EN-01(20181109) T5-4-4
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Air Cleaner / Radiator Assembly

5
1 2 8

5 1

4
3
85Z7BT01-02-05 7 85Z7BT01-02-06
View A

1- Air Cleaner 3- Fan Valve (Refer to T5-4-20.) 5- Reserve Tank 8- Coolant Level Sensor
2- Radiator Assembly (Refer to 4- Intercooler Outlet 6- Air Filter Restriction Switch
T5-4-6.) Temperature Sensor 7- TBAP Sensor

TTNEM50-EN-01(20181109) T5-4-5
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Radiator Assembly

4
1
3 2

Machine
Front Side

5
6

Machine Front Side

View A
85Z7BT01-02-07 85Z7BT01-02-08

1- Reserve Tank 3- Oil Cooler 5- Torque Converter Cooler

2- Radiator 4- Intercooler 6- Fan Motor

TTNEM50-EN-01(20181109) T5-4-6
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Battery Box
A 6 7 8

10

3
4

85Z7BT01-02-09 85Z7BT01-02-10
1 Detail A
2

1- Battery Box 4- Battery Relay 7- Fusible Link (120 A) 10- Intake Air Heater Relay
2- Battery (2 Used) 5- Fusible Link (70 A) 8- Fusible Link (70 A)
3- Battery Disconnect Switch 6- Fusible Link (140 A) 9- Starter Relay

TTNEM50-EN-01(20181109) T5-4-7
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Hydraulic Oil Tank

Machine Front Side

3

4
85Z7BT01-02-11

1- Hydraulic Oil Tank 3- Hydraulic Oil Temperature Sensor 4- Emergency (Secondary) Steering Pump
2- Hydraulic Oil Level Sensor (Refer to T5-4-24.)

TTNEM50-EN-01(20181109) T5-4-8
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Fuel Tank

3
5

Machine Front Side 1

85Z7BT01-02-12
2

1- Fuel Tank 3- Fuel Pump 5- Fuel Prefilter

2- Fuel Level Sensor 4- Water Separator Sensor

TTNEM50-EN-01(20181109) T5-4-9
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Drive Unit
1 2 A
7
6

5 8

4 9

16
a b

17
c
d

15 10

14 11

13 12

Inside of A

View B 85Z7BT01-02-27

a- Transmission Side c- Engine Flywheel e- Machine Front Side

b- Engine Side d- Torque Converter

1- Transmission Intermediate 6- Torque Converter Input 11- Proportional Solenoid Valve 15- Proportional Solenoid Valve
Shaft Sensor Speed Sensor Y2 (For Reverse Clutch) Y6 (For 2nd Speed Clutch)
2- Torque Converter Output 7- Breather Port 12- Proportional Solenoid Valve 16- Proportional Solenoid Valve
Speed Sensor 8- Torque Converter Oil Y3 (For 1st Speed Clutch) (For Lock-up Clutch)
3- Transmission Oil Filter Temperature Sensor 13- Proportional Solenoid Valve 17- Damper Unit
4- Machine Speed Sensor 9- Transmission Control Valve Y4 (For 3rd Speed Clutch)
5- Transmission Oil Filter 10- Proportional Solenoid Valve 14- Proportional Solenoid Valve
Restriction Switch Y1 (For Fast-Speed Forward Y5 (For Slow-Speed Forward
Clutch) Clutch)

TTNEM50-EN-01(20181109) T5-4-10
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Front Axle

85Z7BT01-02-13

1- Pressure Sensor (Brake Secondary 2- Axle Oil Temperature Sensor

Pressure)

TTNEM50-EN-01(20181109) T5-4-11
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Cab

9 10
1 11 2 12

3 3

4
a

Detail D
8
b
13

D e

7
F 5 c
View F

85Z7BT01-02-14

a- Front Console (Refer to T5- b- Right Console (Refer to T5- c- Rear Console (Refer to T5-4- e- Control Unit (Refer to T5-4-
4-13.) 4-14.) 15.) 16.)

1- Radio 5- Accelerator Pedal Sensor 9- Front Wiper (1) Relay 12- Communication Terminal
2- Upper Switch Panel 6- - 10- Front Wiper (2) Relay Antenna
3- Speaker (2 Used) 7- Brake Light Switch 11- GPS Antenna (Option) 13- Outside Air Temperature
4- Rear Wiper Motor 8- Front Wiper Motor Sensor

TTNEM50-EN-01(20181109) T5-4-12
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Front Console

1 2 16 3 4 5 6 7

9 8 MNEC-01-036

12 13 14

11

10

15
MNEC-01-037 MNEC-01-038

1- Hazard Light Switch 6- Monitor Panel (Refer to 10- Front/Rear Wiper Switch 14- Multi-Function Monitor/Air
2- Work Light Switch T5-4-18.) 11- Forward/Reverse Lever/ Conditioner Control Panel
3- Parking Brake Switch 7- Horn Shift Switch 15- Cigar Lighter
4- Neutral Lever Lock for 8- Accelerator Pedal 12- Turn Signal Lever/Light 16- Engine Overrun Alarm
Forward/Reverse Lever 9- Brake/ Declutch Pedal Switch/Dimmer Switch Indicator
5- Steering Wheel (Both at left and right are 13- Key Switch
interlocked.)

TTNEM50-EN-01(20181109) T5-4-13
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Right Console

Fingertip Control Lever Type

4 19
5
6 7 8
3*(1) 9 10
11 12
2*(3)
1*(2) 20

21

18
13
14
15
16
17
MNEC-01-041 MNEC-01-042

Multi-Function Joystick Lever Type

21 19 1
5
6 7 8
2210
11 12
24
23
25
26

13
14
15
16 MNEC-01-044
17
MNEC-01-043

1- Auxiliary Control Lever 8- Power Mode Switch 14- Aftertreatment Device 22- Forward/Reverse Selector
(Option)* 9- Forward/Reverse Selector Regeneration Switch Switch
2- Bucket Control Lever* Switch 15- Auxiliary 23- Forward/Reverse Switch
3- Lift Arm Control Lever* 10- Fan Reverse Rotation 16- 1st Speed Fixing Switch 24- Multi-Function Joystick
4- Forward/Reverse Switch Switch 17- Ride Control Switch Lever
5- Front Control Lever Lock 11- Auxiliary 18- Hold Switch 25- Hold Switch (Under the
Switch 12- Hydraulic Coupler Switch 19- DSS (Down Shift Switch) Lever)
6- Declutch Position Switch 13- Emergency (Secondary) 20- Horn Switch 26- Horn Button (Under the
7- Travel Mode Selector Steering Operation Check 21- Quick Power Switch Lever)
Switch Switch

fNOTE: * The layout of each control lever may depend

on the machine specification.

TTNEM50-EN-01(20181109) T5-4-14
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Rear Console

1 2 3

35
9 8 7 6 5

14 13 12 11 10 4

38
19 18 17 16 15

24 23 22 21 20 36

39
29 28 27 26 25
40
41
34 33 32 31 30 37

85Z7BT01-02-15

1- Fuse Box B 12- Right Turn Signal Light 23- Rear Wiper Relay (B-R9) 34- Additional Work Light
2- Fuse Box A Relay (A-R8) 24- Rear Washer Relay (B-R10) (Front) Relay (C-R10)
3- MPDr. Connector 13- Horn Relay (A-R9) 25- Starter Cut Relay (C-R1) 35- Relay Box A
4- ECM Timer Relay 14- Bucket Angle Position 26- Fuel Pump Relay (C-R2) 36- Relay Box B
5- Headlight Relay (Left) Sensor Relay (A-R10) 27- DEF Heater Relay 1 (C-R3) 37- Relay Box C
(A-R1) 15- Parking Brake Relay 1 (B-R1) 28- DEF Heater Relay 2 (C-R4) 38- ECM Main Relay
6- Headlight Relay (Right) 16- Parking Brake Relay 2 (B-R2) 29- DEF Heater Relay 3 (C-R5) 39- Supply Module Relay
(A-R2) 17- Control Lever Lock Relay 30- SCR Sensor Relay (C-R6) 40- Aftertreatment Device
7- High Beam Relay (A-R3) (B-R3) 31- Emergency (Secondary) Regeneration Relay
8- Bucket Leveler Relay (A-R4) 18- Brake Light Relay (B-R4) Steering Relay (C-R7) 41- Engine Data Link
9- Backup Lamp Relay (A-R5) 19- Load Dump Relay (B-R5) 32- Parking Brake Indicator Connector
10- Work Light (Front) Relay 20- Neutral Relay (B-R6) Relay (C-R8)
(A-R6) 21- Left Turn Signal Light Relay 33- Additional Work Light
11- Work Light (Rear) Relay (B-R7) (Rear) Relay (C-R9)
(A-R7) 22- Front Washer Relay (B-R8)

TTNEM50-EN-01(20181109) T5-4-15
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Control Unit

1
85Z7BT01-02-17

85Z7BT01-02-16
3

4
6

Machine Front Side

85Z7BT01-02-18 85Z7BT01-02-19
Machine Front Side

a- Monitor

1- Monitor Controller 2- TCU (Transmission Control 3- MC (Main Controller) 5- Flasher Relay

Unit) 4- GSM/GPS 6- Air Conditioner Controller

TTNEM50-EN-01(20181109) T5-4-16
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Monitor Panel

21 22 1 2 3 4
20 5
6
19 7
8
9
18
10
17

11

16 15 12

14 13 MNEC-01-001

1- Left Turn Signal Light 7- Hydraulic Oil Level 12- Alternator Indicator 19- Engine Oil Pressure
Indicator Indicator 13- Fuel Gauge Indicator
2- High Beam Indicator 8- Low Steering Oil Pressure 14- Multi-Function Monitor 20- Preheat Indicator
3- Work Light Indicator Indicator 15- Communication System 21- Air Filter Restriction
4- Right Turn Signal Light 9- Transmission Warning Error Indicator Indicator
Indicator Indicator 16- Coolant Temperature 22- Clearance Light Indicator
5- Parking Brake Indicator 10- Control Lever Lock Gauge
6- Brake Oil Low Pressure Indicator 17- Overheat Indicator
Indicator 11- Fuel Level Indicator 18- Engine Warning Indicator

TTNEM50-EN-01(20181109) T5-4-17
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Multi-Function Monitor/Air Conditioner Switch Panel

2 3 1- Select / Confirm Knob 6- Temperature / Mode Switch

2- Return to Previous Screen 7- Defroster Switch
3- Return to Basic Screen 8- Circulation / Fresh Air Switch
4- Blower / Air Conditioner
1 AUTO Switch
5- Air Conditioner ON / OFF
Switch

4 6

5 7

8 MNEC-01-006

Joystick Steering Controls (Electric Type)

3 5

6
7

115Z7BT01-02-10

1- Forward / Reverse Switch 4- Joystick Steering System 6- Left Console Lock Release 8- Wiper Switch
2- Joystick Steering Lever Switch Lever
3- Shift Down Switch 5- Armrest Angle Adjustment 7- Enable/Disabled Detection
Dial Switch (Micro Switch)

TTNEM50-EN-01(20181109) T5-4-18
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Engine 16

2 4 5 6
3
7

17 8

1
15

14 9

13 10

11 85Z7BT01-02-25
12

18

19

20 85Z7BT01-02-26

1- Coolant Temperature 5- Crankcase Pressure Sensor 9- Fuel Supply Pump 16- Turbocharger Speed Sensor
Sensor 6- Boost Pressure/Boost 10- Fuel Main Filter 17- Exhaust Pressure Sensor
2- EGR Gas Differential Temperature Sensor 11- ECM 18- Alternator
Pressure Sensor 7- Common Rail Pressure 12- Crank Revolution Sensor 19- Engine Oil Filter
3- EGR Gas Temperature Sensor 13- Cam Angle Sensor 20- Starter Motor
Sensor 8- Accessory Pump (Fan 14- Engine Oil Pressure Switch
4- EGR Valve Pump) 15- EGR Motor Position Sensor

TTNEM50-EN-01(20181109) T5-4-19
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Aftertreatment Device

4 5
6

Machine Front Side

11

10

8
9 TNEK-02-03-001

1- Aftertreatment Device 4- Diesel Oxidation Catalyst 7- DOC Outlet Exhaust 10- DOC Inlet Exhaust
2- SCR Inlet Exhaust (DOC) 2 Temperature Sensor Temperature Sensor
Temperature Sensor 5- SCR Outlet Exhaust 8- Diesel Oxidation Catalyst 11- Dosing Module
3- SCR Catalyst Temperature Sensor (DOC) 1
6- NOx Sensor (SCR Outlet) 9- NOx Sensor (SCR Inlet)

TTNEM50-EN-01(20181109) T5-4-20
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Fan Valve

Machine Front Side

1
5

2 TNEE-01-02-031

1- Fan Speed Control Solenoid Valve 3- Fan Control Valve

2- Fan Reverse Rotation Control Solenoid 4- Fan Reverse Rotation Spool
Valve 5- Fan Pump Delivery Pressure Sensor

TTNEM50-EN-01(20181109) T5-4-21
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Pump Device
1

Machine Front Side

6 2

5 4 85Z7BT01-02-20

1- Main Pump 3- Priority Valve 5- Pilot Pump

2- Regulator 4- Pump Delivery Pressure Sensor 6- Main Relief Valve (Steering)

Multiple Control Valve

7 9

Machine
Front Side

10

85Z7BT01-02-21

7- Main Relief Valve (Front Attachment) 9- Overload Relief Valve (Bucket: Bottom 10- Overload Relief Valve (Lift Arm: Bottom
8- Overload Relief Valve (Bucket: Rod Side) Side) Side)

TTNEM50-EN-01(20181109) T5-4-22
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Manifold Valve Brake Charge Valve

3 4
5
2
6 7

1
TNED-01-02-021

TNED-01-02-013

1- Pilot Accumulator 4- Pressure Sensor (Primary 6- Pressure Sensor (Brake

(Steering) Pilot Pressure) Primary Pressure)
2- Torque Control Solenoid 5- Pilot Accumulator (Front 7- Priority Valve
Valve Attachment)
3- Control Lever Lock
Solenoid Valve

Parking Brake Solenoid Valve 2-Spool Solenoid Valve Unit

12 11

9 10

TDAA-03-07-002

TNEE-01-02-013

8- Parking Brake Solenoid 9- Parking Brake Pressure 11- Ride Control Solenoid Valve 12- Lift Arm Flow Rate Control
Valve Sensor (SJ) Solenoid Valve (SZ)
10- Parking Brake Accumulator

TTNEM50-EN-01(20181109) T5-4-23
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Steering Valve Block Flow Regulator Valve

1 2 3
Machine Front Side
Machine
Front Side

6 9

5 4
TNEE-01-02-014 TNED-01-02-022

1- Overload Relief Valve 4- Emergency (Secondary) 7- Pressure Sensor (Bucket 9- Pressure Sensor (Bucket
2- Steering Valve Steering Pump Delivery Rollback) Dump)
3- Overload Relief Valve Pressure Sensor 8- Pressure Sensor (Lift Arm
5- Secondary Steering Valve Raise)
6- Steering Pressure Switch

Emergency Steering Pump

12 11 10

Machine
Front Side

TNED-01-02-019

10- Electrical Motor 11- Gear Pump 12- Relief Valve

TTNEM50-EN-01(20181109) T5-4-24
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

DEF Tank
1
6

5
8
10

12

11
2

1 85Z7BT01-02-22
4

85Z7BT01-02-23

1- DEF Sensor Unit 5- DEF Level Sensor 8- DEF Pipe to DEF Supply 10- Coolant Heater Tube
2- DEF Tank 6- DEF Pipe from DEF Supply Module 11- DEF Suction Filter
3- DEF Quality Sensor Module 9- Coolant Pipe from Coolant 12- DEF Suction Tube
4- DEF Temperature Sensor 7- Coolant Pipe to Engine Control Valve

DEF Supply Module

1 1

9 1 5 6 7 8 9

4 3
TNEK-01-02-006

85Z7BT01-02-24

1- DEF Hose (3 Used) 4- Coolant Control Valve (CCV) 7- Heating Wire

2- DEF Supply Module 5- Corrugate Tube 8- Thermoplastic Cover
3- Filter Cap 6- DEF Tube 9- Quick Connector (2 Used)

TTNEM50-EN-01(20181109) T5-4-25
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Joystick Steering Hydraulic Component

Layout

1 2 3 4

9 6

TNEK-05-08-014
8 7

a- Vehicle Front Side

1- Steering Valve 4- 2-Spool Solenoid Valve Unit 6- Stop Valve (Left) 9- Steering Cylinder (Right)
2- Steering Pilot Valve (OP) 7- Steering Accumulator
3- Joystick Steering Valve (OP) 5- Stop Valve (Right) 8- Steering Cylinder (Left)

TTNEM50-EN-01(20181109) T5-4-26
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Joystick Steering Valve

90TNEK-05-08-20

2-Spool Solenoid Valve Unit and Pressure Sensor

2 3

5 85TNEK-05-08-23
4

1- Cut Off Solenoid Valve (Spool) 4- Pressure Sensor (Left Steering) (JPL)
2- Right Steering Proportional Solenoid Valve (Solenoid a) 5- Pressure Sensor (Right Steering) (JPR)
3- Left Steering Proportional Solenoid Valve (Solenoid b) 6- Pressure Sensor (Steering) (JPP)

TTNEM50-EN-01(20181109) T5-4-27
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Joystick Steering Cab Components

Control Unit (JCU)
a

TNEK-05-08-026
TNED-01-02-029

JSS Fuse
JSS Relay

TNEK-05-08-025

TNEK-05-08-027

a- Vehicle Front Side

1- JCU (Joystick Steering Control Unit) 6- JSS ON Relay (JR5) 11- Fuse Box A
2- FNR OFF Relay (JR1) 7- N Relay (JR9) 12- Fuse#20 (5A)
3- JSS OFF Relay (JR2) 8- JSS Hold Relay (JR6) 13- Fuse Box B
4- FNR ON Relay (JR3) 9- Cut Off Relay1 (JR7) 14- Fuse#11 (5A)
5- FNR Hold Relay (JR4) 10- Cut Off Relay2 (JR8)

TTNEM50-EN-01(20181109) T5-4-28
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

Operator's Seat DETAIL A

4 5
8
6

A
3

TNEK-05-08-016

TNEK-05-08-015
2

MNEK-13-003

1- Switch Box 4- DSS Switch 7- Joystick Steering Selector Switch (JSS)

2- Left Console Pipe 5- Forward/Reverse Switch (Left) 8- Joystick Steering Lever
3- Left Armrest 6- Wiper Switch 9- Left Console Lock Release Lever

TTNEM50-EN-01(20181109) T5-4-29
 SECTION 5 TROUBLESHOOTING
Group 4 Component Layout

(Blank)

TTNEM50-EN-01(20181109) T5-4-30
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis

By Using Fault Codes) Procedure

Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing by using MPDr. or fNOTE: The engine controller (ECM) judges the engine
the service menu of the monitor. malfunction. After the engine is repaired, select Fault
Code Clear on Engine Setting. Then, delete the fault code
 Diagnosis Procedure of engine controller (ECM) on Troubleshooting. (Refer to
 Check the symptoms in machine operation for each TROUBLESHOOTING/Monitor.)
fault code. When the symptoms match the machine
operation when trouble occurs, perform the remedy.
 In case more than one fault code are displayed at the
same time, MC may be faulty or the power/ground
of the sensor system may be faulty.
 When the MC fault code is displayed with other fault
code, replace MC.
 When fault code 11003-3 (Abnormal Sensor Voltage)
is displayed with other fault code, diagnose for fault
code 11003-3 first.
 In case more than one fault code other than those
described above are displayed at the same time,
diagnose for each fault code.
 It may be required that the machine is operated or
the test harness is connected at inspection.
Check the items of preparation and perform
inspection according to the procedures when
diagnosing.

fNOTE: All connector images in this section are viewed

from the open end side of wire harness end.

1
2

T6L4-05-03-001

1- Wire Harness End Connector 2- Wire Harness

TTNEM50-EN-01(20181109) T5-5-1
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Contents of Diagnosis

Fault Code

Preparation

Tools for a diagnosis and contents

needing inspection beforehand are
explained.

How to Read Table

Fault Code Trouble Procedure Inspection Evaluation Cause
Method
YES: (E)
1 (C) (D)
NO: (F)
(A) (B)
YES: (I)
2 (G) (H)
NO: (J)
 A: Fault code
 B: Trouble details
 Procedures 1, 2: Inspection order for the fault code
 C, G: Inspection method for trouble cause
 D, H: Evaluation specification of check results
 E, F, I, J: Trouble cause for the fault code

Procedure:
1. Check an applicable line depending on displayed fault code (A).
2. After checking or measuring of inspection method (C) of procedure (1),
refer to evaluation (D) and judge the results.
3. When the results are satisfied (YES) with evaluation (D), the trouble cause
is cause (E).
If the results are not satisfied (NO) with evaluation (D), the trouble cause is
cause (F) or check inspection method (G) of procedure 2.

Circuit Diagram of Test Harness

A connection point of the test harness and a point to check are explained.
(Only Pressure Sensor System Troubleshooting)

TTNEM50-EN-01(20181109) T5-5-2
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table

Fault Code MPDr. Message Category Reference 1 Reference 2

111000-2 Abnormal EEPROM MC T5-5-10 T5-5-79

111001-2 Abnormal RAM MC T5-5-10 T5-5-79

111002-2 Abnormal A/D Converter MC T5-5-10 T5-5-79

111003-3 Abnormal Sensor Voltage MC T5-5-10 T5-5-80

111006-2 (MC) EC Communication Error MC T5-5-11 T5-5-83

111007-2 (MC) IC Communication Error 1 MC T5-5-11 T5-5-83

111008-2 (MC) IC Communication Error 2 MC T5-5-11 T5-5-91

111009-2 (MC) Monitor Controller Communication Error 1 MC T5-5-11 T5-5-83

111010-2 (MC) Monitor Controller Communication Error 2 MC T5-5-11 T5-5-91

111011-2 (MC) Transmission Controller Communication Error MC T5-5-11 T5-5-83

111014-2 (MC) Air Conditioner Controller Communication Error MC T5-5-11 T5-5-91

111025-2 (MC) Column Monitor Communication Error MC T5-5-11 T5-5-91

111033-2 JCU Communication Error (Main Controller) MC T5-5-25 T5-5-

111100-2 Abnormal Engine Speed MC T5-5-12 T5-5-95

111103-3 Accelerator Pedal Circuit High Input MC T5-5-12 T5-5-96

111103-4 Accelerator Pedal Circuit Low Input MC T5-5-12 T5-5-96

111106-3 Abnormal Accelerator Pedal 2 Circuit High Input MC T5-5-12 T5-5-96

111106-4 Abnormal Accelerator Pedal 2 Circuit Low Input MC T5-5-12 T5-5-96

111107-2 Accelerator Pedal Sensor Correlation Diagnosis MC T5-5-12 T5-5-96

111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input MC T5-5-14 T5-5-98

111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-98

111202-3 Bucket Roll-In Pilot Pressure Sensor Circuit High Input MC T5-5-14 T5-5-98

111202-4 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-98

111203-3 Bucket Roll-Out Pilot Pressure Sensor Circuit High Input MC T5-5-14 T5-5-98

111203-4 Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input MC T5-5-14 T5-5-98

TTNEM50-EN-01(20181109) T5-5-3
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

111204-3 Pump Delivery Pressure Sensor Circuit High Input MC T5-5-13 T5-5-100

111204-4 Pump Delivery Pressure Sensor Circuit Low Input MC T5-5-13 T5-5-100

111205-3 Lift Arm Angle Sensor Circuit High Input MC T5-5-20 T5-5-97

111205-4 Lift Arm Angle Sensor Circuit Low Input MC T5-5-20 T5-5-97

111206-3 Hyd. Fan Circut Pressure Sensor Circuit High Input MC T5-5-13 T5-5-101

111206-4 Hyd. Fan Circut Pressure Sensor Circuit Low Input MC T5-5-13 T5-5-101

111207-3 Refrigerant Pressure Sensor Circuit High Input MC T5-5-20 T5-5-97

111207-4 Refrigerant Pressure Sensor Circuit Low Input MC T5-5-20 T5-5-97

111208-3 Emergency Steering Check Pressure Sensor Circuit High MC T5-5-13 T5-5-101
Input
111208-4 Emergency Steering Check Pressure Sensor Circuit Low MC T5-5-13 T5-5-101
Input
111217-3 Pilot Pressure Sensor Circuit High Input MC T5-5-15 T5-5-99

111217-4 Pilot Pressure Sensor Circuit Low Input MC T5-5-15 T5-5-99

111311-3 Service Brake Primary Pressure Sensor Circuit High Input MC T5-5-15 T5-5-102

111311-4 Service Brake Primary Pressure Sensor Circuit Low Input MC T5-5-15 T5-5-102

111312-3 Service Brake Secondary Pressure Sensor Circuit High MC T5-5-16 T5-5-99
Input
111312-4 Service Brake Secondary Pressure Sensor Circuit Low MC T5-5-16 T5-5-99
Input
111313-3 Parking Brake Pressure Sensor Circuit High Input MC T5-5-16 T5-5-102

111313-4 Parking Brake Pressure Sensor Circuit Low Input MC T5-5-16 T5-5-102

111410-2 Parallel/Tandem Control P/S Valve Abnormal FB MC T5-5-17 T5-5-103

111410-3 Parallel/Tandem Control P/S Valve FB High Current MC T5-5-17 T5-5-103

111410-4 Parallel/Tandem Control P/S Valve FB Low Current MC T5-5-17 T5-5-103

TTNEM50-EN-01(20181109) T5-5-4
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

111411-2 Hydraulic Fan Reverse Rotation P/S Valve Abnormal FB MC T5-5-17 T5-5-104

111411-3 Hydraulic Fan Reverse Rotation P/S Valve FB High MC T5-5-17 T5-5-104
Current
111411-4 Fan Reverse Rotation P/S Valve FB Low Current MC T5-5-17 T5-5-104

111412-2 Hyd. Fan P/S Valve Abnormal FB MC T5-5-18 T5-5-105

111412-3 Hyd. Fan P/S Valve FB High Current MC T5-5-18 T5-5-105

111412-4 Hyd. Fan P/S Valve FB Low Current MC T5-5-18 T5-5-105

111413-2 Pump Swash Angle P/S Valve Abnormal FB MC T5-5-18 T5-5-106

111413-3 Pump Swash Angle P/S Valve FB High Current MC T5-5-18 T5-5-106

111413-4 Pump Swash Angle P/S Valve FB Low Current MC T5-5-18 T5-5-106

111422-2 Ride Control (Bottom) P/S Valve Abnormal FB MC T5-5-18 T5-5-107

111422-3 Ride Control (Bottom) P/S Valve FB High Current MC T5-5-18 T5-5-107

111422-4 Ride Control (Bottom) P/S Valve FB Low Current MC T5-5-18 T5-5-107

111720-2 Lift arm angle sensor is Uncalibrated. MC T5-5-19 -

111901-3 Hydraulic Oil Temp Sensor Circuit High Input MC T5-5-20 T5-5-108

111901-4 Hydraulic Oil Temp Sensor Circuit Low Input MC T5-5-20 T5-5-108

111902-3 Axle Oil Temperature Sensor Circuit High Input MC T5-5-20 T5-5-109

111902-4 Axle Oil Temperature Sensor Circuit Low Input MC T5-5-20 T5-5-109

TTNEM50-EN-01(20181109) T5-5-5
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

113002-2 (Monitor Controller) Engine Controller Monitor T5-5-22 T5-5-83

Communication Error
113003-2 (Monitor Controller) Main Controller Communication Monitor T5-5-22 T5-5-83
Error 1
113004-2 (Monitor Controller) Main Controller Communication Monitor T5-5-22 T5-5-91
Error 2
113005-2 (Monitor Controller) ICF Communication Error 1 Monitor T5-5-22 T5-5-83

113006-2 (Monitor Controller) ICF Communication Error 2 Monitor T5-5-22 T5-5-91

113007-2 (Monitor Controller) Column Controller Monitor T5-5-22 T5-5-91

Communication Error
113012-2 (Monitor Controller) Transmission Controller Monitor T5-5-22 T5-5-83
Communication Error
113303-2 Abnormal Thermistor Temperature (Monitor Inside Information T5-5-23 -
Temperature)
113311-3 Fuel Level Sensor Circuit High Input Information T5-5-23 T5-5-110

113311-4 Fuel Level Sensor Circuit Low Input Information T5-5-23 T5-5-110

114001-2 ICF: Flash Memory Read/Write Error Information T5-5-23 -

114002-2 ICF: External RAM Read/Write Error Information T5-5-23 -

114003-2 Abnormal EEPROM Information T5-5-23 -

114008-2 Abnormal Internal RAM Information T5-5-23 -

114100-2 Communication Terminal: Abnormal EEPROM Communication T5-5-28 -

Terminal
114101-2 Communication Terminal: Abnormal IB/OB Queue Communication T5-5-28 -
Terminal
114102-2 Communication Terminal: Abnormal Local Loop Back Communication T5-5-28 -
Terminal
114103-2 Communication Terminal: No Satellite Found Communication T5-5-28 -
Terminal
114104-2 Communication Terminal: Remote Loop Back Error 1 Communication T5-5-28 -
Terminal
114105-2 Communication Terminal: Remote Loop Back Error 2 Communication T5-5-28 -
Terminal
114106-2 Communication Terminal: Transmission/Receiving Communication T5-5-28 -
Data Unmatched Terminal

TTNEM50-EN-01(20181109) T5-5-6
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

115001-2 Abnormal REG Input H level Column Display T5-5-24 T5-5-112

115003-2 Abnormal EEPROM Column Display T5-5-24 -

116000-2 Abnormal Power Source (Engine Speed) JCU T5-5-25 -

116001-2 Abnormal Solenoid Pilot Source Pressure JCU T5-5-25 -

116002-3 Controller Source Voltage Abnormally High JCU T5-5-25 -

116002-4 Controller Source Voltage Abnormally Low JCU T5-5-25 -

116003-3 Joystick Signal 1 Voltage Abnormally High JCU T5-5-25 T5-5-113

116003-4 Joystick Signal 1 Voltage Abnormally Low JCU T5-5-25 T5-5-113

116004-3 Joystick Signal 2 Voltage Abnormally High JCU T5-5-25 T5-5-113

116004-4 Joystick Signal 2 Voltage Abnormally Low JCU T5-5-25 T5-5-113

116005-2 Joystick Signal Correlative Diagnosis Error JCU T5-5-25 -

116006-3 Right Steering Solenoid Valve Pressure Sensor Voltage JCU T5-5-25 T5-5-114
Abnormally High
116006-4 Right Steering Solenoid Valve Pressure Sensor Voltage JCU T5-5-25 T5-5-114
Abnormally Low
116007-3 Left Steering Solenoid Valve Pressure Sensor Voltage JCU T5-5-25 T5-5-114
Abnormally High
116007-4 Left Steering Solenoid Valve Pressure Sensor Voltage JCU T5-5-25 T5-5-114
Abnormally Low
116008-3 Solenoid Valve Source Pressure: Pressure Sensor JCU T5-5-25 T5-5-114
Voltage Abnormally High
116008-4 Solenoid Valve Source Pressure: Pressure Sensor JCU T5-5-25 T5-5-114
Voltage Abnormally Low
116010-2 Main Controller Communication Error JCU T5-5-25 -

116013-2 Monitor Controller Communication Error JCU T5-5-25 -

116118-2 Right Steering Solenoid Valve Abnormal Feedback JCU T5-5-26 T5-5-115

116118-3 Right Steering Solenoid Valve Feedback Current JCU T5-5-26 T5-5-115
Abnormally High
116118-4 Right Steering Solenoid Valve Feedback Current JCU T5-5-26 T5-5-115
Abnormally Low
116119-2 Left Steering Solenoid Valve Feedback Abnormal JCU T5-5-26 T5-5-116

116119-3 Left Steering Solenoid Valve Feedback Current JCU T5-5-26 T5-5-116
Abnormally High
116119-4 Left Steering Solenoid Valve Feedback Current JCU T5-5-26 T5-5-116
Abnormally Low

TTNEM50-EN-01(20181109) T5-5-7
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

120000-2 Hydraulic Oil Overheat Alarm MC T5-5-21 T5-5-111

120002-2 Axle Oil Temperature Alarm MC T5-5-21 T5-5-111

120003-2 Emergency Steering Activated MC T5-5-21 T5-5-111

120004-2 Emergency Steering Activated Pressure Alarm MC T5-5-21 T5-5-111

120005-2 Transmission Oil Temperature Overheat Alarm MC T5-5-21 T5-5-111

120014-2 Overrun Alarm MC T5-5-21 T5-5-111

120017-2 Engine Overrun Alarm MC T5-5-21 -

120300-2 System Failure Alarm Monitor T5-5-24 T5-5-117

120400-2 Fuel Filter Restriction Alarm Information T5-5-24 T5-5-117

120401-2 Water Separator Alarm Information T5-5-24 T5-5-117

120500-2 Overheat Alarm Column Display T5-5-24 T5-5-118

120501-2 Engine Error Column Display T5-5-24 T5-5-118

120502-2 Engine Oil Pressure Alarm Column Display T5-5-24 T5-5-118

120503-2 Air Cleaner Restriction Alarm Column Display T5-5-24 T5-5-118

120504-2 Hydraulic Oil Level Alarm Column Display T5-5-24 T5-5-118

120505-2 Brake Pressure Alarm Column Display T5-5-24 T5-5-119

120506-2 Steering Oil Pressure Alarm Column Display T5-5-24 T5-5-119

120507-2 T/M Malfunction Column Display T5-5-24 T5-5-119

120600-2 Abnormal Joystick Function (Joystick Function JCU T5-5-26 -

Enabled 1)
120601-2 Abnormal Joystick Function (Joystick Function JCU T5-5-26 -
Disabled)
120602-2 Abnormal Joystick Function (Joystick Function can not JCU T5-5-26 -
be enabled.)

TTNEM50-EN-01(20181109) T5-5-8
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MPDr. Fault Code Reference Table (Continued)

Fault Code MPDr. Message Category Reference 1 Reference 2

120603-2 Abnormal Joystick Function (Joystick Function can not JCU T5-5-26 -
be disabled.)
120604-2 Abnormal Joystick Function (Joystick Function Enabled JCU T5-5-26 -
2)
120605-2 Abnormal Joystick Function (Right Steering Pressure 1) JCU T5-5-26 -

120606-2 Abnormal Joystick Function (Right Steering Pressure 2) JCU T5-5-26 -

120607-2 Abnormal Joystick Function (Left Steering Pressure 1) JCU T5-5-27 -

120608-2 Abnormal Joystick Function (Left Steering Pressure 2) JCU T5-5-27 -

120609-2 Abnormal FNR (Switch FNR Function enabled 1) JCU T5-5-27 -

120610-2 Abnormal FNR (Switch FNR Function disabled) JCU T5-5-27 -

120611-2 Abnormal FNR (Switch FNR Function can not be JCU T5-5-27 -
enabled.)
120612-2 Abnormal FNR (Switch FNR Function can not be JCU T5-5-27 -
disabled.)
120613-2 Abnormal FNR (Switch FNR Function enabled 2) JCU T5-5-27 -

120614-2 Abnormal Switch (FNR Switching: OFF operation) JCU T5-5-27 -

120615-2 Abnormal Switch (Joystick Function: OFF operation) JCU T5-5-27 -

120616-2 Abnormal Switch (Arm Rest Switch) JCU T5-5-27 -

120617-2 Abnormal Switch (FNR Switch) JCU T5-5-27 -

120618-2 Abnormal Switch (Joystick FNR Switch) JCU T5-5-27 -

fNOTE:
 Refer to page T5-5-28 for the air conditioner controller fault code list.
 Refer to page T5-5-29 for the ECM fault code list.
 Refer to page T5-5-59 for the TCU fault code list.

TTNEM50-EN-01(20181109) T5-5-9
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code List

Controller Hardware Failure
Fault Code Trouble Cause Symptoms in machine Remedy
operation when trouble
occurs
111000-2 Abnormal EEPROM Faulty MC - Replace MC.
111001-2 Abnormal RAM Faulty MC - Replace MC.
111002-2 Abnormal A/D Faulty MC - Replace MC.
Converter
111003-3 Abnormal Sensor Faulty MC Although the accelerator Check the sensor connected
Voltage Faulty sensor pedal is operated, the engine to MC.
Faulty wire harness speed does not change. Check the wire harness.
Replace MC.

TTNEM50-EN-01(20181109) T5-5-10
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

CAN Data Reception Failure

Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111006-2 (MC) EC Faulty wire Although the accelerator pedal is Check the wire
Communication Error harness operated, the engine speed does not harness.
change.
Manual regeneration of
aftertreatment device cannot be
performed.
111007-2 (MC) IC Faulty MC The information for e-Service cannot Check the CAN1
Communication Error Faulty CAN1 be collected. harness.
1 harness Check MC.
111008-2 (MC) IC Faulty MC The information for e-Service cannot Check the CAN2
Communication Error Faulty CAN2 be collected. harness.
2 harness Check MC.
111009-2 (MC) Monitor Faulty MC The LCD monitor display is faulty. Check the CAN1
Controller Faulty CAN1 harness.
Communication Error harness Check MC.
1
111010-2 (MC) Monitor Faulty MC The LCD monitor display is faulty. Check the CAN2
Controller Faulty CAN2 harness.
Communication Error harness Check MC.
2
111011-2 (MC) Transmission Faulty MC The automatic speed shift cannot be Check the wire
Controller Faulty wire performed. harness.
Communication Error harness Check MC.
111014-2 (MC) Air Conditioner Faulty MC The air conditioner is not effective. Check the CAN2
Controller Faulty CAN2 harness.
Communication Error harness Check MC.
111025-2 (MC) Column Monitor Faulty MC The alarms and meters on column Check the CAN2
Communication Error Faulty CAN2 display cannot be displayed correctly. harness.
harness Check MC.

fNOTE: IC and ICF are the information control unit of the monitor controller.

TTNEM50-EN-01(20181109) T5-5-11
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Engine Failure
Fault Code Trouble Cause Symptoms in machine Remedy
operation when trouble
occurs
111100-2 Abnormal Engine Engine speed: over The machine operation Check the wire harness.
Speed 4000 min-1 speed is slow. (During Check the crank speed
Or engine speed speed sensing, the torque is sensor.
(ECM): less than 500 decreased.) Replace the cam angle
min-1 sensor. (Refer to Engine
And engine speed Manual.)
(TCU): over 500
min-1
111103-3 Accelerator Pedal Voltage: over 4.74 V The engine speed is fixed to Check the wire harness.
Circuit High Input 1100 min-1. Replace the accelerator
pedal.
111103-4 Accelerator Pedal Voltage: less than The engine speed is fixed to Check the wire harness.
Circuit Low Input 0.25 V 1100 min-1. Replace the accelerator
pedal.
111106-3 Abnormal Voltage: over 4.74 V The engine speed is fixed to Check the wire harness.
Accelerator Pedal 2 1100 min-1. Replace the accelerator
Circuit High Input pedal.
111106-4 Abnormal Voltage: less than The engine speed is fixed to Check the wire harness.
Accelerator Pedal 2 0.25 V 1100 min-1. Replace the accelerator
Circuit Low Input pedal.
111107-2 Accelerator Pedal Voltage sum of The engine speed is fixed to Check the wire harness.
Sensor Correlation accelerator pedals 1 1100 min-1. Replace the accelerator
Diagnosis and 2: over 5.5 V or pedal.
less than 4.5 V

TTNEM50-EN-01(20181109) T5-5-12
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Pump Failure
Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111204-3 Pump Delivery Voltage: over Traction force is lack during Check the wire harness.
Pressure Sensor 4.75 V digging operation. Replace the pump delivery
Circuit High Input pressure sensor.
111204-4 Pump Delivery Voltage: less Traction force is lack during Check the wire harness.
Pressure Sensor than 0.25 V digging operation. Replace the pump delivery
Circuit Low Input pressure sensor.
111206-3 Hyd. Fan Circut Voltage: over Fan rotation direction (in normal/ Check the wire harness.
Pressure Sensor 4.75 V reverse) cannot change manually Replace the fan pump
Circuit High Input and automatically. delivery pressure sensor.
111206-4 Hyd. Fan Circut Voltage: less Fan rotation direction (in normal/ Check the wire harness.
Pressure Sensor than 0.25 V reverse) cannot change manually Replace the fan pump
Circuit Low Input and automatically. delivery pressure sensor.
111208-3 Emergency Steering Voltage: over The initial automatic check for Check the wire harness.
Check Pressure 4.75 V emergency steering operation Replace the emergency
Sensor Circuit High cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
Emergency steering indicator of
monitor blinks.
111208-4 Emergency Steering Voltage: less The initial automatic check for Check the wire harness.
Check Pressure than 0.25 V emergency steering operation Replace the emergency
Sensor Circuit Low cannot be performed. (When the steering pump delivery
Input engine starts) pressure sensor.
Emergency steering indicator of
monitor blinks.

TTNEM50-EN-01(20181109) T5-5-13
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Pilot Failure
Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111200-3 Lift Arm Raise Pilot Voltage: over Bucket speed is slow during Check the wire harness.
Pressure Sensor 4.75 V combined operation of lift arm Replace the pressure sensor
Circuit High Input and bucket. (lift arm raise).
Ride control is not activated.
Speed shift retard control is always
retarded at AUTO 2 mode.
111200-4 Lift Arm Raise Pilot Voltage: less Bucket speed is slow during Check the wire harness.
Pressure Sensor than 0.25 V combined operation of lift arm Replace the pressure sensor
Circuit Low Input and bucket. (lift arm raise).
Ride control is not activated.
Speed shift retard control is always
retarded at AUTO 2 mode.
111202-3 Bucket Roll-In Pilot Voltage: over Bucket speed is slow during Check the wire harness.
Pressure Sensor 4.75 V combined operation of lift arm Replace the pressure sensor
Circuit High Input and bucket. (bucket tilt).
111202-4 Bucket Roll-In Pilot Voltage: less Bucket speed is slow during Check the wire harness.
Pressure Sensor than 0.25 V combined operation of lift arm Replace the pressure sensor
Circuit Low Input and bucket. (bucket tilt).
111203-3 Bucket Roll-Out Voltage: over Bucket speed is slow during Check the wire harness.
Pilot Pressure 4.75 V combined operation of lift arm Replace the pressure sensor
Sensor Circuit High and bucket. (bucket dump).
Input Speed shift retard control is always
retarded at AUTO 2 mode.
111203-4 Bucket Roll-Out Voltage: less Bucket speed is slow during Check the wire harness.
Pilot Pressure than 0.25 V combined operation of lift arm Replace the pressure sensor
Sensor Circuit Low and bucket. (bucket dump).
Input Speed shift retard control is always
retarded at AUTO 2 mode.

TTNEM50-EN-01(20181109) T5-5-14
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Pilot Failure
Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111217-3 Pilot Pressure Voltage: over Control lever lock indicator Check the wire harness.
Sensor Circuit High 4.75 V of monitor is always OFF. The Replace the pressure sensor
Input aftertreatment device manual (primary pilot pressure).
regeneration are not released
even if the control lever lock is
released.
111217-4 Pilot Pressure Voltage: less Control lever lock indicator Check the wire harness.
Sensor Circuit Low than 0.25 V of monitor is always OFF. The Replace the pressure sensor
Input aftertreatment device manual (primary pilot pressure).
regeneration are not released
even if the control lever lock is
released.
111311-3 Service Brake Voltage: over The low brake oil pressure Check the wire harness.
Primary Pressure 4.75 V indicator is always ON. Replace the pressure sensor
Sensor Circuit High Although the service brake is (brake primary pressure).
Input applied, the brake oil pressure
gauge points at the minimum
value, zero.
111311-4 Service Brake Voltage: less The low brake oil pressure Check the wire harness.
Primary Pressure than 0.25 V indicator is always ON. Replace the pressure sensor
Sensor Circuit Low Although the service brake is (brake primary pressure).
Input applied, the brake oil pressure
gauge points at the minimum
value, zero.

TTNEM50-EN-01(20181109) T5-5-15
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Symptoms in machine operation Remedy

when trouble occurs
111312-3 Service Brake Voltage: over The clutch cutoff control becomes Check the wire harness.
Secondary Pressure 4.75 V ineffective. The clutch cut is Replace the pressure sensor
Sensor Circuit High impossible. The speed shift does (brake secondary pressure).
Input not automatically downshift to
first speed with the travel mode
set in AUTO 1 mode.
111312-4 Service Brake Voltage: less The clutch cutoff control becomes Check the wire harness.
Secondary Pressure than 0.25 V ineffective. The clutch cut is Replace the pressure sensor
Sensor Circuit Low impossible. The speed shift does (brake secondary pressure).
Input not automatically downshift to
first speed with the travel mode
set in AUTO 1 mode.
111313-3 Parking Brake Voltage: over Although the parking brake Check the wire harness.
Pressure Sensor 4.75 V is applied, the parking brake Replace the pressure sensor
Circuit High Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)
111313-4 Parking Brake Voltage: less Although the parking brake Check the wire harness.
Pressure Sensor than 0.25 V is applied, the parking brake Replace the pressure sensor
Circuit Low Input indicator is not ON. (The parking (parking brake).
brake signal is forcibly fixed to the
Release side.)

TTNEM50-EN-01(20181109) T5-5-16
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Proportional Solenoid Valve Failure

Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111410-2 Parallel/Tandem Solenoid valve Bucket speed is slow during Check the harness.
Control P/S Valve output: over 140 combined operation of lift arm and
Abnormal FB mA, feedback bucket.
current: over 920
mA or less than
70 mA; both are
detected.
111410-3 Parallel/Tandem Current: over 920 Lift arm raise speed becomes slow Check the harness.
Control P/S Valve FB mA during combined operation of lift arm
High Current and bucket.
111410-4 Parallel/Tandem Current: less than Bucket speed is slow during Check the harness.
Control P/S Valve FB 70 mA combined operation of lift arm and
Low Current bucket.
111411-2 Hydraulic Fan Reverse Solenoid valve The fan reverse rotation control Check the wire
Rotation P/S Valve output: over 140 becomes ineffective. harness.
Abnormal FB mA, feedback Fan rotation direction (in normal/
current: over 920 reverse) cannot change manually and
mA or less than automatically.
70 mA; both are
detected.
111411-3 Hydraulic Fan Reverse Current: over 920 Fan rotation direction is fixed in Check the wire
Rotation P/S Valve FB mA reverse. harness.
High Current
111411-4 Fan Reverse Rotation Current: less than Fan rotation direction (in normal/ Check the wire
P/S Valve FB Low 70 mA reverse) cannot change manually and harness.
Current automatically.

TTNEM50-EN-01(20181109) T5-5-17
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Symptoms in machine operation Remedy

when trouble occurs
111412-2 Hyd. Fan P/S Valve Solenoid valve The fan speed is fixed to the Check the wire
Abnormal FB output: over 140 maximum. harness.
mA, feedback
current: over 920
mA or less than
70 mA; both are
detected.
111412-3 Hyd. Fan P/S Valve FB Current: over 920 The fan speed is fixed to the Check the wire
High Current mA minimum. harness.
111412-4 Hyd. Fan P/S Valve FB Current: less than The fan speed is fixed to the Check the wire
Low Current 70 mA maximum. harness.
111413-2 Pump Swash Angle P/S Solenoid valve Machine overall operation is slow. Check the wire
Valve Abnormal FB output: over 140 harness.
mA, feedback
current: over 920
mA or less than
70 mA; both are
detected.
111413-3 Pump Swash Angle P/S Current: over 920 The engine stalls is remarkable at high Check the wire
Valve FB High Current mA loaded. Or, the engine lug-down is harness.
remarkable.
111413-4 Pump Swash Angle P/S Current: less than Machine overall operation is slow. Check the wire
Valve FB Low Current 70 mA harness.
111422-2 Ride Control (Bottom) Solenoid valve The ride control becomes ineffective. Check the wire
P/S Valve Abnormal FB output: over 140 harness.
mA, feedback
current: over 920
mA or less than
70 mA; both are
detected.
111422-3 Ride Control (Bottom) Current: over 920 The ride control is always activated. Check the wire
P/S Valve FB High mA harness.
Current
111422-4 Ride Control (Bottom) Current: less than The ride control is always activated. Check the wire
P/S Valve FB Low 70 mA harness.
Current

TTNEM50-EN-01(20181109) T5-5-18
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Learning Failure
Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111720-2 Lift arm angle sensor is The lift arm angle Dual lift arm auto leveler cannot be Perform lift arm
uncalibrated. sensor calibration set. angle sensor
is not performed. calibration.
Or, it fails.

TTNEM50-EN-01(20181109) T5-5-19
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Other Failures
Fault Code Trouble Cause Symptoms in machine operation Remedy
when trouble occurs
111901-3 Hydraulic Oil Temp Voltage: over When hydraulic oil temperature is Check the wire
Sensor Circuit High 4.35 V less than 0 °C, the auto-warming up harness.
Input control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated. Even if power
mode is selected, engine speed
does not increase over the speed at
standard mode.
111901-4 Hydraulic Oil Temp Voltage: less than When hydraulic oil temperature is Check the wire
Sensor Circuit Low 0.1 V less than 0 °C, the auto-warming up harness.
Input control is not effective.
The fan speed is always fixed to the
maximum. The fan reverse rotation
control is not activated. Even if power
mode is selected, engine speed
does not increase over the speed at
standard mode.
111902-3 Axle Oil Temperature Voltage: over Even if power mode is selected, Check the wire
Sensor Circuit High 4.75 V engine speed does not increase over harness.
Input the speed at standard mode.
111902-4 Axle Oil Temperature Voltage: less than Even if power mode is selected, Check the wire
Sensor Circuit Low 0.1 V engine speed does not increase over harness.
Input the speed at standard mode.
111205-3 Lift Arm Angle Sensor Voltage: over Dual lift arm auto leveler operation is Check the wire
Circuit High Input 4.75 V not effective. harness.
Speed shift retard control is always Replace the lift arm
retarded at second speed. angle sensor.
111205-4 Lift Arm Angle Sensor Voltage: less than Dual lift arm auto leveler operation is Check the wire
Circuit Low Input 0.25 V not effective. harness.
Speed shift retard control is always Replace the lift arm
retarded at second speed. angle sensor.
111207-3 Refrigerant Pressure Voltage: over The fan speed is always fixed to the Check the wire
Sensor Circuit High 4.74 V maximum. The fan cannot rotate in harness.
Input reverse. Replace the
refrigerant pressure
sensor.
111207-4 Refrigerant Pressure Voltage: less than The fan speed is always fixed to the Check the wire
Sensor Circuit Low 0.25 V maximum. The fan cannot rotate in harness.
Input reverse. Replace the
refrigerant pressure
sensor.

TTNEM50-EN-01(20181109) T5-5-20
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Other Failures
Fault Code Trouble Cause Symptoms in machine Remedy
operation when trouble
occurs
120000-2 Hydraulic Oil Overheat Hydraulic oil temperature The alarm is displayed on Check the wire harness.
Alarm is high. the monitor. Replace the hydraulic oil
temperature sensor.
120002-2 Axle Oil Temperature Axle oil temperature is The alarm is displayed on Check the wire harness.
Alarm high. the monitor. Replace the axle oil
temperature sensor.
120003-2 Emergency Steering Emergency steering The alarm is displayed -
Activated pump is activated. on the monitor. (It
is displayed during
operation.)
120004-2 Emergency Steering Emergency steering The alarm is displayed on Check the wire harness.
Activated Pressure pump delivery pressure the monitor. Replace the emergency
Alarm does not increase up steering pump delivery
to the specified value. pressure sensor.
(When the engine starts)
120005-2 Transmission Oil Transmission oil The alarm is displayed on Check the wire harness.
Temperature Overheat temperature is high. the monitor. Replace the torque
Alarm converter oil
temperature sensor.
120014-2 Overrun Alarm The vehicle speed is over The buzzer sounds. Check the wire harness.
the upper limit. Replace the vehicle
speed sensor.
120017-2 Engine Overrun Alarm The engine speed is over The engine overrun Depress the brake pedal
the upper limit. warning indicator turns to reduce machine
ON, and the buzzer speed.
sounds. Refer to the Operator's
Manual for more
information.

TTNEM50-EN-01(20181109) T5-5-21
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Monitor Controller (Monitor) Fault Code List

Fault Code Trouble Cause Remedy

113002-2 (Monitor Controller) Faulty monitor controller Check the CAN1 harness.
Engine Controller Faulty CAN1 harness Replace the monitor controller.
Communication
Error
113003-2 (Monitor Controller) Faulty monitor controller Check the CAN1 harness.
Main Controller Faulty CAN1 harness Replace the monitor controller.
Communication
Error 1
113004-2 (Monitor Controller) Faulty monitor controller Check the CAN2 harness.
Main Controller Faulty CAN2 harness Replace the monitor controller.
Communication
Error 2
113005-2 (Monitor Controller) Faulty monitor controller Check the CAN1 harness.
ICF Communication Faulty CAN1 harness Replace the monitor controller.
Error 1
113006-2 (Monitor Controller) Faulty monitor controller Check the CAN2 harness.
ICF Communication Faulty CAN2 harness Replace the monitor controller.
Error 2
113007-2 (Monitor Controller) Faulty monitor controller Check the CAN2 harness.
Column Controller Faulty CAN2 harness Replace the monitor controller.
Communication
Error
113012-2 (Monitor Controller) Faulty monitor controller Check the CAN1 harness.
Transmission Faulty CAN1 harness Replace the monitor controller.
Controller
Communication
Error

TTNEM50-EN-01(20181109) T5-5-22
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Monitor Controller (Information) Fault Code

List

Fault Code Trouble Cause Symptoms in machine Remedy

operation when
trouble occurs
113303-2 Abnormal Thermistor Thermistor The screen of the Cool the monitor and so on
Temperature (Monitor temperature: over monitor becomes until the temperature inside
Inside Temperature) 85°C (185°F) dark. the monitor is less than 85°C
(185°F).
Replace the monitor.
113311-3 Fuel Level Sensor Less than 131±5 The fuel gauge Check the wire harness.
Circuit High Input Ω continues for 5 (pointer) points to E. Replace the fuel sensor.
seconds.
113311-4 Fuel Level Sensor Less than 4±2 Ω The fuel gauge Check the wire harness.
Circuit Low Input continues for 5 (pointer) points to E. Replace the fuel sensor.
seconds.

Fault Code Trouble Cause Remedy

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

fNOTE: ICF is the information control unit of the monitor

controller.

TTNEM50-EN-01(20181109) T5-5-23
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Column Display Controller Fault Code List

Fault Code Trouble Cause Symptoms in machine Remedy

operation when trouble
occurs
115001-2 Abnormal REG Input Alternator generating The alternator indicator Check the wire harness.
H level voltage: over 33.5 V is ON. Check the battery.
Check the alternator.
115003-2 Abnormal EEPROM Faulty column display - Replace the column display
controller controller.

Fault Code Trouble Cause Remedy

120300-2 System Failure Alarm Faulty CAN communication Check the CAN harness.
bus line
120400-2 Fuel Filter Restriction Fuel filter is clogged. Replace the fuel filter element.
Alarm Check the harness.
120401-2 Water Separator The water separator (option) Drain off water.
Alarm (Option) is full. Check the harness.
Open circuit in harness.
120500-2 Overheat Alarm Coolant temperature is high Check the wire harness.
while the engine runs. Replace the overheat switch.
120501-2 Engine Error Faulty engine system Refer to ECM fault code list.
120502-2 Engine Oil Pressure Engine oil pressure Check the wire harness.
Alarm decreases. Replace the engine oil pressure switch.
120503-2 Air Cleaner Restriction Clogged air cleaner Check the wire harness.
Alarm Replace the air cleaner restriction switch.
120504-2 Hydraulic Oil Level Hydraulic oil level decreases. Check the wire harness.
Alarm Replace the hydraulic oil level sensor.
120505-2 Brake Pressure Alarm Brake oil pressure decreases. Check the wire harness.
Replace the pressure sensor (brake primary
pressure).
120506-2 Steering Oil Pressure Faulty steering pressure Check the wire harness.
Alarm switch (Optional) Replace the steering pressure switch.
120507-2 T/M Malfunction Faulty transmission system Refer to TCU fault code list.

TTNEM50-EN-01(20181109) T5-5-24
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

JCU Fault Code List

Fault Code Trouble Cause Symptoms in machine Remedy

operation when trouble
occurs
111033-2 JCU Faulty harness Forced Disabling the Check the harness. Check
Communication Error Faulty JCU Joystick Steering the JCU.
(Main Controller)
116000-2 Abnormal Power Source The engine stops after After detecting a failure, -
(Engine Speed) starting. the joystick steering can
not be enabled.
116001-2 Abnormal Solenoid Pilot Pilot pump delivery After detecting a failure, Check the hydraulic
Source Pressure pressure decreases after the joystick steering can circuit.
starting the engine. not be enabled.
116002-3 Controller Source Voltage Power voltage is 32 V or Forced Disabling the Check the harness.
Abnormally High higher. Joystick Steering
116002-4 Controller Source Voltage Power voltage is 20 V or Forced Disabling the Check the harness.
Abnormally Low lower. Joystick Steering
116003-3 Joystick Signal 1 Voltage Voltage is 4.75 V or Forced Disabling the Check the harness and
Abnormally High higher. Joystick Steering joystick signal.
116003-4 Joystick Signal 1 Voltage Voltage is 0.25 V or lower. Forced Disabling the Check the harness and
Abnormally Low Joystick Steering joystick signal.
116004-3 Joystick Signal 2 Voltage Voltage is 4.75 V or Forced Disabling the Check the harness and
Abnormally High higher. Joystick Steering joystick signal.
116004-4 Joystick Signal 2 Voltage Voltage is 0.25 V or lower. Forced Disabling the Check the harness and
Abnormally Low Joystick Steering joystick signal.
116005-2 Joystick Signal Joystick signals 1, 2: Forced Disabling the Check the harness and
Correlative Diagnosis Signal error (mismatch) Joystick Steering joystick signal.
Error
116006-3 Right Steering Solenoid Voltage is 4.75 V or After detecting a failure, Check the harness and
Valve Pressure Sensor higher. the joystick steering can sensor.
Voltage Abnormally High not be enabled.
116006-4 Right Steering Solenoid Voltage is 0.25 V or lower. After detecting a failure, Check the harness and
Valve Pressure Sensor the joystick steering can sensor.
Voltage Abnormally Low not be enabled.
116007-3 Left Steering Solenoid Voltage is 4.75 V or After detecting a failure, Check the harness and
Valve Pressure Sensor higher. the joystick steering can sensor.
Voltage Abnormally High not be enabled.
116007-4 Left Steering Solenoid Voltage is 0.25 V or After detecting a failure, Check the harness and
Valve Pressure Sensor lower. the joystick steering can sensor.
Voltage Abnormally Low not be enabled.
116008-3 Solenoid Valve Source Voltage is 4.75 V or After detecting a failure, Check the harness and
Pressure: Pressure Sensor higher. the joystick steering can sensor.
Voltage Abnormally High not be enabled.
116008-4 Solenoid Valve Source Voltage is 0.25 V or lower. After detecting a failure, Check the harness and
Pressure: Pressure Sensor the joystick steering can sensor.
Voltage Abnormally Low not be enabled.
116010-2 Main Controller Faulty harness, Faulty Forced Disabling the Check the harness,
Communication Error main controller Joystick Steering Check the main
controller
116013-2 Monitor Controller Faulty harness, Faulty Forced Disabling the Check the harness. Check
Communication Error monitor controller Joystick Steering the monitor controller

TTNEM50-EN-01(20181109) T5-5-25
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Symptoms in machine Remedy

operation when trouble
occurs
116118-2 Right Steering Solenoid Feedback current: Both Forced Disabling the Check the harness.
Valve Abnormal more than 920 mA and Joystick Steering
Feedback less than 70 mA are
detected
116118-3 Right Steering Solenoid Feedback current: more Forced Disabling the Check the harness.
Valve Feedback Current than 920 mA Joystick Steering
Abnormally High
116118-4 Right Steering Solenoid Feedback current: less Forced Disabling the Check the harness.
Valve Feedback Current than 70 mA Joystick Steering
Abnormally Low
116119-2 Left Steering Solenoid Feedback current: Both Forced Disabling the Check the harness.
Valve Feedback more than 920 mA and Joystick Steering
Abnormal less than 70 mA are
detected
116119-3 Left Steering Solenoid Feedback current: more Forced Disabling the Check the harness.
Valve Feedback Current than 920 mA Joystick Steering
Abnormally High
116119-4 Left Steering Solenoid Feedback current: less Forced Disabling the Check the harness.
Valve Feedback Current than 70 mA Joystick Steering
Abnormally Low
120600-2 Abnormal Joystick Joystick steering is After detecting a failure, Check the harness and
Function (Joystick enabled without the joystick steering can enabling/disabling
Function Enabled 1) enabling it. not be enabled. switch.
120601-2 Abnormal Joystick Joystick steering is After detecting a failure, Check the harness and
Function (Joystick disabled without the joystick steering can enabling/disabling
Function Disabled) disabling it. not be enabled. switch.
120602-2 Abnormal Joystick Joystick steering is not After detecting a failure, Check the harness and
Function (Joystick enabled after enabling it. the joystick steering can enabling/disabling
Function can not be not be enabled. switch.
enabled.)
120603-2 Abnormal Joystick Joystick steering is not The joystick steering can Check the harness and
Function (Joystick disabled after disabling not be disabled. enabling/disabling
Function can not be it. switch.
disabled.)
120604-2 Abnormal Joystick Joystick steering is After detecting a failure, Check the harness and
Function (Joystick enabled though enabling the joystick steering can enabling/disabling
Function Enabled 2) conditions are not not be enabled. switch.
satisfied.
120605-2 Abnormal Joystick Command signal Forced Disabling the Check the harness and
Function (Right Steering and actual pressure Joystick Steering hydraulic circuit.
Pressure 1) are mismatching.
Pressure does not
increase although it is
commanded to increase.
120606-2 Abnormal Joystick Command signal and Forced Disabling the Check the harness and
Function (Right Steering actual pressure are Joystick Steering hydraulic circuit.
Pressure 2) mismatching. Pressure
increases although it
is commanded not to
increase.

TTNEM50-EN-01(20181109) T5-5-26
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Symptoms in machine Remedy

operation when trouble
occurs
120607-2 Abnormal Joystick Command signal Forced Disabling the Check the harness and
Function (Left and actual pressure Joystick Steering hydraulic circuit.
Steering Pressure 1) are mismatching.
Pressure does not
increase although it is
commanded to increase.
120608-2 Abnormal Joystick Command signal and Forced Disabling the Check the harness and
Function (Left actual pressure are Joystick Steering hydraulic circuit.
Steering Pressure 2) mismatching. Pressure
increases although it
is commanded not to
increase.
120609-2 Abnormal FNR Forward/Reverse switch After detecting a failure, Check the harness and
(Switch FNR Function (right) is enabled without the forward/reverse switch enabling/disabling switch.
enabled 1) enabling it. (right) can not be enabled.
120610-2 Abnormal FNR Forward/Reverse switch After detecting a failure, Check the harness and
(Switch FNR Function (right) is disabled the forward/reverse switch enabling/disabling switch.
disabled) without disabling it. (right) can not be enabled.
120611-2 Abnormal FNR Forward/Reverse switch After detecting a failure, Check the harness and
(Switch FNR Function (right) is not enabled the forward/reverse switch enabling/disabling switch.
can not be enabled.) after enabling it. (right) can not be enabled.
120612-2 Abnormal FNR Forward/Reverse switch The forward/reverse switch Check the harness and
(Switch FNR Function (right) is not disabled (right) can not be disabled. enabling/disabling switch.
can not be disabled.) after disabling it.
120613-2 Abnormal FNR Forward/Reverse switch After detecting a failure, Check the harness and
(Switch FNR Function (right) is enabled though the forward/reverse switch enabling/disabling switch.
enabled 2) enabling conditions are (right) can not be enabled.
not satisfied.
120614-2 Abnormal Switch Two lines of switch signal After detecting a failure, Check the harness and
(FNR Switching: OFF errors that detect OFF the forward/reverse switch enabling/disabling switch.
operation) operation (right) can not be enabled.
120615-2 Abnormal Switch Two lines of switch signal After detecting a failure, the Check the harness and
(Joystick Function: errors that detect OFF joystick steering can not be enabling/disabling switch.
OFF operation) operation enabled.
120616-2 Abnormal Switch Error of two lines of After detecting a failure, the Check the harness and arm
(Arm Rest Switch) switch signals that detect joystick steering can not be rest limit switch.
raise operation of the left enabled.
arm rest.
120617-2 Abnormal Switch Signal error of Forward/ After detecting a failure, Check the harness. Check
(FNR Switch) Reverse switch (right) the forward/reverse switch the combination of signals
(right) can not be enabled. at each F-N-R position of the
forward/reverse switch.
120618-2 Abnormal Switch Signal error of Forward/ After detecting a failure, Check the harness. Check
(Joystick FNR Switch) Reverse switch (left) the forward/reverse switch the combination of signals
(right) can not be enabled. at each F-N-R position of the
forward/reverse switch.

TTNEM50-EN-01(20181109) T5-5-27
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Communication Terminal Fault Code List

Fault Code Trouble Cause Remedy

114100-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal EEPROM communication terminal communication terminal).
(optional) is abnormal.
114101-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal IB/OB Queue communication terminal communication terminal).
(optional) is abnormal.
114102-2 Communication Terminal: Abnormality is detected on Check the communication
Abnormal Local Loop Back communication test with the antenna for satellite.
satellite.
114103-2 Communication Terminal: No Satellite can not be caught. Check the communication
Satellite Found antenna for satellite.
114104-2 Communication Terminal: Remote Abnormality is detected on Replace the controller (satellite
Loop Back Error 1 communication test with the communication terminal).
satellite and base station.
114105-2 Communication Terminal: Remote Abnormality is detected on Replace the controller (satellite
Loop Back Error 2 communication test with the communication terminal).
satellite and base station.
114106-2 Communication Terminal: Transmission/receiving data with Replace the controller (satellite
Transmission/Receiving Data the satellite is unmatched. communication terminal).
Unmatched

Air Conditioner Controller Fault Code List

fNOTE: Refer to TROUBLESHOOTING/Air Conditioner for

the fault code of air conditioner controller.

TTNEM50-EN-01(20181109) T5-5-28
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

ECM Fault Code List

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
27-4 2272 EGR Valve Position Circuit - Voltage Below Normal, EGR valve actuation will be disabled.
or Shorted to Low Source
91-0 148 Accelerator Pedal or Lever Position Sensor Circuit - Severe derate in power output of the
Abnormal Frequency, Pulse Width, or Period engine. Limp home power only.
91-1 147 Accelerator Pedal or Lever Position Sensor Circuit - Severe derate in power output of the
Abnormal Frequency, Pulse Width, or Period engine. Limp home power only.
91-2 1242 Accelerator Pedal or Lever Position Sensor 1 and 2 - Engine will only idle.
Data Erratic, Intermittent, or Incorrect
91-3 131/1358 Accelerator Pedal or Lever Position Sensor 1 Circuit - Severe derate in power output of the
Voltage above normal, or shorted to high source engine. Limp home power only.

TTNEM50-EN-01(20181109) T5-5-29
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
91-4 132/1359 Accelerator Pedal or Lever Position Sensor 1 Circuit - Severe derate in power output of the
Voltage below normal, or shorted to low source engine. Limp home power only.
91-9 3326 Accelerator Pedal Position 1 - Abnormal Update Rate Engine will only idle.
91-19 1515 SAE J1939 Multiplexing Accelerator Pedal or Lever The engine will only idle.
Sensor System Error - Received Network Data In
Error
94-3 546 Fuel Delivery Pressure Sensor Circuit - Voltage above Possible white smoke. Fan will stay ON
normal, or shorted to high source if controlled by the electronic control
module (ECM).
94-4 547 Fuel Delivery Pressure Sensor Circuit - Voltage below Possible white smoke. Fan will stay ON
normal, or shorted to low source if controlled by the electronic control
module (ECM).
95-16 2372 Fuel Filter Differential Pressure - Data Valid But Possible white smoke. Fan will stay ON
Above Normal Operating Range - Moderately if controlled by the electronic control
Severe Level module (ECM).
97-3 428 Water in Fuel Sensor Circuit - Voltage Above Normal, None on performance. No water-in-fuel
or Shorted to High Source warning available.
97-4 429 Water in Fuel Sensor Circuit - Voltage Below Normal, None on performance. No water-in-fuel
or Shorted to Low Source warning available.
97-15 418 Water in Fuel Indicator High - Data Valid but Above Possible loss of power, or hard starting.
Normal Operational Range - Least Severe Level
97-16 1852 Water in Fuel Indicator - Data Valid But Above None on performance.
Normal Operating Range - Moderately Severe Level
100-1 415 Oil Pressure Low - Data Valid but Below Normal Progressive power derate is increasing
Operational Range - Most Severe Level in severity from time of alert. Engine will
shutdown.
100-2 435 Oil Pressure Sensor Circuit - Data Erratic, None on performance. No engine
Intermittent, or Incorrect protection for oil pressure.
100-3 135 Oil Pressure Sensor Circuit - Voltage Above Normal, None on performance. No engine
or Shorted to High Source protection for oil pressure.
100-4 141 Oil Pressure Sensor Circuit - Voltage Below Normal, None on performance. No engine
or Shorted to Low Source protection for oil pressure.
100-18 143 Oil Pressure Low - Data Valid but Below Normal Engine power derate. Engine will
Operational Range - Moderately Severe Level shutdown.

TTNEM50-EN-01(20181109) T5-5-30
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
101-0 556 Crankcase Pressure - Data Valid But Above Normal None on performance.
Operating Range - Moderately Severe Level
101-2 1942 Crankcase Pressure - Data Erratic, Intermittent or None on performance.
Incorrect
101-3 1843 Crankcase Pressure Circuit - Voltage Above Normal, None on performance.
or Shorted to High Source
101-4 1844 Crankcase Pressure Circuit - Below Normal, or None on performance.
Shorted to Low Source
101-15 1974 Crankcase Pressure - Data Valid But Above Normal None on performance.
Operating Range - Least Severe Level
101-16 555 Crankcase Pressure - Data Valid But Above Normal None on performance.
Operating Range - Moderately Severe Level
102-3 122 Intake Manifold Pressure Sensor Circuit - Voltage Engine power derate.
Above Normal, or Shorted to High Source
102-4 123 Intake Manifold Pressure Sensor Circuit - Voltage Engine power derate.
Below Normal, or Shorted to Low Source
102-16 124 Intake Manifold 1 Pressure - Data Valid But Below Engine power derate.
Normal Operating Range - Moderately Severe Level
103-15 2288 Turbocharger 1 Speed - Data Valid But Above Engine power derate to lower the
Normal Operating Range - Least Severe Level turbocharger speed.
103-16 595 Intake Manifold 1 Pressure - Data Valid But Above Engine power derate. The ECM uses an
Normal Operating Range - Moderately Severe Level estimated turbocharger speed.
103-18 687 Turbocharger #1 Speed Low - Data Valid but Below Engine power derate. The ECM uses an
Normal Operational Range - Moderately Severe estimated turbocharger speed.
Level
105-0 155 Intake Manifold Air Temperature High - Data Valid Progressive power and derate increasing
but Above Normal Operational Range - Most Severe in severity from time of alert.
Level

TTNEM50-EN-01(20181109) T5-5-31
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
105-3 153 Intake Manifold Air Temperature Sensor Circuit - Possible white smoke. Fan will stay ON
Voltage Above Normal, or Shorted to High Source if controlled by the electronic control
module (ECM). No engine protection for
intake manifold air temperature.
105-4 154 Intake Manifold Air Temperature Sensor Circuit - Possible white smoke. Fan will stay ON
Voltage Below Normal, or Shorted to Low Source if controlled by the electronic control
module (ECM). No engine protection for
intake manifold air temperature.
105-15 2964 Intake Manifold 1 Temperature - Data Valid But Progressive power and/or speed derate
Above Normal Operating Range - Least Severe Level increasing in severity from time of alert.
105-16 488 Intake Manifold 1 Temperature - Data Valid But Progressive power derate increasing in
Above Normal Operating Range - Moderately Severe severity from time of alert.
Level
107-15 5576 Engine Air Filter Differential Pressure - Data Valid But Possible reduced engine performance.
Above Normal Operating Range - Least Severe Level
107-16 3341 Engine Air Filter Differential Pressure - Data Valid But Possible reduced engine performance.
Above Normal Operating Range - Moderately Severe
Level
108-3 221 Barometric Pressure Sensor Circuit - Voltage Above Engine power derate.
Normal, or Shorted to High Source
108-4 222 Barometric Pressure Sensor Circuit - Voltage Below Engine power derate.
Normal, or Shorted to Low Source
110-0 151 Coolant Temperature Low - Data Valid but Above Progressive power derate increasing in
Normal Operational Range - Most Severe Level severity from time of alert.
110-3 144 Coolant Temperature Sensor Circuit - Voltage Above Possible white smoke. Fan will stay ON
Normal, or Shorted to High Source if controlled by the electronic control
module (ECM). No engine protection for
engine coolant temperature circuit faults.

TTNEM50-EN-01(20181109) T5-5-32
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
110-4 145 Coolant Temperature Sensor Circuit - Voltage Below Possible white smoke. Fan will stay ON
Normal, or Shorted to Low Source if controlled by the electronic control
module (ECM). No engine protection for
engine coolant temperature circuit faults.
110-16 146 Coolant Temperature High - Data Valid but Above Power derate and possible engine
Normal Operational Range - Moderately Severe shutdown.
Level
110-31 2646/2659 Engine Coolant Temperature - Condition Exists EGR valve actuation will be disabled.
111-1 235 Coolant Level Low - Data Valid but Below Normal Engine protection shut down.
Operational Range - Most Severe Level
111-3 195/6522 Coolant Level Sensor Circuit - Voltage Above Normal, None on performance.
or Shorted to High Source
111-4 196/6523 Coolant Level Sensor Circuit - Voltage Below Normal, None on performance.
or Shorted to Low Source
111-9 3613 SAE J1939 Multiplexing PGN Timeout Error - Possible reduced engine performance.
Abnormal update rate
111-17 2448/5167 Coolant Level - Data Valid But Below Normal None on performance.
Operating Range - Least Severe Level
111-18 197/3366 Coolant Level - Data Valid but Below Normal Possible power derate and possible
Operational Range - Moderately Severe Level engine shutdown.
111-19 3614 Coolant Level Sensor - Received Network Data in Possible reduced engine performance.
Error
157-0 449 Injector Metering Rail 1 Pressure - Data Valid but None or possible engine noise associated
Below Normal Operational Range - Most Severe with higher injection pressures
Level (especially at idle or light load). Possible
reduced engine performance.
157-3 451 Injector Metering Rail 1 Pressure Sensor Circuit - Power and/or speed derate.
Voltage above normal, or shorted to high source
157-4 452 Injector Metering Rail 1 Pressure Sensor Circuit - Power and/or speed derate.
Voltage below normal, or shorted to low source
157-16 553 Injector Metering Rail #1 Pressure High - Data Valid None or possible engine noise associated
but Above Normal Operational Range - Moderately with higher injection pressures
Severe Level (especially at idle or light load). Possible
reduced engine performance.

TTNEM50-EN-01(20181109) T5-5-33
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
157-18 559 Injector Metering Rail #1 Pressure Low - Data Valid Possibly hard to start or low power.
but Below Normal Operational Range - Moderately Engine could possibly not start.
Severe Level
168-16 442 Battery #1 Voltage High - Data Valid but Above Possible electrical damage to all electrical
Normal Operational Range - Moderately Severe components.
Level
168-17 3724/6257 Battery 1 Voltage - Data Valid But Below Normal EGR valve actuation will be disabled.
Operating Range - Least Severe Level
168-18 441 Battery #1 Voltage Low - Data Valid but Below Engine may stop running or be difficult
Normal Operational Range - Moderately Severe to start.
Level
171-3 249 Ambient Air Temperature Sensor 1 Circuit - Voltage Possible low power.
above normal, or shorted to high source
171-4 256 Ambient Air Temperature Sensor 1 Circuit - Voltage None on performance.
below normal, or shorted to low source
171-9 3531 Ambient Air Temperature - Abnormal update rate Possible low power.
190-0 234 Engine Speed High - Data Valid but Above Normal Fuel injection disabled until engine
Operational Range - Most Severe Level speed falls below the overspeed limit.
190-2 689/2321 Engine Crankshaft Speed/Position - Data erratic, Possible low power.
intermittent or incorrect
190-16 1992/2468 Engine Crankshaft Speed/Position - Data Valid Engine will be shut down.
But Above Normal Operating Range - Moderately
Severe Level

TTNEM50-EN-01(20181109) T5-5-34
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
237-13 4517 Vehicle Identification Number - Out of Calibration None on performance.
411-2 1866 Exhaust Gas Recirculation Differential Pressure - EGR valve actuation will be disabled.
Data erratic, intermittent or incorrect
411-3 2273 Exhaust Gas Recirculation Differential Pressure EGR valve actuation will be disabled.
Sensor Circuit - Voltage above normal, or shorted to
high source
411-4 2274 Exhaust Gas Recirculation Differential Pressure EGR valve actuation will be disabled.
Sensor Circuit - Voltage below normal, or shorted to
low source
412-3 2375 Exhaust Gas Recirculation (EGR) Temperature Sensor EGR valve actuation will be disabled.
Circuit - Voltage Above Normal, or Shorted to High
Source
412-4 2376 Exhaust Gas Recirculation (EGR) Temperature Sensor EGR valve actuation will be disabled.
Circuit - Voltage Below Normal, or Shorted to Low
Source
412-15 2961 Exhaust Gas Recirculation Temperature - Data Valid Slight fueling derate to bring EGR
But Above Normal Operating Range - Least Severe temperature under the maximum limit.
Level Engine will shutdown.
412-16 2962 Exhaust Gas Recirculation (EGR) Temperature Severe fueling derate to bring EGR
- Data Valid But Above Normal Operating Range - temperature under the maximum limit.
Moderately Severe Level Engine will shutdown.
441-3 293 Auxiliary Temperature Sensor Input 1 Circuit - None on performance.
Voltage above normal, or shorted to high source
441-4 294 Auxiliary Temperature Sensor Input 1 Circuit - None on performance.
Voltage below normal, or shorted to low source
441-14 292/6583 Auxiliary Temperature Sensor Input 1 - Special Possible engine power derate.
Instructions

TTNEM50-EN-01(20181109) T5-5-35
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
558-2 431 Accelerator Pedal or Lever Idle Validation Circuit - Engine will only idle.
Data Erratic, Intermittent, or Incorrect
558-13 432 Accelerator Pedal or Lever Idle Validation Circuit - Engine will only idle.
Out of Calibration
558-19 3527 Accelerator Pedal or Lever Idle Validation Switch - The engine will only idle.
Received Network Data In Error
612-2 115 Engine Speed/Position Sensor Circuit lost both of Fueling to injectors is disabled and the
two signals from the magnetic pickup sensor - Data engine can not be started.
Erratic, Intermittent, or incorrect
629-12 111/343 Engine Control Module Warning internal hardware Engine may not start.
failure - Bad Intelligent Device or Component
630-12 3697 Engine Control Module Calibration Memory - Bad Engine may not start.
intelligent device or component
633-31 2311 Fueling Actuator #1 Circuit Error - Condition Exists Engine may exhibit misfire as control
switches from the primary to the backup
speed sensor. Engine power is reduced
while the engine operates on the backup
speed sensor.
639-9 285/427 SAE J1939 Multiplexing PGN Timeout Error - At least one multiplexed device will not
Abnormal Update Rate operate properly.
639-13 286 SAE J1939 Multiplexing Configuration Error - Out of At least one multiplexed device will not
Calibration operate properly.
640-14 599 Auxiliary Commanded Dual Output Shutdown - Engine will shut down.
Special Instructions

TTNEM50-EN-01(20181109) T5-5-36
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
641-7 2387 VGT Actuator Driver Circuit (Motor) - Mechanical VGT travel may be limited.
System Not Responding or Out of Adjustment
641-9 2636 VGT Actuator Driver Circuit - Abnormal Update Rate The VGT will move to the default open
position.
641-11 2198 VGT Actuator Driver Circuit - Root Cause Not Known Possible reduced engine performance.
641-12 2634 VGT Actuator Controller - Bad intelligent Device or VGT actuation will be disabled.
Component
641-13 1898/2449 VGT Actuator Controller - Out of Calibration Low intake manifold pressure. The VGT
will be in the open position.
641-15 1962/1976 VGT Actuator Driver Over Temperature (Calculated) None on performance.
- Data Valid But Above Normal Operating Range -
Least Severe Level
641-31 2635 VGT Actuator Driver Circuit - Condition Exists VGT actuation will be disabled.
651-5 322 Injector Solenoid Cylinder #1 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
652-5 331 Injector Solenoid Cylinder #2 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
652-7 1141 Injector Solenoid Driver Cylinder 2 - Mechanical
system not responding or out of adjustment
653-5 324 Injector Solenoid Cylinder #3 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
653-7 1142 Injector Solenoid Driver Cylinder 3 - Mechanical
system not responding or out of adjustment
654-5 332 Injector Solenoid Cylinder #4 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
654-7 1143 Injector Solenoid Driver Cylinder 4 - Mechanical
system not responding or out of adjustment
655-5 323 Injector Solenoid Cylinder #5 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
655-7 1144 Injector Solenoid Driver Cylinder 5 - Mechanical
system not responding or out of adjustment
656-5 325 Injector Solenoid Cylinder #6 Circuit - Current Below Engine can possibly misfire or run rough.
Normal, or Open Circuit
656-7 1145 Injector Solenoid Driver Cylinder 6 - Mechanical
system not responding or out of adjustment

TTNEM50-EN-01(20181109) T5-5-37
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
677-3 584 Starter Relay Driver Circuit- Voltage Above Normal, Either the engine will not start or the
or Shorted to High Source engine will not have starter lockout
protection.
677-4 585 Starter Relay Driver Circuit - Voltage below normal, Either the engine will not start or the
or shorted to low source engine will not have starter lockout
protection.
702-3 527 Auxiliary Input/Output 2 Circuit - Voltage above None on performance.
normal, or shorted to high source
703-3 529 Auxiliary Input/Output 3 Circuit - Voltage above None on performance.
normal, or shorted to high source
723-2 778/2322 Engine Speed Sensor (Camshaft) Error - Data Erratic, Possible low power.
Intermittent, or Incorrect
723-7 731 Engine Speed/Position #2 Mechanical Misalignment Engine will run derated. Excessive
Between Camshaft and Crankshaft Sensors - black smoke, hard start, and rough idle
Mechanical System Not Responding Properly or Out possible.
of
729-3 2555 Intake Air Heater #1 Circuit - Voltage Above Normal, The intake air heaters may be ON or OFF
or Shorted to High Source all the time.
729-4 2556 Intake Air Heater #1 Circuit - Voltage Below Normal, The intake air heaters may be ON or OFF
or Shorted to Low Source all the time.

TTNEM50-EN-01(20181109) T5-5-38
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
974-3 133 Remote Accelerator Pedal or Lever Position Sensor Remote accelerator will not operate.
1 Circuit - Voltage above normal, or shorted to high Remote accelerator position will be set to
source 0 percent.
974-4 134 Remote Accelerator Pedal or Lever Position Sensor Remote accelerator will not operate.
1 Circuit - Voltage below normal, or shorted to low Remote accelerator position will be set to
source 0 percent.
974-19 288 SAE J1939 Multiplexing Remote Accelerator Pedal or The engine will not respond to the
Lever Data Error - Received Network Data In Error remote throttle. Engine may only idle.
The primary or cab accelerator may be
able to be used.
1075-3 2265/6258 Fuel Priming Pump Control Signal Circuit - Voltage Engine may be difficult to start.
Above Normal, or Shorted to High Source
1075-4 2266 Fuel Priming Pump Control Signal Circuit - Voltage Engine may be difficult to start.
Below Normal, or Shorted to Low Source

TTNEM50-EN-01(20181109) T5-5-39
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
1081-9 3555 Engine Wait to Start Lamp - Abnormal update rate None on performance.
1172-3 691 Turbocharger 1 Compressor Inlet Temperature Engine power derate.
Circuit-Voltage Above Normal, or Shorted to High
Source
1172-4 692 Turbocharger 1 Compressor Intake Temperature Possible reduced engine performance.
Circuit - Voltage below normal, or shorted to low
source
1176-2 743 Turbocharger 1 Compressor Intake Pressure - Data Possible reduced engine performance.
erratic, intermittent or incorrect
1176-3 741 Turbocharger 1 Compressor Intake Pressure Circuit - Possible reduced engine performance.
Voltage above normal, or shorted to high source
1176-4 742 Turbocharger 1 Compressor Intake Pressure Circuit - Possible reduced engine performance.
Voltage below normal, or shorted to low source
1209-2 2554 Exhaust Gas Pressure - Data Erratic, Intermittent or The ECM will estimate the exhaust gas
Incorrect pressure.
1209-3 2373 Exhaust Gas Pressure Sensor 1 Circuit - Voltage Possible reduced engine performance.
above normal, or shorted to high source
1209-4 2374 Exhaust Gas Pressure Sensor 1 Circuit - Voltage Possible reduced engine performance.
below normal, or shorted to low source
1231-2 3329 J1939 Network #2 - Data erratic, intermittent or Possible reduced engine performance.
incorrect
1235-2 3331 J1939 Network #3 - Data erratic, intermittent or Possible reduced engine performance.
incorrect
1323-31 1654 Engine Misfire Cylinder 1 - Condition Exists Possible reduced engine performance.
1324-31 1655 Engine Misfire Cylinder 2 - Condition Exists Possible reduced engine performance.
1325-31 1656 Engine Misfire Cylinder 3 - Condition Exists Possible reduced engine performance.

TTNEM50-EN-01(20181109) T5-5-40
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
1326-31 1657 Engine Misfire Cylinder 4 - Condition Exists Possible reduced engine performance.
1327-31 1658 Engine Misfire Cylinder 5 - Condition Exists Possible reduced engine performance.
1328-31 1659 Engine Misfire Cylinder 6 - Condition Exists Possible reduced engine performance.
1347-3 272 High Fuel Pressure Solenoid Valve Circuit - Voltage Engine will not run or engine will run
Above Normal, or Shorted to High Source poorly.
1347-4 271 High Fuel Pressure Solenoid Valve Circuit - Voltage Engine will run poorly at idle. Engine will
Below Normal, or Shorted to Low Source have low power. Fuel pressure will be
higher than commanded.
1347-7 281 Engine Fuel Pump Pressurizing Assembly 1 - Engine will not run or possible low
Mechanical system not responding or out of power.
adjustment
1349-3 483 Injector Metering Rail 2 Pressure Sensor Circuit - Possible reduced engine performance.
Voltage above normal, or shorted to high source
1569-31 3714 Engine Protection Torque Derate - Condition Exists Possible reduced engine performance.
1632-14 2998 Engine Torque Limit Feature - Special Instructions None on performance.

TTNEM50-EN-01(20181109) T5-5-41
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
1668-2 4437 J1939 Network #4 - Data erratic, intermittent or
incorrect
1675-31 3737 [C2ST] Engine Starter Mode Overcrank Protection - Starter operation is prohibited until the
Condition Exists starter motor has adequately cooled.
1761-1 1673 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Possible reduced engine performance.
- Data valid but below normal operational range
-Most Severe Level
1761-3 1669 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Possible reduced engine performance.
Sensor Circuit - Voltage above normal, or shorted to
high source
1761-4 1668 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Possible reduced engine performance.
Sensor Circuit - Voltage below normal, or shorted to
low source
1761-10 4769 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Possible reduced engine performance.
Sensor - Abnormal Rate of Change
1761-11 4739/6562 Aftertreatment 1 Diesel Exhaust Fluid Tank Level Possible reduced engine performance.
Sensor - Root Cause Not Known
1761-13 4732/6526 Aftertreatment 1 Diesel Exhaust Fluid Tank Level None on performance.
Sensor - Out of Calibration
1761-17 3497 Aftertreatment 1 Diesel Exhaust Fluid Tank Level None on performance.
- Data Valid But Below Normal Operating Range -
Least Severe Level
1761-18 3498 Aftertreatment 1 Diesel Exhaust Fluid Tank Level None on performance.
- Data Valid But Below Normal Operating Range -
Moderately Severe Level

TTNEM50-EN-01(20181109) T5-5-42
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
2789-15 2346 Turbocharger Turbine Intake Temperature - Data Possible reduced engine performance.
Valid But Above Normal Operating Range - Least
Severe
2791-5 2349 EGR Valve Control Circuit - Current below normal or EGR valve actuation will be disabled.
open circuit
2791-6 2353 EGR Valve Control Circuit - Current above normal or Possible reduced engine performance.
grounded circuit
2791-7 2357 EGR Valve Control Circuit - Mechanical system not EGR valve actuation will be disabled.
responding or out of adjustment
2791-13 1896 EGR Valve Controller - Out of Calibration EGR valve actuation will be disabled.
2791-15 1961 EGR Valve Control Circuit Over Temperature - Data
Valid But Above Normal Operating Range - Least
Severe Level
3031-2 1679 Aftertreatment 1 Diesel Exhaust Fluid Tank Possible reduced engine performance.
Temperature - Data erratic, intermittent or incorrect
3031-3 1678 Aftertreatment 1 Diesel Exhaust Fluid Tank Possible reduced engine performance.
Temperature Sensor - Voltage above normal, or
shorted to high source
3031-4 1677/6559 Aftertreatment 1 Diesel Exhaust Fluid Tank Possible reduced engine performance.
Temperature Sensor - Voltage below normal, or
shorted to low source
3031-9 4572 Aftertreatment 1 Diesel Exhaust Fluid Tank Possible reduced engine performance.
Temperature - Abnormal Update Rate
3031-11 4737 Aftertreatment 1 Diesel Exhaust Fluid Tank Engine power derate.
Temperature - Root Cause Not Known
3031-13 4731 Aftertreatment 1 Diesel Exhaust Fluid Tank Possible reduced engine performance.
Temperature Sensor - Out of Calibration
3216-2 3228 Aftertreatment 1 Intake NOx Sensor - Data erratic, Possible reduced engine performance.
intermittent or incorrect

TTNEM50-EN-01(20181109) T5-5-43
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
3216-4 1885 Aftertreatment 1 Intake NOx Sensor Circuit - Voltage Possible reduced engine performance.
below normal, or shorted to low source
3216-9 3232 Aftertreatment 1 Intake NOx Sensor - Abnormal Possible reduced engine performance.
update rate
3216-10 3725 Aftertreatment 1 Intake NOx Sensor - Abnormal rate None on performance.
of change
3216-13 3718 Aftertreatment 1 Intake NOx - Out of Calibration None on performance.
3216-16 3726 Aftertreatment 1 Intake NOx - Data Valid But Above Engine power derate.
Normal Operating Range - Moderately Severe Level
3216-20 3748/6458 Aftertreatment 1 Intake NOx Sensor - Data not None on performance.
Rational - Drifted High
3218-2 3682 Aftertreatment 1 Intake NOx Sensor Power Supply - None on performance.
Data erratic, intermittent or incorrect
3226-2 1694/6464 Aftertreatment 1 Outlet NOx Sensor - Data erratic, Possible reduced engine performance.
intermittent or incorrect
3226-4 1887/6521 Aftertreatment 1 Outlet NOx Sensor Circuit - Voltage Possible reduced engine performance.
below normal, or shorted to low source
3226-9 2771 Aftertreatment 1 Outlet NOx Sensor - Abnormal Possible reduced engine performance.
update rate
3226-10 3545/6565 Aftertreatment 1 Outlet NOx Sensor - Abnormal rate None on performance.
of change
3226-13 3717 Aftertreatment 1 Outlet NOx Sensor - Out of None on performance.
Calibration
3226-20 3749/6462 Aftertreatment 1 Outlet NOx Sensor - Data not Possible reduced engine performance.
Rational - Drifted High
3228-2 3681/6582 Aftertreatment 1 Outlet NOx Sensor Power Supply - None on performance.
Data erratic, intermittent or incorrect
3361-2 2976 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Temperature - Data erratic, intermittent or incorrect
3361-3 3558 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit - Possible reduced engine performance.
Voltage below normal, or shorted to low source
3361-4 3559 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit - Possible reduced engine performance.
Voltage below normal, or shorted to low source

TTNEM50-EN-01(20181109) T5-5-44
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
3362-31 1682 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Input Lines - Condition Exists
3363-3 1683/6479 Aftertreatment 1 Diesel Exhaust Fluid Tank Heater - Possible reduced engine performance.
Voltage above normal, or shorted to high source
3363-4 1684/6481 Aftertreatment 1 Diesel Exhaust Fluid Tank Heater - Possible reduced engine performance.
Voltage below normal, or shorted to low source
3363-7 3242/6475 Aftertreatment 1 Diesel Exhaust Fluid Tank Heater Possible reduced engine performance.
- Mechanical system not responding or out of
adjustment
3363-16 1713 Aftertreatment 1 Diesel Exhaust Fluid Tank Heater None on performance.
- Data Valid But Above Normal Operating Range -
Moderately Severe Level
3363-18 1712/6476 Aftertreatment 1 Diesel Exhaust Fluid Tank Heater Possible reduced engine performance.
- Data Valid But Below Normal Operating Range -
Moderately Severe Level
3364-2 3878 Aftertreatment Diesel Exhaust Fluid Quality - Data Engine power derate.
erratic, intermittent or incorrect
3364-3 1686 Aftertreatment Diesel Exhaust Fluid Quality Sensor Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source
3364-4 1685 Aftertreatment Diesel Exhaust Fluid Quality Sensor Possible reduced engine performance.
Circuit - Voltage below normal, or shorted to low
source
3364-5 4741 Aftertreatment Diesel Exhaust Fluid Quality Sensor
Circuit - Current below normal or open circuit
3364-6 4742 Aftertreatment Diesel Exhaust Fluid Quality Sensor
Circuit - Current above normal or grounded circuit
3364-7 3876 Aftertreatment Diesel Exhaust Fluid Quality Sensor Engine power derate.
- Mechanical system not responding or out of
adjustment
3364-9 3868 Aftertreatment Diesel Exhaust Fluid Quality - Engine power derate.
Abnormal update rate
3364-10 4277 Aftertreatment Diesel Exhaust Fluid Quality - Engine power derate.
Abnormal Rate of Change

TTNEM50-EN-01(20181109) T5-5-45
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
3364-11 1715 Aftertreatment Diesel Exhaust Fluid Quality - Root Engine power derate.
Cause Not Known
3364-12 3877 Aftertreatment Diesel Exhaust Fluid Quality Sensor - Engine power derate.
Bad intelligent device or component
3364-13 1714 Aftertreatment Diesel Exhaust Fluid Quality - Out of Engine power derate.
Calibration
3364-15 4842 Aftertreatment Diesel Exhaust Fluid Quality - Data
Valid But Above Normal Operating Range - Least
Severe Level
3364-18 3867 Aftertreatment Diesel Exhaust Fluid Quality - Data Possible reduced engine performance.
Valid But Below Normal Operating Range - Moderate
Severe Level
3364-19 4241 Aftertreatment Diesel Exhaust Fluid Quality -
Received Network Data In Error
3509-3 386 Sensor Supply Voltage #1 Circuit - Voltage Above Engine power derate.
Normal, or Shorted to High Source
3509-4 352 Sensor Supply Voltage #1 Circuit - Voltage Below Engine power derate.
Normal, or Shorted to Low Source
3510-3 227 Sensor Supply Voltage #2 Circuit - Voltage Above Engine power derate.
Normal, or Shorted to High Source
3510-4 187 Sensor Supply Voltage #2 Circuit - Voltage Below Engine power derate.
Normal, or Shorted to Low Source
3511-3 239 Sensor Supply Voltage #3 Circuit - Voltage Above Possible hard starting and rough running.
Normal, or Shorted to High Source
3511-4 238 Sensor Supply Voltage #3 Circuit - Voltage Below Possible hard starting and rough running.
Normal, or Shorted to Low Source
3512-3 2185 Sensor Supply 4 Circuit - Voltage above normal, or Engine will only idle.
shorted to high source
3512-4 2186 Sensor Supply 4 Circuit - Voltage below normal, or Engine will only idle.
shorted to low source

TTNEM50-EN-01(20181109) T5-5-46
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
3513-3 1695 Sensor Supply 5 - Voltage Above Normal, or Shorted Severe derate in power output of the
to High Source engine. Limp home power only. None on
performance.
3513-4 1696 Sensor Supply 5 - Voltage Below Normal, or Shorted Severe derate in power output of the
to Low Source engine. Limp home power only.
3514-3 515 Sensor Supply 6 Circuit - Voltage above normal, or Engine power derate.
shorted to high source
3514-4 516 Sensor Supply 6 Circuit - Voltage below normal, or Engine power derate.
shorted to low source
3515-5 4743 Aftertreatment 1 Diesel Exhaust Fluid Temperature
2 Sensor Circuit - Current below normal or open
circuit
3515-6 4744 Aftertreatment 1 Diesel Exhaust Fluid Temperature 2
Sensor Circuit - Current above normal or grounded
3515-10 4243 Aftertreatment 1 Diesel Exhaust Fluid Temperature
2 - Abnormal Rate of Change
3515-11 4745 Aftertreatment 1 Diesel Exhaust Fluid Temperature Possible reduced engine performance.
2 - Root Cause Not Known
3521-11 4768 Aftertreatment 1 Diesel Exhaust Fluid Property - Engine power derate.
Root Cause Not Known
3597-2 1117 Power Supply Lost With Ignition On - Data erratic, Possible reduced engine performance.
intermittent or incorrect
3597-12 351 Injector Power Supply - Bad intelligent device or Possible reduced engine performance.
component
3597-18 1938 ECU Power Output Supply Voltage 1 - Data Valid But None on performance.
Below Normal Operating Range - Moderately Severe
Level

TTNEM50-EN-01(20181109) T5-5-47
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
3695-2 4213 Aftertreatment Regeneration Inhibit Switch - Data Possible frequent need for aftertreatment
erratic, intermittent or incorrect regeneration.
4094-31 3543 NOx limits exceeded due to Insufficient Reagent Possible reduced engine performance.
Quality - Condition Exists
4096-31 3547 Aftertreatment Diesel Exhaust Fluid Tank Empty - Possible reduced engine performance.
Condition Exists
4334-2 3596 Aftertreatment 1 Diesel Exhaust Fluid Pressure Possible reduced engine performance.
Sensor - Data erratic, intermittent or incorrect

TTNEM50-EN-01(20181109) T5-5-48
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
4334-3 3571 Aftertreatment 1 Diesel Exhaust Fluid Pressure Possible reduced engine performance.
Sensor - Voltage above normal, or shorted to high
source
4334-4 3572 Aftertreatment 1 Diesel Exhaust Fluid Pressure Possible reduced engine performance.
Sensor - Voltage below normal, or shorted to low
source
4334-16 3575 Aftertreatment 1 Diesel Exhaust Fluid Pressure Possible reduced engine performance.
Sensor - Data Valid But Above Normal Operating
Range
4334-18 3574 Aftertreatment 1 Diesel Exhaust Fluid Pressure Possible reduced engine performance.
Sensor - Data Valid But Below Normal Operating
Range
4337-10 4249 Aftertreatment 1 Diesel Exhaust Fluid Dosing None on performance.
Temperature - Abnormal Rate of Change
4340-3 3237/6531 Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source
4340-4 3238/6532 Aftertreatment 1 Diesel Exhaust Fluid Line Heater Possible reduced engine performance.
1 Circuit - Voltage below normal, or shorted to low
source
4340-5 3258/6482 Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 Possible reduced engine performance.
Circuit - Current below normal or open circuit
4342-3 3239/6533 Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source
4342-4 3241/6534 Aftertreatment 1 Diesel Exhaust Fluid Line Heater Possible reduced engine performance.
2 Circuit - Voltage below normal, or shorted to low
source
4342-5 3261/6483 Aftertreatment 1 Diesel Exhaust Fluid Line Heater 2 Possible reduced engine performance.
Circuit - Current below normal or open circuit
4344-3 3422/6535 Aftertreatment Diesel Exhaust Fluid Line Heater 3 Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source

TTNEM50-EN-01(20181109) T5-5-49
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
4344-4 3423/6536 Aftertreatment Diesel Exhaust Fluid Line Heater 3 Possible reduced engine performance.
Circuit - Voltage below normal, or shorted to low
source
4344-5 3425/6484 Aftertreatment Diesel Exhaust Fluid Line Heater 3 Possible reduced engine performance.
Circuit - Current below normal or open circuit
4360-0 3229 Aftertreatment 1 SCR Intake Temperature - Data Progressive power and/or speed derate
valid but above normal operational range - Most increasing in severity from time of alert. If
Severe Level the Engine Protection Shutdown feature
is enabled, the engine will shut down 30
seconds after the red STOP lamps starts
flashing.
4360-2 3144 Aftertreatment 1 SCR Intake Temperature Sensor - Possible reduced engine performance.
Data erratic, intermittent or incorrect
4360-3 3142 Aftertreatment 1 SCR Intake Temperature Sensor Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source
4360-4 3143 Aftertreatment 1 SCR Intake Temperature Sensor Possible reduced engine performance.
Circuit - Voltage below normal, or shorted to low
source
4360-15 3164 Aftertreatment 1 SCR Intake Temperature - Data
Valid But Above Normal Operating Range - Least
Severe
4360-16 3231/5247 Aftertreatment 1 SCR Intake Temperature - Data Progressive power and/or speed derate
Valid But Above Normal Operating Range - increasing in severity from time of alert. If
Moderately Severe Level the Engine Protection Shutdown feature
is enabled, the engine will shut down 30
seconds after the red STOP lamps starts
flashing.
4363-0 3165 Aftertreatment 1 SCR Outlet Temperature - Data Possible reduced engine performance.
valid but above normal operational range - Most
Severe
4363-2 3148 Aftertreatment 1 SCR Outlet Temperature Sensor - Possible reduced engine performance.
Data erratic, intermittent or incorrect

TTNEM50-EN-01(20181109) T5-5-50
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
4363-3 3146/6569 Aftertreatment 1 SCR Outlet Temperature Sensor Possible reduced engine performance.
Circuit - Voltage above normal, or shorted to high
source
4363-4 3147/6571 Aftertreatment 1 SCR Outlet Temperature Sensor Possible reduced engine performance.
Circuit - Voltage below normal, or shorted to low
source
4363-16 3235 Aftertreatment 1 SCR Outlet Temperature - Data Possible reduced engine performance.
Valid But Above Normal Operating Range -
Moderately Severe Level
4364-18 3582 Aftertreatment SCR Catalyst Conversion Efficiency Possible reduced engine performance.
- Data Valid But Below Normal Operating Range -
Moderately Severe Level
4376-3 3577 Aftertreatment Diesel Exhaust Fluid Return Valve - Possible reduced engine performance.
Voltage above normal, or shorted to high source
4376-4 3578 Aftertreatment Diesel Exhaust Fluid Return Valve - Possible reduced engine performance.
Voltage below normal, or shorted to low source
4376-7 4157/6527 Aftertreatment Diesel Exhaust Fluid Return Valve - None on performance.
Mechanical system not responding or out of adjust
4765-2 3315/6539 Aftertreatment 1 Diesel Oxidation Catalyst Intake Possible reduced engine performance.
Temperature - Data erratic, intermittent or incorrect
4765-3 3314 Aftertreatment 1 Diesel Oxidation Catalyst Intake Possible reduced engine performance.
Temperature Sensor Circuit - Voltage above normal,
or shorted to high source
4765-4 3313 Aftertreatment 1 Diesel Oxidation Catalyst Intake Possible reduced engine performance.
Temperature Sensor Circuit - Voltage below normal,
or shorted to low source
4765-16 3251 Aftertreatment 1 Diesel Oxidation Catalyst Intake Progressive power and/or speed derate
Temperature - Data Valid But Above Normal increasing in severity from time of alert. If
Operating Range the Engine Protection Shutdown feature
is enabled, the engine will shut down 30
seconds after the red STOP lamps starts
flashing.

TTNEM50-EN-01(20181109) T5-5-51
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
4766-0 5387 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Progressive power and/or speed derate
Gas Temperature - Data Valid But Above Normal increasing in severity from time of alert. If
Operating Range - Most Severe Level the Engine Protection Shutdown feature
is enabled, the engine will shut down 30
seconds after the red STOP lamps starts
flashing.
4766-2 5386 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Possible reduced engine performance.
Gas Temperature - Data Erratic, Intermittent, or
Incorrect
4766-3 4533 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Possible reduced engine performance.
Gas Temperature Sensor Circuit - Voltage above
normal, or shorted to high source
4766-4 4534 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Possible reduced engine performance.
Gas Temperature Sensor Circuit - Voltage below
normal, or shorted to low source
4766-15 5389 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Possible reduced engine performance.
Gas Temperature - Data Valid But Above Normal
Operating Range - Least Severe Level
4766-16 5388 Aftertreatment 1 Diesel Oxidation Catalyst Outlet Progressive power and/or speed derate
Gas Temperature - Data Valid But Above Normal increasing in severity from time of alert. If
Operating Range - Moderately Severe Level the Engine Protection Shutdown feature
is enabled, the engine will shut down 30
seconds after the red STOP lamps starts
flashing.
4792-7 3751 Aftertreatment SCR Catalyst System - Mechanical
system not responding or out of adjustment
4792-14 4585 Aftertreatment 1 SCR Catalyst System - Special Engine will be shut down.
Instructions
4794-31 3151 Aftertreatment 1 SCR Catalyst System Missing - Possible reduced engine performance.
Condition Exists
4796-31 1664 Aftertreatment 1 Diesel Oxidation Catalyst Missing - Active aftertreatment diesel particulate
Condition Exists filter regeneration will be disabled.
5018-11 2637 Aftertreatment 1 Diesel Oxidation Catalyst Face Possible reduced engine performance.
Plugged - Root Cause Not Known

TTNEM50-EN-01(20181109) T5-5-52
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
5024-10 3649 Aftertreatment 1 Intake NOx Sensor Heater - None on performance.
Abnormal rate of change
5031-10 3583/6581 Aftertreatment 1 Outlet NOx Sensor Heater - None on performance.
Abnormal rate of change
5125-3 3419 Sensor Supply 7 Circuit - Voltage above normal, or Unstable engine speed.
shorted to high source
5125-4 3421 Sensor Supply 7 Circuit - Voltage below normal, or Unstable engine speed.
shorted to low source
5245-31 4863 Aftertreatment SCR Operator Inducement Active - Possible reduced engine performance.
Condition Exists
5246-0 3712 Aftertreatment SCR Operator Inducement - Data Engine power derate.
valid but above normal operational range - Most
Severe level
5298-18 1691 Aftertreatment 1 Diesel Oxidation Catalyst Possible frequent need for aftertreatment
Conversion Efficiency - Data Valid But Below Normal regeneration.
Operating Range - Moderately Severe Level
5394-2 3755 Aftertreatment Diesel Exhaust Fluid Dosing Valve - None on performance.
Data erratic, intermittent or incorrect
5394-5 3567 Aftertreatment Diesel Exhaust Fluid Dosing Valve - Possible reduced engine performance.
Current below normal or open circuit
5394-7 3568 Aftertreatment Diesel Exhaust Fluid Dosing Valve Possible reduced engine performance.
- Mechanical system not responding or out of
adjustment
5491-3 3562/6477 Aftertreatment Diesel Exhaust Fluid Line Heater Possible reduced engine performance.
Relay - Voltage above normal, or shorted to high
source
5491-4 3563/6478 Aftertreatment Diesel Exhaust Fluid Line Heater Possible reduced engine performance.
Relay - Voltage below normal, or shorted to low
source

TTNEM50-EN-01(20181109) T5-5-53
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
5491-7 3713/6537 Aftertreatment 1 Diesel Exhaust Fluid Line Heater Possible reduced engine performance.
Relay - Mechanical system not responding or out of
adjustment
5571-0 3741 High Pressure Common Rail Fuel Pressure Relief Possible engine noise associated with
Valve - Data valid but above normal operational higher injection pressures (especially
range at idle or light load) or possible power
interruption associated with high-
pressure relief valve reset.
5571-3 4262 High Pressure Common Rail Fuel Pressure Relief Engine may run rough, may stop running,
Valve - Voltage Above Normal, or Shorted to High may not start, or may be difficult to start.
Source
5571-4 4263 High Pressure Common Rail Fuel Pressure Relief Engine may run rough, may stop running,
Valve - Voltage below normal, or shorted to low may not start, or may be difficult to start.
source
5571-7 3727 High Pressure Common Rail Fuel Pressure Relief Possible reduced engine performance.
Valve - Mechanical system not responding or out of
adjustment
5571-15 5585 High Pressure Common Rail Fuel Pressure Relief Possible reduced engine performance.
Valve - Data Valid But Above Normal Operating
Range - Least Severe Level
5571-31 4867 High Pressure Common Rail Fuel Pressure Relief Engine may run rough, may stop running,
Valve - Condition Exists may not start, or may be difficult to start.

TTNEM50-EN-01(20181109) T5-5-54
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
5743-3 4164 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Voltage Above
Normal, or Shorted to high source
5743-4 4165 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Voltage below
normal, or Shorted to low source
5743-9 4152 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Abnormal update rate
5743-11 4261 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Root Cause Not
Known
5743-12 4159 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Bad intelligent device
or component
5743-16 4166 Aftertreatment Selective Catalytic Reduction Possible reduced engine performance.
Temperature Sensor Module - Data Valid But Above
Normal
5745-3 4168 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit None on performance.
Heater - Voltage Above Normal, or Shorted to High
5745-4 4169 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Heater - Voltage below normal, or shorted to low
source
5745-18 4171 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Heater - Data Valid But Below Normal Operating
Range
5746-3 4155/6529 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Heater Relay - Voltage Above Normal, or Shorted to
high source

TTNEM50-EN-01(20181109) T5-5-55
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
5746-4 4156 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit Possible reduced engine performance.
Heater Relay - Voltage below normal, or shorted to
low source
5798-10 4251 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit None on performance.
Heater Temperature - Abnormal Rate of Change
6655-3 4951/6511 Maintain ECU Power Lamp - Voltage Above Normal, None on performance.
or Shorted to High Source
6655-4 4952/6512 Maintain ECU Power Lamp - Voltage Below Normal, None on performance.
or Shorted to Low Source
6713-9 5177 VGT Actuator Driver Circuit - Abnormal update rate Possible reduced engine performance.
6713-13 4956 Variable Geometry Turbocharger Actuator Software Possible reduced engine performance.
- Out of Calibration
6713-31 4957 Variable Geometry Turbocharger Actuator Software Possible reduced engine performance.
- Condition Exists
6802-31 5278 Aftertreatment 1 Diesel Exhaust Fluid Dosing Engine power derate.
System Frozen - Condition Exists
6881-9 5653 SCR Operator Inducement Override Switch - At least one multiplexed device will not
Abnormal Update Rate operate properly.
6881-13 5654 SCR Operator Inducement Override Switch - Out of At least one multiplexed device will not
Calibration operate properly.
6882-3 5393 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Voltage Above
Normal or Shorted to High Source
6882-4 5394 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Voltage Below Normal
or Shorted to Low Source
6882-9 5391 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Abnormal Update
Rate
6882-11 5395 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Root Cause Not
Known

TTNEM50-EN-01(20181109) T5-5-56
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Symptoms in Machine Operation When

MPDr. CUMMINS Trouble Occurs.
6882-12 5392 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Bad Intelligent Device
or Component
6882-16 5396 Aftertreatment Diesel Oxidation Catalyst Possible reduced engine performance.
Temperature Sensor Module - Data Valid But Above
Normal Operating Range - Moderately Severe Level
6918-31 5632 SCR System Cleaning Inhibited Due to Inhibit Switch None on performance.
- Condition Exists
6928-31 5631/6597 SCR System Cleaning Inhibited Due to System None on performance.
Timeout - Condition Exists
520968-9 5939 Machine Constrained Operation- Abnormal Update Possible reduced engine performance.
Rate. No Communication or an invalid data transfer
rate has been detected on the J1939 data link
between the ECM and the machine electronic
control unit.
520968-19 5941 Machine Constrained Operation- Received Network Possible reduced engine performance.
Data in Error. The received J1939 datalink message
was not valid.

TTNEM50-EN-01(20181109) T5-5-57
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

(Blank)

TTNEM50-EN-01(20181109) T5-5-58
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

TCU Fault Code List

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-59
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-60
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-61
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-62
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-63
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-64
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

5490-3 Abnormal Shorted circuit in power Turn TCU to neutral. Check the harness between
Second circuit because of faulty After returning the TCU and transmission control
Speed Clutch harness or faulty connector. forward/reverse lever valve.
Proportional Faulty proportional solenoid to neutral, operate it Check the connector between
Solenoid Valve valve. again. Then, machine TCU and transmission control
High Voltage can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5490-4 Abnormal Grounding to body because Turn TCU to neutral. Check the harness between
Second of faulty harness or faulty After returning the TCU and transmission control
Speed Clutch connector. forward/reverse lever valve.
Proportional Shorted circuit to other to neutral, operate it Check the connector between
Solenoid Valve proportional solenoid valve again. Then, machine TCU and transmission control
Low Voltage output circuit in TCU. can travel only at first or valve.
Faulty proportional solenoid second speed. Check resistance in the
valve. If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5490-5 Open Circuit Faulty contact of harness, Turn TCU to neutral. Check the harness between
in Second connector, and TCU. After returning the TCU and transmission control
Speed Clutch Faulty proportional solenoid forward/reverse lever valve.
Proportional valve. to neutral, operate it Check the connector between
Solenoid Valve again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.

TTNEM50-EN-01(20181109) T5-5-65
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

5500-3 Abnormal Third Shorted circuit in power Turn TCU to neutral. Check the harness between
Speed Clutch circuit because of faulty After returning the TCU and transmission control
Proportional harness or faulty connector. forward/reverse lever valve.
Solenoid Valve Faulty proportional solenoid to neutral, operate it Check the connector between
High Voltage valve. again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5500-4 Abnormal Third Grounding to body because Turn TCU to neutral. Check the harness between
Speed Clutch of faulty harness or faulty After returning the TCU and transmission control
Proportional connector. forward/reverse lever valve.
Solenoid Valve Faulty shorted circuit to other to neutral, operate it Check the connector between
Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control
output circuit in TCU because can travel only at first or valve.
of faulty harness or faulty second speed. Check resistance in the
connector. If other proportional proportional solenoid valve.
Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F))
valve. abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5500-5 Open Circuit Faulty contact of harness, Turn TCU to neutral. Check the harness between
in Third connector, and TCU. After returning the TCU and transmission control
Speed Clutch Faulty proportional solenoid forward/reverse lever valve.
Proportional valve. to neutral, operate it Check the connector between
Solenoid Valve again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.

TTNEM50-EN-01(20181109) T5-5-66
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

5510-3 High-Speed Shorted circuit in power Turn TCU to neutral. Check the harness between
Forward Clutch circuit because of faulty After returning the TCU and transmission control
Proportional harness or faulty connector. forward/reverse lever valve.
Solenoid Valve Faulty proportional solenoid to neutral, operate it Check the connector between
High Voltage valve. again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5510-4 High-Speed Grounding to body because Turn TCU to neutral. Check the harness between
Forward Clutch of faulty harness or faulty After returning the TCU and transmission control
Proportional connector. forward/reverse lever valve.
Solenoid Valve Faulty shorted circuit to other to neutral, operate it Check the connector between
Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control
output circuit in TCU because can travel only at first or valve.
of faulty harness or faulty second speed. Check resistance in the
connector. If other proportional proportional solenoid valve.
Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F))
valve. abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5510-5 Open Circuit Faulty contact of harness, Turn TCU to neutral. Check the harness between
in High-Speed connector, and TCU. After returning the TCU and transmission control
Forward Clutch Faulty proportional solenoid forward/reverse lever valve.
Proportional valve. to neutral, operate it Check the connector between
Solenoid Valve again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.

TTNEM50-EN-01(20181109) T5-5-67
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

5520-3 Low-Speed Shorted circuit in power Turn TCU to neutral. Check the harness between
Forward Clutch circuit because of faulty After returning the TCU and transmission control
Proportional harness or faulty connector. forward/reverse lever valve.
Solenoid Valve Faulty proportional solenoid to neutral, operate it Check the connector between
High Voltage valve. again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5520-4 Low-Speed Grounding to body because Turn TCU to neutral. Check the harness between
Forward Clutch of faulty harness or faulty After returning the TCU and transmission control
Proportional connector. forward/reverse lever valve.
Solenoid Valve Shorted circuit to other to neutral, operate it Check the connector between
Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control
output circuit in TCU because can travel only at first or valve.
of faulty harness or faulty second speed. Check resistance in the
connector. If other proportional proportional solenoid valve.
Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F))
valve. abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5520-5 Open Circuit Faulty contact of harness, Turn TCU to neutral. Check the harness between
in Low-Speed connector, and TCU. After returning the TCU and transmission control
Forward Clutch Faulty proportional solenoid forward/reverse lever valve.
Proportional valve. to neutral, operate it Check the connector between
Solenoid Valve again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.

TTNEM50-EN-01(20181109) T5-5-68
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

5530-3 Abnormal Shorted circuit in harness or Turn TCU to neutral. Check the harness between
Reverse Clutch connector and power circuit. After returning the TCU and transmission control
Proportional Faulty proportional solenoid forward/reverse lever valve.
Solenoid Valve valve. to neutral, operate it Check the connector between
High Voltage again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5530-4 Abnormal Grounding to body because Turn TCU to neutral. Check the harness between
Reverse Clutch of faulty harness or faulty After returning the TCU and transmission control
Proportional connector. forward/reverse lever valve.
Solenoid Valve Shorted circuit to other to neutral, operate it Check the connector between
Low Voltage proportional solenoid valve again. Then, machine TCU and transmission control
output circuit in TCU because can travel only at first or valve.
of faulty harness or faulty second speed. Check resistance in the
connector. If other proportional proportional solenoid valve.
Faulty proportional solenoid solenoid valve is (19 Ω at 20 °C (68 °F))
valve. abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.
5530-5 Open Circuit in Faulty contact of harness, Turn TCU to neutral. Check the harness between
Reverse Clutch connector, and TCU. After returning the TCU and transmission control
Proportional Faulty proportional solenoid forward/reverse lever valve.
Solenoid Valve valve. to neutral, operate it Check the connector between
again. Then, machine TCU and transmission control
can travel only at first or valve.
second speed. Check resistance in the
If other proportional proportional solenoid valve.
solenoid valve is (19 Ω at 20 °C (68 °F))
abnormal, TCU is fixed Check the internal harness in
to neutral. transmission control valve.

TTNEM50-EN-01(20181109) T5-5-69
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-70
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-71
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-72
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-73
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-74
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-75
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-76
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-77
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Fault Code Trouble Cause Behavior of TCU Repair Procedure

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

TTNEM50-EN-01(20181109) T5-5-78
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111000 to 111002

Fault Code Trouble Cause

111000-2 Abnormal EEPROM Faulty MC
111001-2 Abnormal RAM Faulty MC
111002-2 Abnormal A/D Converter Faulty MC

fNOTE: Even if the engine and the machine are operated

normally with the fault code displayed after retrial, the
machine can be operated as it is.

TTNEM50-EN-01(20181109) T5-5-79
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111003

IMPORTANT: When fault code 111003-3 (Abnormal
Sensor Voltage) is displayed with other fault code,
diagnose on fault code 111003-3 first.

Fault Code Trouble Procedure Inspection Method Evaluation Cause

111003-3 Abnormal 1 Disconnect connectors Un-displayed YES: Faulty sensor
Sensor Voltage from all sensors and fault codes
emergency steering 11003-3 NO: Go to Procedure No. 2.
pump delivery pressure
switch. Retry the
troubleshooting by
using MPDr.
2 Measure voltage Less than YES: Open circuit in wire harness #1
between sensor harness 0.25 V NO: Go to Procedure No. 3.
end #1 and the body.
3 Check short circuit in 0Ω YES: Short circuit in wire harness
wire harness between between #1 and #3
sensor harness end #1 NO: Faulty MC
and #3.

Accelerator Pedal Sensor

Pump Delivery Pressure Sensor

Pressure Sensor (Primary Pilot Pressure)

1

Pressure Sensor (Lift Arm Raise)

Pressure Sensor (Bucket Roll Back)

Pressure Sensor (Bucket Dump)

Pressure Sensor (Parking Brake)

Pressure Sensor (Service Brake
Primary Pressure)
Pressure Sensor (Refrigerant Pressure)

Load Computer (+5 V)

Lift Arm Angle Sensor
Hydraulic Fan Circuit Pressure Sensor
Pressure Sensor (Service Brake
Secondary Pressure)

Emergency Steering Operation Check

Pressure Switch

Steering Pressure Switch

Hydraulic Oil Temperature Sensor

Axle Oil Temperature Sensor
Load Computer (-)

85Z7BTT05-05-01
1- Main Controller (MC)

TTNEM50-EN-01(20181109) T5-5-80
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Connector (Harness end of connector viewed from the

open end side)

 Pressure Sensor (Lift Arm Raise)  Lift Arm Angle Sensor

 Pressure Sensor (Bucket Dump)
 Pressure Sensor (Bucket Roll Back)
 Pressure Sensor (Service Brake Secondary Pressure)
 Pressure Sensor (Primary Pilot Pressure)

90Z7-05-CN04

 Pressure Sensor (Refrigerant Pressure)

90Z7-05-CN01

 Steering Pressure Switch

90Z7-05-CN05

 Accelerator Pedal Sensor

90Z7-05-CN02

 Pump Delivery Pressure Sensor

 Hydraulic Fan Circuit Pressure Sensor
 Emergency (Secondary) Steering Operation Check
Pressure Sensor
 Pressure Sensor (Service Brake Primary Pressure)
90Z7B-05-CN01
 Pressure Sensor (Parking Brake)

fNOTE: P: 5 V or 24 V power supply

S: Signal
G: Ground (chassis)
90Z7-05-CN03 S2: Signal 2 (for fault detection)

TTNEM50-EN-01(20181109) T5-5-81
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

(Blank)

TTNEM50-EN-01(20181109) T5-5-82
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111006, 111007, 111009,

111011
Monitor Controller (Monitor) Fault Codes
113002, 113003, 113005, 113012
Preparation
 Check the wiring connections first.
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check.)

Fault Code Trouble Inspection Method Cause

111006-2 (MC) EC Communication Error Continuity check (open circuit) Open circuit in wire harness

Discontinuity check Short circuit in wire harness

111007-2 (MC) IC Communication Error 1 Continuity check (open circuit) Open circuit in wire harness

Discontinuity check Short circuit in wire harness

111009-2 (MC) Monitor Controller Continuity check (open circuit) Open circuit in wire harness
Communication Error 1
Discontinuity check Short circuit in wire harness

111011-2 (MC) Transmission Controller Continuity check (open circuit) Open circuit in wire harness
Communication Error
Discontinuity check Short circuit in wire harness

113002-2 (Monitor Controller) Engine Continuity check (open circuit) Open circuit in wire harness
Controller Communication Error
Discontinuity check Short circuit in wire harness

113003-2 (Monitor Controller) Main Continuity check (open circuit) Open circuit in wire harness
Controller Communication Error
1 Discontinuity check Short circuit in wire harness

113005-2 (Monitor Controller) ICF Continuity check (open circuit) Open circuit in wire harness
Communication Error 1
Discontinuity check Short circuit in wire harness

113012-2 (Monitor Controller) Transmission Continuity check (open circuit) Open circuit in wire harness
Controller Communication Error
Discontinuity check Short circuit in wire harness

fNOTE: IC and ICF are the information control unit of the

monitor controller.

TTNEM50-EN-01(20181109) T5-5-83
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

CAN1 Harness Check

Preparation
 Before continuity check, set the key switch to the OFF position.

Evaluation

Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Incorrect (Open
(open circuit) circuit)
Discontinuity check Incorrect (Short Correct
circuit)

Inspection CAN Harness MC ECM TCU Monitor Controller Column Display

Controller
Continuity check High side #D2 #22 #25 #A24 #1-6
between MC and Low side #D3 #46 #26 #A23 #1-7
each controller
Discontinuity High side #D2-#E1 #22-#73 #25-#1 #A24-#B36 #1-6-#1-19
check between #D2-#E2 #22-#49 #25-#2 - -
CAN circuit and #D2-#F4 #22-#50 - - -
ground circuit in
#D2-#F5 #22-#51 - - -
each controller
#D2-#F6 #22-#52 - - -
Low side #D3-#E1 #46-#73 #26-#1 #A23-#B36 #1-7-#1-19
#D3-#E2 #46-#49 #26-#2 - -
#D3-#F4 #46-#50 - - -
#D3-#F5 #46-#51 - - -
#D3-#F6 #46-#52 - - -

TTNEM50-EN-01(20181109) T5-5-84
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Inspection CAN Harness MC ECM TCU Monitor Controller Column Display

Controller
Discontinuity High side #D2-#E5 #22-#1 #25-#23 #A24-#B18 #1-6-#2-1
check between #D2-#E6 #22-#25 #25-#68 - -
CAN circuit and #D2-#F1 #22-#26 - - -
power circuit in
#D2-#F2 #22-#27 - - -
each controller
#D2-#F3 #22-#28 - - -
Low side #D3-#E5 #46-#1 #26-#23 #A23-#B18 #1-7-#2-1
#D3-#E6 #46-#25 #26-#68 - -
#D3-#F1 #46-#26 - - -
#D3-#F2 #46-#27 - - -
#D3-#F3 #46-#28 - - -
Discontinuity High side #D2-#E4 #22-#5 #25-#45 #A24-#B17 #1-6-#2-2
check between
CAN circuit and
Low side #D3-#E4 #46-#5 #26-#45 #A23-#B17 #1-7-#2-2
key signal circuit
in each controller
Discontinuity - #D2-#D3 #22-#46 #25-#26 #A24-#A23 #1-6-#1-7
check between
CAN (High side)
circuit and CAN
(Low side) circuit
in each controller

TTNEM50-EN-01(20181109) T5-5-85
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Connector (Wire harness end)

 MC-D Connector  Column Display Controller 1 Connector

TNEK-05-05-004

85Z7BTT05-05-02
 Column Display Controller 2 Connector

 MC-E Connector

TNEK-05-05-013

 Monitor Controller-A Connector

85Z7BTT05-05-03

 MC-F Connector
85Z7BTT05-05-05

 Monitor Controller-B Connector

85Z7BTT05-05-04

85Z7BTT05-05-06

TTNEM50-EN-01(20181109) T5-5-86
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

 TCU Connector

85Z7BTT05-05-07

 ECM Connector

90Z7B-05-ECM

TTNEM50-EN-01(20181109) T5-5-87
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

CAN3 Harness Check

Preparation
 Before continuity check, set the key switch to the
OFF position.

Evaluation

Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Discontinuity
(open circuit)
Discontinuity check Shorted circuit Correct
(shorted circuit)

Inspection CAN Harness CC24B Connector Thermistor (SCR) NOx Sensor (SCR) Thermistor (DOC)
Continuity check High side #22 #3 #3 #3
between each unit Low side #23 #2 #2 #2
Discontinuity check High side - #3-#4 #3-#1 #3-#4
between CAN circuit Low side - #2-#4 #2-#1 #2-#4
and power supply
circuit for each unit
Discontinuity check High side - #3-#1 #3-#4 #3-#1
between CAN circuit Low side - #2-#1 #2-#4 #2-#1
and ground circuit for
each unit
Discontinuity check #22-#23 #3-#2 #3-#2 #3-#2
between CAN (high)
circuit and CAN (low)
circuit for each unit

Inspection CAN Harness NOx Sensor DEF Tank Sensor Terminator

(DOC)
Continuity check High side #3 #2 #A
between each unit Low side #2 #1 #B
Discontinuity check High side #3-#1 #2-#4 -
between CAN circuit Low side #2-#1 #1-#4 -
and power supply
circuit for each unit
Discontinuity check High side #3-#4 #2-#3 -
between CAN circuit Low side #2-#4 #1-#3 -
and ground circuit for
each unit
Discontinuity check #3-#2 #2-#1 #A-#B
between CAN (high)
circuit and CAN (low)
circuit for each unit

TTNEM50-EN-01(20181109) T5-5-88
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Connector (Harness end)

 CC24B

90Z7B-05-CC24B

 Thermistor (SCR/DOC)
 NOx Sensor (SCR/DOC)

90Z7B-05-05-CN02

 DEF Tank Sensor

90Z7B-05-DEF

 CAN Terminator

90Z7B-05-CAN

TTNEM50-EN-01(20181109) T5-5-89
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

(Blank)

TTNEM50-EN-01(20181109) T5-5-90
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111008, 111010, 111014,

111025
Monitor Controller (Monitor) Fault Codes
113004, 113006, 113007
Preparation
 Check the wiring connections first.
 Check the CAN2 harness between the controllers.
(Refer to CAN2 Harness Check.)

Fault Code Trouble Inspection Method Cause

111008-2 (MC) IC Communication Error 2 Continuity check (open circuit) Open circuit in wire harness

Discontinuity check Short circuit in wire harness

111010-2 (MC) Monitor Controller Continuity check (open circuit) Open circuit in wire harness
Communication Error 2
Discontinuity check Short circuit in wire harness

111014-2 (MC) Air Conditioner Controller Continuity check (open circuit) Open circuit in wire harness
Communication Error
Discontinuity check Short circuit in wire harness

111025-2 (MC) Column Monitor Continuity check (open circuit) Open circuit in wire harness
Communication Error
Discontinuity check Short circuit in wire harness

113004-2 (Monitor Controller) Main Continuity check (open circuit) Open circuit in wire harness
Controller Communication Error
2 Discontinuity check Short circuit in wire harness

113006-2 (Monitor Controller) ICF Continuity check (open circuit) Open circuit in wire harness
Communication Error 2
Discontinuity check Short circuit in wire harness

113007-2 (Monitor Controller) Column Continuity check (open circuit) Open circuit in wire harness
Controller Communication Error
Discontinuity check Short circuit in wire harness

fNOTE: IC and ICF stand for the information control unit

of the monitor controller.

TTNEM50-EN-01(20181109) T5-5-91
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

CAN2 Harness Check

Preparation
 Before continuity check, set the key switch to the
OFF position.

Evaluation

Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Open circuit
(open circuit)
Discontinuity check Shorted circuit Correct
(shorted circuit)

Inspection CAN Harness MC Monitor Controller Column Display Air Conditioner

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

TTNEM50-EN-01(20181109) T5-5-92
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Inspection CAN Harness MC Monitor Controller Column Display Air Conditioner

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

Discontinuity check - #D4-#D5 #A26-#A25 #1-8-#1-9 #A10(A/C2)-#A11(A/C2)

between CAN (High
side) circuit and CAN
(Low side) circuit in
each controller

TTNEM50-EN-01(20181109) T5-5-93
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Connector (Wire harness end)

 MC-D Connector  Monitor Controller-A Connector

85Z7BTT05-05-05

85Z7BTT05-05-02

 Monitor Controller-B Connector

 MC-E Connector

85Z7BTT05-05-06

85Z7BTT05-05-03

 A/C1 Connector
 MC-F Connector

TNED-05-05-018

 A/C2 Connector
85Z7BTT05-05-04

 Column Display Controller 1 Connector

TNED-05-05-019

TNEK-05-05-004

 Column Display Controller 2 Connector

TNEK-05-05-013

TTNEM50-EN-01(20181109) T5-5-94
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111100

Preparation
 Check the wiring connections first.
 The actual engine speed which ECM sends by using
the CAN bus line might be abnormal.
Diagnose ECM.
 The engine speed which TCU sends by using the CAN
bus line might be abnormal. Diagnose TCU.

Fault Code Trouble Cause

111100-2 Abnormal Engine Speed Engine speed is over 4000 min-1, or engine
speed (TCU) is 500 min-1 with engine speed
(ECM) is less than 500 min-1

TTNEM50-EN-01(20181109) T5-5-95
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111103, 111106, 111107

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111103-3 Accelerator 1 Measure resistance between 0 Ω YES: Short circuit in wire harness
Pedal Circuit #1 and #2 of accelerator between #1 and #2
High Input pedal sensor end. NO: Faulty accelerator pedal sensor

111103-4 Accelerator 1 Measure voltage between Less than YES: Open circuit in wire harness #2
Pedal Circuit wire harness end #2 of 0.25 V
Low Input accelerator pedal sensor NO: Go to Procedure No. 2.
and the body.

2 Measure voltage between Less than YES: Open circuit in wire harness #1
wire harness end #1 and #6 0.25 V
of accelerator pedal sensor. NO: Faulty accelerator pedal

111106-3 Abnormal 1 Measure resistance 0Ω YES: Shorted circuit in harness #2

Accelerator between accelerator pedal and #5.
Pedal 2 Circuit sensor end #2 and #5. NO: Faulty accelerator pedal sensor
High Input

111106-4 Abnormal 1 Measure voltage between Less than YES: Open circuit in rear console
Accelerator accelerator pedal sensor 0.25 V harness #2 (power supply line).
Pedal 2 Circuit connector pins #2 and #6. NO: Faulty accelerator pedal
Low Input

2 Measure resistance ∞Ω YES: Open circuit in rear console

between accelerator pedal harness #5 (signal 2 line).
sensor connector pins #5 NO: Faulty accelerator pedal
and MC-D connector #D25.

111107-2 Accelerator 1 Voltage difference between Engine YES: Check the wire harness.
pedal sensor #1 and #2 of accelerator speed is
correlation pedal sensor end: over 0.5 V fixed to NO: Replace the accelerator pedal.
diagnosis 1100 min .
-1

Connector (Wire harness end)

 Accelerator Pedal Sensor Connector (Rear Console
Cable Assy)
Accelerator pedal
2 sensor connector

6
90Z7B-05-CN01

fNOTE: P: 5 V power supply

S: Signal
G: Ground (chassis)
S2: Signal 2
85Z7BTT05-05-13

TTNEM50-EN-01(20181109) T5-5-96
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111205, 111207

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111205-3 Lift Arm Angle 1 Measure resistance 0Ω YES: Short circuit in wire harness
Sensor Circuit between lift arm angle between #1 and #2
High Input sensor end #1 and #2. NO: Open circuit lift arm angle
sensor
111205-4 Lift Arm Angle 1 Measure voltage Less than YES: Open circuit in wire harness #1
Sensor Circuit between lift arm angle 0.25 V NO: Go to Procedure No. 2.
Low Input sensor harness end #1
and chassis.
2 Measure voltage Less than YES: Open circuit in wire harness #3
between wire harness 0.25 V NO: Faulty lift arm angle sensor
end #1 and #3 of
accelerator pedal sensor.
111207-3 Refrigerant 1 Measure resistance 0Ω YES: Short circuit in wire harness
Pressure Circuit between refrigerant between #1 and #2
High Input pressure sensor end #1 NO: Open circuit refrigerant
and #2. pressure sensor
111207-4 Refrigerant 1 Measure voltage Less than YES: Open circuit in wire harness #1
Pressure Sensor between refrigerant 0.25 V NO: Go to Procedure No. 2.
Circuit Low pressure sensor harness
Input end #1 and chassis.
2 Measure voltage Less than YES: Open circuit in wire harness #3
between wire harness 0.25 V NO: Faulty refrigerant pressure
end #1 and #3 of sensor
accelerator pedal sensor.
Connector (Wire harness end)
 Refrigerant Pressure Sensor
 Lift Arm Angle Sensor

90Z7-05-CN05
90Z7-05-CN04

fNOTE: See p. T5-4-4 for the lift arm angle sensor

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

TTNEM50-EN-01(20181109) T5-5-97
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111200, 111202, 111203

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

Fault Code Details Procedure Inspection Method Evaluation Cause

111200-3 Lift Arm Raise 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pilot Pressure between B and the body. between #1 and #2
Sensor Circuit NO: Faulty sensor
High Input
111200-4 Lift Arm Raise 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pilot Pressure fault code NO: Go to Procedure No. 2.
Sensor Circuit 2 Measure voltage Less than YES: Open circuit in wire harness #1
Low Input between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
111202-3 Bucket Roll-In 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pilot Pressure between B and the body. between #1 and #2
Sensor Circuit NO: Faulty sensor
High Input
111202-4 Bucket Roll-In 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pilot Pressure fault code NO: Go to Procedure No. 2.
Sensor Circuit 2 Measure voltage Less than YES: Open circuit in wire harness #1
Low Input between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
111203-3 Bucket Roll-Out 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pilot Pressure between B and the body. between #1 and #2
Sensor Circuit NO: Faulty sensor
High Input
111203-4 Bucket Roll-Out 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pilot Pressure fault code NO: Go to Procedure No. 2.
Sensor Circuit 2 Measure voltage Less than YES: Open circuit in wire harness #1
Low Input between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-98
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111217, 111312

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

Fault Code Details Procedure Inspection Method Evaluation Cause

111217-3 Pilot Pressure 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Sensor Circuit between B and the between #1 and #2
High Input body. NO: Faulty sensor

111217-4 Pilot Pressure 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Sensor Circuit fault code NO: Go to Procedure No. 2.
Low Input 2 Measure voltage Less than YES: Open circuit in wire harness #1
between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
111312-3 Service Brake 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Secondary between B and the between #1 and #2
Pressure Sensor body. NO: Faulty sensor
Circuit High
Input
111312-4 Service Brake 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Secondary fault code NO: Go to Procedure No. 2.
Pressure Sensor 2 Measure voltage Less than YES: Open circuit in wire harness #1
Circuit Low between A and the 0.25 V NO: Go to Procedure No. 3.
Input body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-99
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111204

Preparation
 Check the wiring connections first.
 Connect test harness (ST 6701) and dummy sensor
equivalent to #4436271.
 Before inspection, set the key switch to the ON
position.

Fault Code Details Procedure Inspection Method Evaluation Cause

111204-3 Pump Delivery 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pressure Sensor between B and the body. between #1 and #2
Circuit High NO: Faulty sensor
Input
111204-4 Pump Delivery 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pressure Sensor fault code NO: Go to Procedure No. 2.
Circuit Low 2 Measure voltage Less than YES: Open circuit in wire harness #1
Input between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

fNOTE: The pump delivery pressure sensor is installed to

the main pump mount.

85Z7BTT05-05-12

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-100
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111206, 111208

Preparation
 Check the wiring connections first.
 Connect test harness (ST 6701) and dummy sensor
equivalent to #4436271.
 Before inspection, set the key switch to the ON
position.

Fault Code Details Procedure Inspection Method Evaluation Cause

111206-3 Hyd. Fan Circuit 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pressure Sensor between B and the between #1 and #2
Circuit High body. NO: Faulty sensor
Input
111206-4 Hyd. Fan Circuit 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pressure Sensor fault code NO: Go to Procedure No. 2.
Circuit Low
2 Measure voltage Less than YES: Open circuit in wire harness #1
Input
between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
111208-3 Emergency 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Steering Check between B and the between #1 and #2
Pressure Sensor body. NO: Faulty sensor
Circuit High
Input
111208-4 Emergency 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Steering Check fault code NO: Go to Procedure No. 2.
Pressure Sensor 2 Measure voltage Less than YES: Open circuit in wire harness #1
Circuit Low between A and the 0.25 V NO: Go to Procedure No. 3.
Input body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-101
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 111311, 111313

Preparation
 Check the wiring connections first.
 Connect test harness (ST 6701) and dummy sensor
equivalent to #4436271.
 Before inspection, set the key switch to the ON
position.

Fault Code Details Procedure Inspection Method Evaluation Cause

111311-3 Service Brake 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Primary between B and the between #1 and #2
Pressure Sensor body. NO: Faulty sensor
Circuit High
Input
111311-4 Service Brake 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Primary fault code NO: Go to Procedure No. 2.
Pressure Sensor 2 Measure voltage Less than YES: Open circuit in wire harness #1
Circuit Low between A and the 0.25 V NO: Go to Procedure No. 3.
Input body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
111313-3 Parking Brake 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Pressure Sensor between B and the between #1 and #2
Circuit High body. NO: Faulty sensor
Input
111313-4 Parking Brake 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Pressure Sensor fault code NO: Go to Procedure No. 2.
Circuit Low 2 Measure voltage Less than YES: Open circuit in wire harness #1
Input between A and the 0.25 V NO: Go to Procedure No. 3.
body.
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-102
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111410

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111410-2 Parallel/Tandem 1 Measure resistance 0/∞ Ω YES: Faulty solenoid valve (SZ)
Control P/S between solenoid valve (Specification: NO: Go to Procedure No. 2.
Valve Abnormal #1 and #2. 22±0.4 Ω)
FB 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Parallel/Tandem 0 mA YES: Open circuit in wire harness #2
Control P/S FB. NO: Short circuit in wire harness
between #1 and #2
111410-3 Parallel/Tandem 1 Measure resistance 0Ω YES: Faulty solenoid valve (SZ)
Control P/S between solenoid valve (Specification: NO: Short circuit in wire harness
Valve FB High #1 and #2. 22±0.4 Ω) between #1 and #2
Current
111410-4 Parallel/Tandem 1 Measure resistance ∞Ω YES: Faulty solenoid valve (SZ)
Control P/S between solenoid valve (Specification: NO: Go to Procedure No. 2.
Valve FB Low #1 and #2. 22±0.4 Ω)
Current 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

90Z7B-05-05-20

fNOTE: The parallel/tandem switching solenoid valve

(lift arm flow rate control solenoid valve (SZ)) is installed
to the 2-spool solenoid valve unit. (See p. T5-4-22.)

TTNEM50-EN-01(20181109) T5-5-103
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111411

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111411-2 Hydraulic 1 Measure resistance 0/∞Ω YES: Faulty solenoid valve
Fan Reverse between solenoid valve (Specification: NO: Go to Procedure No. 2.
Rotation P/S #1 and #2. 22±0.4 Ω)
Valve Abnormal 2 Measure voltage 0V YES: Open circuit in wire harness #1
FB between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Oil Pressure 0 mA YES: Open circuit in wire harness #2
Driving Fan Reverse P/S NO: Short circuit in wire harness
FB. between #1 and #2
111411-3 Hydraulic 1 Measure resistance 0Ω YES: Faulty solenoid valve
Fan Reverse between solenoid valve (Specification: NO: Short circuit in wire harness
Rotation P/S #1 and #2. 22±0.4 Ω) between #1 and #2
Valve FB High
Current
111411-4 Hydraulic 1 Measure resistance ∞Ω YES: Faulty solenoid valve
Fan Reverse between solenoid valve (Specification: NO: Go to Procedure No. 2.
Rotation P/S #1 and #2. 22±0.4 Ω)
Valve FB Low 2 Measure voltage 0V YES: Open circuit in wire harness #1
Current between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

90Z7B-05-05-20

85Z7BTT05-05-09

fNOTE: The fan reverse control solenoid valve is installed

to the fan control valve. (Refer to F&S S/M p. T3-3-4 Fan
Valve.)

TTNEM50-EN-01(20181109) T5-5-104
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111412

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111412-2 Hyd. Fan P/S 1 Measure resistance 0/∞Ω YES: Faulty solenoid valve
Valve Abnormal between solenoid valve (Specification:
FB #1 and #2. 22.3±0.4 Ω) NO: Go to Procedure No. 2.

2 Measure voltage 0V YES: Open circuit in wire harness #1

between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Oil Pressure 0 mA YES: Open circuit in wire harness #2
Driving Fan Control P/S NO: Short circuit in wire harness
FB. between #1 and #2
111412-3 Hyd. Fan P/S 1 Measure resistance 0Ω YES: Faulty solenoid valve
Valve FB High between solenoid valve (Specification: NO: Short circuit in wire harness
Current #1 and #2. 22.3±0.4 Ω) between #1 and #2
111412-4 Hyd. Fan P/S 1 Measure resistance ∞Ω YES: Faulty solenoid valve
Valve FB Low between solenoid valve (Specification:
Current #1 and #2. 22.3±0.4 Ω) NO: Go to Procedure No. 2.

2 Measure voltage 0V YES: Open circuit in wire harness #1

between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

90Z7B-05-05-20

85Z7BTT05-05-09

fNOTE: The fan reverse control solenoid valve is installed

to the fan control valve. (Refer to F&S S/M p. T3-3-4 Fan
Valve.)

TTNEM50-EN-01(20181109) T5-5-105
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111413

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111413-2 Pump Swash 1 Measure resistance 0/∞ Ω YES: Faulty solenoid valve
Angle P/S Valve between solenoid valve (Specification:
Abnormal FB #1 and #2. 10.3±0.515 Ω) NO: Go to Procedure No. 2.
2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Pump Torque 0 mA YES: Open circuit in wire harness #2
Control P/S valve output NO: Short circuit in wire harness
FB. between #1 and #2
111413-3 Pump Swash 1 Measure resistance 0Ω YES: Faulty solenoid valve
Angle P/S Valve between solenoid valve (Specification: NO: Short circuit in wire harness
FB High Current #1 and #2. 10.3±0.515 Ω) between #1 and #2
111413-4 Pump Swash 1 Measure resistance ∞Ω YES: Faulty solenoid valve
Angle P/S Valve between solenoid valve (Specification:
FB Low Current #1 and #2. 10.3±0.515 Ω) NO: Go to Procedure No. 2.
2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

90Z7B-05-05-CN05

fNOTE: The pump swash angle solenoid valve is

installed to the manifold valve. (See p. T5-4-22, #2 torque
control solenoid valve.)

TTNEM50-EN-01(20181109) T5-5-106
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111422

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111422-2 Ride Control 1 Measure resistance 0/∞ Ω YES: Faulty solenoid valve (SJ)
(Bottom) P/S between solenoid valve (Specification: NO: Go to Procedure No. 2.
Valve Abnormal #1 and #2. 22±0.4 Ω)
FB 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Ride Control 0 mA YES: Open circuit in wire harness #2
(Bottom) P/S FB. NO: Short circuit in wire harness
between #1 and #2
111422-3 Ride Control 1 Measure resistance 0Ω YES: Faulty solenoid valve (SJ)
(Bottom) P/S between solenoid valve (Specification: NO: Short circuit in wire harness
Valve FB High #1 and #2. 22±0.4 Ω) between #1 and #2
Current
111422-4 Ride Control 1 Measure resistance ∞Ω YES: Faulty solenoid valve (SJ)
(Bottom) P/S between solenoid valve (Specification: NO: Go to Procedure No. 2.
Valve FB Low #1 and #2. 22±0.4 Ω)
Current 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

90Z7B-05-05-CN01

fNOTE: The ride control solenoid valve (SJ) is installed to

the 2-spool solenoid valve unit. (See p. T5-4-22.)

TTNEM50-EN-01(20181109) T5-5-107
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111901

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111901-3 Hyd. Oil Temp 1 Measure resistance 0Ω YES: Faulty sensor
Sensor Circuit between sensor #1 and #2. NO: Go to Procedure No. 2.
High Input 2 Measure voltage between 0 V YES: Open circuit in wire harness #1
sensor harness end #1 and NO: Open circuit in wire harness #2
the body.
111901-4 Hyd. Oil Temp 1 Measure resistance ∞Ω YES: Faulty sensor
Sensor Circuit between sensor #1 and #2. NO: Short circuit in wire harness #1
Low Input and #2.

Specification of Hydraulic Oil Temperature Sensor

2
Hydraulic Oil Resistance (kΩ)
Temperature (°C (°F))
-30 (-22) (25.4)
-20 (-4) 15.04+1.29/-1.20
-10 (14) (9.16)
0 (32) (5.74)
10 (50) (3.70)
20 (68) 2.45+0.14/-0.13
30 (86) (1.66)
40 (104) (1.15) 1
50 (122) (0.811)
60 (140) (0.584) 85Z7BTT05-05-11
70 (158) (0.428)
1- Hydraulic Oil Temperature Sensor
80 (176) 0.318±0.008 2- Hydraulic Oil Level Switch
90 (194) (0.240)
100 (212) (0.1836)
110 (230) 0.1417±0.0018
120 (248) (0.1108) Connector
 Hydraulic Oil Temperature Sensor (Harness end)

90Z7-05-CN11

 Hydraulic Oil Temperature Sensor

35829-60160

TTNEM50-EN-01(20181109) T5-5-108
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Code 111902

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation Cause

111902-3 Axle Oil 1 Measure resistance 0Ω YES: Faulty sensor
Temperature between sensor #1 and #2. NO: Go to Procedure No. 2.
Sensor Circuit
High Input 2 Measure voltage between 0 V YES: Open circuit in wire harness #1
sensor harness end #1 and NO: Open circuit in wire harness #2
the body.
111902-4 Axle Oil 1 Measure resistance ∞Ω YES: Faulty sensor
Temperature between sensor #1 and #2. NO: Short circuit in wire harness #1
Sensor Circuit and #2.
Low Input

Specification of Axle Oil Temperature Sensor Connector (Harness end)

 Axle Oil Temperature Sensor
Hydraulic Oil Temperature Resistance (kΩ)
(°C (°F))
-30 (-22) 112.5
-20 (-4) 67.9
-10 (14) 42.4
90Z7-05-CN12
0 (32) 27.2
10 (50) 17.9
20 (68) 12.1
25 (77) 10 fNOTE: Axle oil temperature sensor is installed to the
30 (86) 8.3 front axle. (See p. T5-4-11.)
40 (104) 5.8
50 (122) 4.2
60 (140) 3.1
70 (158) 2.3
80 (176) 1.7
90 (194) 1.3
100 (212) 1.0
110 (230) 0.78
120 (248) 0.62
130 (266) 0.49
140 (284) 0.39
150 (302) 0.32
160 (320) 0.27
170 (338) 0.22
180 (356) 0.18

TTNEM50-EN-01(20181109) T5-5-109
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Monitor Controller (Information) Fault Code

113311

Fault Code Details Procedure Inspection Method Evaluation Cause

113311-3 Fuel Level 1 Measure resistance 0Ω YES: Faulty sensor
Sensor Circuit between sensor #1 and NO: Go to Procedure No. 2.
High Input #2.
2 Measure voltage 0V YES: Open circuit in wire harness #1
between sensor harness NO: Open circuit in wire harness #2
end #1 and the body.
113311-4 Fuel Level 1 Measure resistance ∞Ω YES: Faulty sensor
Sensor Circuit between sensor #1 and NO: Short circuit in wire harness
Low Input #2. between #1 and #2

Fuel Level Sensor

Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)

A 100 (FULL) 100-4
A
B 50 38±5
C 0 (EMPTY) 90+100

TNED-05-05-008

Connector (Wire harness end)

 Fuel Sensor Connector

90Z7B-05-05-CN05

TTNEM50-EN-01(20181109) T5-5-110
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

MC Fault Codes 120000, 120002 to 120005

Fault Code Trouble Procedure Inspection Method Evaluation Cause

120000-2 Hydraulic Oil 1 Disconnect a connector Displayed fault code YES: Faulty MC or
Overheat Alarm from the hydraulic oil short circuit in wire
temperature sensor. Retry harness
by using MPDr. NO: Faulty hydraulic
oil temperature
sensor
120002-2 Axle Oil 1 Disconnect a connector Displayed fault code YES: Faulty MC or
Temperature from the axle oil short circuit in wire
Alarm temperature sensor. Retry harness
by using MPDr. NO: Faulty axle oil
temperature sensor
120003-2 Emergency 1 Check emergency Displayed fault code YES: Faulty wire
Steering (secondary) steering check harness
Activated switch. NO: Faulty emergency
steering check switch
120004-2 Emergency 1 Disconnect a connector Displayed fault code YES: Faulty MC or
Steering from the steering pressure short circuit in wire
Activated switch. Retry by using harness
Pressure Alarm MPDr. NO: Faulty steering
pressure switch
120005-2 Transmission 1 Diagnose on fault codes - -
Oil Temperature of TCU.
Overheat Alarm

MC Fault Code 120014

Fault Code Trouble Inspection Method Evaluation Cause

120014-2 Overrun Alarm Diagnose on fault codes - -
of TCU.

TTNEM50-EN-01(20181109) T5-5-111
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Monitor Controller Fault Code 115001

Fault Code Details Procedure Inspection Method Evaluation Cause

115001-2 Abnormal REG 1 Measure voltage 13 to 33.5 V YES: Faulty monitor controller
Input H Level between monitor
controller harness end NO: Go to Procedure No. 2.
#A15 and the body.
2 Measure voltage at 13 to 33.5 V YES: Open circuit in wire harness
alternator terminal L. NO: Faulty alternator
Connector (Wire harness end)
 Monitor Controller-A Connector

85Z7BTT05-05-05

TTNEM50-EN-01(20181109) T5-5-112
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

JCU Fault Codes 116003, 116004

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation: Cause

116003-3 Joystick Signal 1 Measure resistance 0Ω YES: Short circuit in wire harness
1 Voltage between lift arm angle between #2 and #3
Abnormally sensor end #2 and #3. NO: Faulty lift arm angle sensor
High
116003-4 Joystick Signal 1 Measure voltage Less than YES: Open circuit in wire harness #1
1 Voltage between lift arm angle 0.25 V NO: Go to Procedure No. 2.
Abnormally sensor harness end #1
Low and the body.
2 Measure voltage Less than YES: Open circuit in wire harness #2
between wire harness 0.25 V NO: Faulty Joystick Signal sensor
end #1 and #2 of
accelerator pedal sensor.
116004-3 Joystick Signal 1 Measure resistance 0Ω YES: Short circuit in wire harness
2 Voltage between refrigerant between #2 and #4
Abnormally pressure sensor end #2 NO: Faulty refrigerant pressure
High and #4. sensor
116004-4 Joystick Signal 1 Measure voltage Less than YES: Open circuit in wire harness #1
2 Voltage between refrigerant 0.25 V NO: Go to Procedure No. 2.
Abnormally pressure sensor harness
Low end #1 and the body.
2 Measure voltage Less than YES: Open circuit in wire harness #2
between wire harness 0.25 V NO: Faulty Joystick Signal sensor
end #1 and #2 of
accelerator pedal sensor.

Connector (Wire harness end)

 Joystick Signal Sensor

TNEK-05-08-013

1- GND 3- OUT-A
2- +5V 4- OUT-B

TTNEM50-EN-01(20181109) T5-5-113
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

JCU Fault Codes 116006, 116007, 116008

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

Fault Code Details Procedure Inspection Method Evaluation: Cause

116006-3 Right Steering 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Solenoid between B and the body. between #1 and #2
Valve Pressure NO: Faulty sensor
Sensor Voltage
Abnormally High
116006-4 Right Steering 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Solenoid fault code NO: Go to Procedure No. 2.
Valve Pressure 2 Measure voltage Less than YES: Open circuit in wire harness #1
Sensor Voltage between A and the body. 0.25 V NO: Go to Procedure No. 3.
Abnormally Low
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
116007-3 Left Steering 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Solenoid between B and the body. between #1 and #2
Valve Pressure NO: Faulty sensor
Sensor Voltage
Abnormally High
116007-4 Left Steering 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Solenoid fault code NO: Go to Procedure No. 2.
Valve Pressure 2 Measure voltage Less than YES: Open circuit in wire harness #1
Sensor Voltage between A and the body. 0.25 V NO: Go to Procedure No. 3.
Abnormally Low
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2
116008-3 Solenoid Valve 1 Measure voltage over 4.75 V YES: Short circuit in wire harness
Source Pressure: between B and the body. between #1 and #2
Pressure NO: Faulty sensor
Sensor Voltage
Abnormally High
116008-4 Solenoid Valve 1 Retry by using MPDr.. Un-displayed YES: Faulty sensor
Source Pressure: fault code NO: Go to Procedure No. 2.
Pressure 2 Measure voltage Less than YES: Open circuit in wire harness #1
Sensor Voltage between A and the body. 0.25 V NO: Go to Procedure No. 3.
Abnormally Low
3 Measure voltage Less than YES: Open circuit in wire harness #3
between A and C (GND). 0.25 V NO: Open circuit in wire harness #2

C B A

TDAA-05-06-003

TTNEM50-EN-01(20181109) T5-5-114
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

JCU Fault Code 116118

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation: Cause

116118-2 Right Steering 1 Measure resistance 0/∞ Ω YES: Faulty solenoid valve (SJ)
Solenoid Valve between solenoid valve (Specification: NO: Go to Procedure No. 2.
Abnormal #1 and #2. 22±0.4 Ω)
Feedback 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Right Steering 0 mA YES: Open circuit in wire harness #2
Solenoid Valve NO: Short circuit in wire harness
between #1 and #2
116118-3 Right Steering 1 Measure resistance 0Ω YES: Faulty solenoid valve (SJ)
Solenoid Valve between solenoid valve (Specification: NO: Short circuit in wire harness
Feedback #1 and #2. 12±1.2 Ω) between #1 and #2
Current
Abnormally
High
116118-4 Right Steering 1 Measure resistance ∞Ω YES: Faulty solenoid valve (SJ)
Solenoid Valve between solenoid valve (Specification: NO: Go to Procedure No. 2.
Feedback #1 and #2. 12±1.2 Ω)
Current 2 Measure voltage 0V YES: Open circuit in wire harness #1
Abnormally Low between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

TNED-05-05-020

TTNEM50-EN-01(20181109) T5-5-115
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

JCU Fault Code 116119

Preparation
 Check the wiring connections first.

Fault Code Details Procedure Inspection Method Evaluation: Cause

116119-2 Left Steering 1 Measure resistance 0/∞Ω YES: Faulty solenoid valve
Solenoid Valve between solenoid valve (Specification: NO: Go to Procedure No. 2.
Feedback #1 and #2. 12±1.2 Ω)
Abnormal 2 Measure voltage 0V YES: Open circuit in wire harness #1
between solenoid valve NO: Go to Procedure No. 3.
harness end #1 and the
body.
3 Monitor Oil Pressure Left 0 mA YES: Open circuit in wire harness #2
Steering Solenoid Valve NO: Short circuit in wire harness
FB. between #1 and #2
116119-3 Left Steering 1 Measure resistance 0Ω YES: Faulty solenoid valve
Solenoid Valve between solenoid valve (Specification: NO: Short circuit in wire harness
Feedback #1 and #2. 12±1.2 Ω) between #1 and #2
Current
Abnormally
High
116119-4 Left Steering 1 Measure resistance ∞Ω YES: Faulty solenoid valve
Solenoid Valve between solenoid valve (Specification: NO: Go to Procedure No. 2.
Feedback #1 and #2. 12±1.2 Ω)
Current 2 Measure voltage 0V YES: Open circuit in wire harness #1
Abnormally Low between solenoid valve NO: Open circuit in wire harness #2
harness end #1 and the
body.

Connector (Wire harness end)

 Solenoid Valve Connector

TNED-05-05-020

TTNEM50-EN-01(20181109) T5-5-116
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Monitor Controller (Monitor) Fault Code 120300

Fault Code Trouble Inspection Method Evaluation Cause

120300-2 System Failure Alarm Check the CAN harness. - Faulty CAN harness

Monitor Controller (Information) Fault Codes 120400, 120401

Fault Code Trouble Inspection Method Evaluation Cause

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

1 85Z7B-7-67-1

fNOTE: Water-in-fuel sensor (WIF sensor) (1), which

sends a signal to ECM, is installed to fuel filter (2).

TTNEM50-EN-01(20181109) T5-5-117
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Column Display Controller Fault Codes 120500 to 120504

Fault Code Trouble Procedure Inspection Method Evaluation Cause

120500-2 Overheat 1 Disconnect a connector Displayed fault code YES: Faulty column
Alarm from the overheat switch. display controller or
Retry by using MPDr. short circuit in wire
harness
NO: Faulty overheat
switch
120501-2 Engine Error 1 Diagnose on fault codes of - -
ECM.
120502-2 Engine Oil 1 Diagnose on fault codes of - -
Pressure ECM.
Alarm
120503-2 Air Cleaner 1 Disconnect a connector Displayed fault code YES: Faulty column
Restriction from air filter restriction display controller or
Alarm switch. Retry by using short circuit in wire
MPDr. harness
NO: Faulty air cleaner
restriction switch
120504-2 Hydraulic Oil 1 Disconnect a connector Displayed fault code YES: Faulty column
Level Alarm from the hydraulic oil level display controller or
switch. Retry by using short circuit in wire
MPDr. harness
NO: Faulty hydraulic
oil level switch
Connector (Wire harness end)
Hydraulic Oil Level Switch  Column Display Controller 2 Connector
1

ON level
OFF level
TNEK-05-05-013
(Standard)

2 3 4

1- Reed Switch
2- Float
3- Weight
4- Magnet
35824-60040

Liquid Gravity ON Level OFF Level

Water 1.00 9.0 mm (0.35 in) 1.0 mm (0.04 in)
or less or more
Oil 0.88 (SAE10W-40 10.5 mm (0.41 2.0 mm (0.08 in)
equivalent) in) or less or more

fNOTE: Refer to p. T5-5-108 for the switch location.

TTNEM50-EN-01(20181109) T5-5-118
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

Column Display Controller (Information) Fault Codes 120505 to 120507

Fault Code Trouble or MP Dr. Message Inspection Method Evaluation Cause

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

Connector (Harness end)

Brake Primary Pressure Sensor
 Column Display Controller 1 Connector

TNEK-05-05-004

fNOTE: Brake Primary Pressure Sensor is installed to

the brake charge valve. (Identical to the pump delivery
pressure sensor.)
fNOTE: The steering pressure switch is installed to the
steering valve. (See p. T5-4-23.)
TNED-01-02-021

Pressure Sensor Specifications (Brake Primary

Pressure)
Rated Voltage 5.0 VDC
Power Consumption Max. 10 mA
Output Voltage 0.5~4.5 V
Operation Pressure 0~34.3 MPa (0~4975 PSI)
Withstanding Pressure 49 MPa (7107 PSI)

1- Ground 35830-20060A
2- Output (Vout) 1 2 3
3- Power Source (5V) (Vin)

TTNEM50-EN-01(20181109) T5-5-119
 SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A

(Blank)

TTNEM50-EN-01(20181109) T5-5-120
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Troubleshooting B (Machine Diagnosis by

Using Trouble Symptom) Procedure

Refer to troubleshooting B procedures for diagnosis

by using trouble symptom when no fault codes are
displayed.

 Diagnosis Procedure
 Perform diagnosis by using MPDr. or the service
menu of monitor first.
 When the fault code is displayed, refer to the
troubleshooting A group and diagnose.
 In case any fault code has not been displayed by
diagnosis, perform inspection according to the
procedures in this group when diagnosing.
 On the front section pages of this group, there are
the tables indicating the relationship between
machine trouble symptoms and related parts
which may cause such trouble if failed. Start the
troubleshooting with more probable causes selected
by referring to these tables.

fNOTE: All connector images in this section are viewed

from the open end side of wire harness end.

1
2

T6L4-05-03-001
1- Harness End Connector 2- Harness

TTNEM50-EN-01(20181109) T5-6-1
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Contents of Diagnosis

Trouble Symptom

Preparation

Viewpoints for a diagnosis and contents

needing inspection beforehand are
explained.

How to Read Table

Inspection
Procedure Condition Evaluation Cause
Method
YES: (D)
1 (A) (B) (C)
NO: (E)
YES: (J)
2 (G) (H) (I)
NO: (K)

 Procedure 1, 2 Inspection order

 A, G: Inspection method for trouble cause
 B, H: Conditions for inspection
 C, I: Evaluation specification of check results
 D, E, J, K: Trouble cause for trouble symptom

Method:
1. Perform inspection according to Inspection Method (A) and Condition (B) of
Procedure (1).
2. When the results are satisfied (YES) with Evaluation (C), the trouble cause is Cause
(D).
When the results are not satisfied (NO) with Evaluation (C), go to Cause (E) or
Inspection Method (G) of Procedure (2).

TTNEM50-EN-01(20181109) T5-6-2
 SECTION 5 TROUBLESHOOTING
Group 6 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.

Parts MC (Main Controller) Accelerator Pedal (Accelerator Travel Mode Selector Switch
Pedal Sensor)
Item
Function Controls engine, pump, and valve Instructs target engine speed Shifts the travel mode into AUTO
operation. according to accelerator pedal 1, AUTO 2, and Manual modes.
depressing amount.
Symptoms Depending on trouble situations, MC holds engine speed in 1000 MC holds the travel mode in
in control control system malfunction may min-1. Manual mode.
system when differ. (The following symptoms
trouble occurs in machine operation indicates
that MC logic circuit has failed.)
Symptoms The engine speed is fixed to 1100 Same as shown above Open circuit: Travel mode is
in machine min-1. always Manual mode.
operation As pump displacement is held at Short circuit: Travel mode is
when trouble minimum, all actuator speeds are always AUTO 1 or AUTO 2 mode.
occurs slow.
Evaluation by 111000, 111001, 111002, 111003 111103, 111106, 111107 -
Fault Code
Evaluation by - MC: Demand Engine Speed MC: Travel Mode Selector Switch
Monitoring ECM: Actual Engine Speed
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-3
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Power Mode Switch Quick Power Switch Declutch Position Switch

Item
Function Turns power mode ON/OFF. Turns power mode ON/OFF. Activates or deactivates the
declutch control.
Symptoms Power mode (ON/OFF) can not Open Circuit: Even if push the Declutch control is not activated.
in control shift. switch, work mode is not shift to
system when The power mode indicator on power mode.
trouble occurs monitor is not shifted. Short circuit: The quick power
mode control is always effective.
Symptoms Same as shown above Same as shown above Although declutch position
in machine switch is turned ON, the declutch
operation indicator on monitor is not ON.
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by MC: Power Mode Switch MC: Quick Power Switch MC: Declutch Position Switch
Monitoring
Evaluation by - - -
Light Harness
Note - Quick power mode is not There are two ON positions
activated when travel is in neutral (brake pedal depressing amount
or the travel load is light. is Fully and Lightly) in the
declutch position switch.
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-4
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Fan Reverse Rotation Switch Forward/Reverse Lever

Item
Function Shifts the fan reverse rotation Shifts the clutch solenoid valves
control solenoid valve of fan of fast-forward, slow-forward, and
valve. reverse.
Symptoms Open circuit: Cooling fan does TCU holds the travel in neutral.
in control not rotate in reverse.
system when The fan reverse rotation indicator
trouble occurs on monitor is not ON. (The
indicator does not blink when
shifting.)
Short circuit: Fan reverse rotation
control is always effective.
Symptoms Same as shown above Although forward/reverse lever
in machine is operated, machine does not
operation travel forward/reverse.
when trouble The FNR indication on monitor is
occurs not shifted.
Evaluation by - TCU: 5010
Fault Code
Evaluation by - TCU: Forward/Reverse Lever (N)/
Monitoring (F)/(R)
Evaluation by - -
Light Harness
Note There are two ON positions -
(MANU and AUTO) in the fan
reverse switch.
Descriptions T2-2, 2-4 T2-2, T2-5
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-5
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Forward/Reverse Selector Switch Forward/Reverse Switch

Item
Function Selects forward/reverse lever or Shifts the clutch solenoid valves
forward/reverse switch operation of fast-forward, slow-forward, and
(Makes forward/reverse switch reverse of trans mission.
operation effective.)
Symptoms Open circuit: Even if turn ON TCU makes forward/reverse
in control the switch, the forward/reverse switch operation ineffective.
system when switch operation is ineffective.
trouble occurs Short circuit: With the forward/
reverse switch is effective
condition, the forward/reverse
switch is not in effective when
the switch is turned OFF.
Symptoms Same as shown above. Even if the switch is shifted,
in machine forward/Reverse travel direction
operation is not change.
when trouble
occurs
Evaluation by - TCU: 5040
Fault Code
Evaluation by TCU: Forward/Reverse Selector TCU: Option Forward/Reverse
Monitoring Switch Switch (N)/(F)/(R)
Evaluation by - -
Light Harness
Note The operation is effective with When forward/reverse lever
forward/reverse lever and is operated, forward/reverse
forward/reverse switch set in the selector switch operation
neutral position. becomes ineffective. (forward/
reverse lever priority)
Descriptions T2-2, T2-5 T2-2, T2-5
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-6
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Shift Switch Downshift Switch (DSS) Hold Switch

Item
Function Shifts solenoid valves of Shifts speed shift solenoid Shifts the speed shift solenoid
transmission control valve. valves of transmission and shifts valves of transmission and
down the speed range during holds the speed range during
automatic speed shift. automatic speed shift.
Symptoms When there are no output from Open circuit: The speed shift The speed shift is not held
in control shift switch, TCU holds the speed is not shifted down although although hold switch is turned
system when range in third speed with Manual downshift switch (DSS) is turned ON during automatic speed shift.
trouble occurs mode, and TCU controls the ON during automatic speed shift. The hold indication on monitor is
speed range up to third speed The shift indication on monitor is not displayed.
with AUTO 1/AUTO 2 mode. not shifted.
Short circuit: The speed shift
automatically downshifts to first
speed and does not upshift.
Symptoms The speed shift is held in third Same as shown above Same as shown above
in machine speed with travel mode set in
operation Manual mode. The speed shift is
when trouble automatically changed to third
occurs speed as max. speed in AUTO 1/
AUTO 2 mode.
Evaluation by - - -
Fault Code
Evaluation by TCU: Shift Switch TCU: DSS Switch TCU: Gear Hold Switch
Monitoring
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-2, T2-5 T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-7
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Manual Regeneration Switch Ride Control Switch, Ride Control

Switch (AUTO)
Item
Function Performs manual regeneration of Shifts 2-spool solenoid valve unit
the aftertreatment device. (SJ) and activates or deactivates
the ride control.
Symptoms Open circuit: Manual Open circuit: Ride control switch
in control regeneration switch is is always OFF. Although ride
system when always OFF. Even if manual control switch is turned ON, the
trouble occurs regeneration switch is turned ride control is not activated.
ON, aftertreatment device is not Shorted circuit: Ride control
regenerated. switch is always ON.
Short circuit: Manual
regeneration switch is always ON.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - -
Fault Code
Evaluation by ECM: Manual Regeneration MC: Ride Control Switch, Ride
Monitoring Switch Control Switch (AUTO)
Evaluation by - -
Light Harness
Note - -
Descriptions T2-2 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-8
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Parking Brake Switch Front Control Lever Lock Switch Pilot Shut-Off Solenoid Valve

Item
Function Shifts parking brake solenoid Shifts pilot shut-off solenoid Opens and closes the front pilot
valve. valve. circuit.
Symptoms Although the parking brake Open circuit: Front control lever When closed: The lift arm and
in control switch is turned ON/OFF, the lock switch is always OFF. Pilot bucket are not operated. (Pilot
system when parking brake is not released/ shut-off solenoid valve is not pressure oil is not supplied to
trouble occurs applied with the engine running. shifted. The lift arm and bucket pilot valve.)
are not operated although the When open: Pilot pressure oil is
control lever is operated with the always supplied to pilot valve.
front control lever lock switch set
in UNLOCK position.
Shorted circuit: Front control
lever lock switch is always ON.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by Column Display Controller: MC: Front Control Lever Lock -
Monitoring Parking Brake Signal Output Switch
Evaluation by - - -
Light Harness
Note Although the parking brake is - -
turned OFF, the parking brake is
applied with the engine stopped.
Descriptions T2-2, T2-5 T2-4 T2-5
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-9
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Hydraulic Oil Temperature Sensor Torque Converter Oil

Temperature Sensor
Item
Function Detects hydraulic oil Detects torque converter oil
temperature. temperature.
Symptoms MC recognizes that hydraulic MC recognizes that torque
in control oil temperature is 120°C (248°F) converter oil temperature is
system when when open circuit occurs. 120°C (248°F) when open circuit
trouble occurs (Hydraulic oil temperature: occurs.
120°C (248°F) is not displayed on
monitoring.)
Symptoms When hydraulic oil temperature The color of transmission oil
in machine is 0°C (32°F) or less when starting temperature on monitor is red.
operation engine, auto-warming up control The alarm sounds and indicator is
when trouble is not operated. displayed.
occurs
Evaluation by 111901 111011
Fault Code
Evaluation by MC: Hydraulic Oil Temperature TCU: Torque Converter Oil
Monitoring Temperature
Evaluation by - -
Light Harness
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-10
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts DOC Inlet Exhaust Temperature DOC Outlet Exhaust Temperature SCR Inlet Exhaust Temperature
Sensor Sensor Sensor, SCR Outlet Exhaust
Item Temperature Sensor
Function Detects exhaust temperature of Detects exhaust temperature of Detects exhaust temperature at
the inlet of DOC. the outlet of DOC. inlet and outlet of the SCR.
Symptoms ECM judges that DOC inlet ECM judges that DOC outlet ECM judges that SCR exhaust
in control exhaust temperature is 0°C (32°F). exhaust temperature is 0°C (32°F). temperature is 0°C (32°F).
system when
trouble
occurs
Symptoms Engine output power decreases. Engine output power decreases. Engine output power decreases.
in machine Aftertreatment device is not Aftertreatment device is not Aftertreatment device is not
operation regenerated. regenerated. regenerated.
when trouble
occurs
Evaluation by ECM: 4765 ECM: 4766 ECM: 4360, 4363
Fault Code
Evaluation by ECM: DOC Inlet Exhaust ECM: DOC Outlet Exhaust ECM: SCR Inlet Exhaust
Monitoring Temperature Temperature Temperature, SCR Outlet Exhaust
Temperature
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-3 T2-3 T2-3
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-11
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Pump Delivery Pressure Sensor Fan Pump Delivery Pressure Emergency (Secondary) Steering
Sensor Pump Delivery Pressure Sensor
Item
Function Detects pump delivery pressure. Detects fan pump delivery Detects emergency steering
pressure. pump delivery pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Matching control while digging is Although fan reverse rotation When the engine starts, the
in machine not activated. switch is operated, fan rotation emergency steering pump
operation direction can not change. is operated and Emergency
when trouble Steering Alarm is indicated.
occurs When the engine stops while
driving, the emergency steering
pump is normally operated.
Evaluation by 111204 111206 111208
Fault Code
Evaluation by MC: Pump Delivery Pressure MC: Hydraulic Fan Circuit Pressure MC: Emergency Steering Pump
Monitoring Delivery Pressure
Evaluation by - - -
Light Harness
Note Possible to judge if sensor or Possible to judge if sensor or Possible to judge if sensor or
harness is faulty by switching harness is faulty by switching harness is faulty by switching
pressure sensor with other pump pressure sensor with other pump pressure sensor with other pump
delivery pressure sensor. delivery pressure sensor. delivery pressure sensor.
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-12
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Steering Pressure Switch Pressure Sensor (Parking Brake Pressure Sensor (Brake Primary
Pressure) Pressure)
Item
Function Detects steering circuit pressure. Detects parking brake pressure. Detects brake pressure.
Symptoms Open circuit: Emergency steering When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control operation condition (Steering following symptoms occur. following symptoms occur.
system when pressure decreases)
trouble occurs
Symptoms Emergency steering pump is Although the parking brake The low brake oil pressure
in machine operated when the harness is is applied, the parking brake indicator is always ON.
operation broken while traveling. indicator is not ON.
when trouble The low steering oil pressure The machine does not accelerate.
occurs indicator is always ON. (with the parking brake dragging)
Evaluation by - 111313 111311
Fault Code
Evaluation by MC: Steering Pressure Switch MC: Parking Brake Pressure MC: Service Brake Primary
Monitoring Pressure
Evaluation by - - -
Light Harness
Note - Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2, T2-4 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-13
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Pressure Sensor (Brake Secondary Lift Arm Angle Sensor Pressure Sensor (Lift Arm Raise)
Pressure)
Item
Function Detects front brake pressure. Detects operation angle of the Detects lift arm raise pilot
lift arm. pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms The speed shift does not The lift arm auto leveler lower Front attachment operation
in machine automatically downshift to first kickout control is not activated. circuit selection control is not
operation speed with the travel mode set in The lift arm auto leveler height activated during combined
when trouble AUTO 1 mode. kickout control is not activated. operation of lift arm and bucket
occurs Declutch control is not activated. dump.
The ride control is not activated.
Evaluation by 111312 111205 111200
Fault Code
Evaluation by MC: Service Brake Secondary MC: Lift Arm Angle Sensor MC: Lift Arm Raise Pilot Pressure
Monitoring Pressure (For Clutch Cut Off )
Evaluation by - - -
Light Harness
Note - - Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2 T2-2 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-14
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Pressure Sensor (Bucket Dump) Pressure Sensor (Bucket Roll Pressure Sensor (Primary Pilot
Back) Pressure)
Item
Function Detects bucket dump pilot Detects bucket tilt pilot pressure. Detects pilot primary pressure.
pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Front attachment operation Front attachment operation Although front control lever lock
in machine circuit selection control is not circuit selection control is not solenoid valve is operated with
operation activated during combined activated during combined front control lever lock switch set
when trouble operation of lift arm and bucket. operation of lift arm and bucket. in the OFF (Lock) position, front
occurs control lever lock indicator is not
ON.
Evaluation by 111203 111202 111217
Fault Code
Evaluation by MC: Bucket Dump Pilot Pressure MC: Bucket Tilt Pilot Pressure MC: Pilot Primary Pressure
Monitoring
Evaluation by - - -
Light Harness
Note Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
Descriptions T2-2, T2-4 T2-2, T2-4 T2-2, T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-15
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Torque Converter Input Speed Torque Converter Output Speed Transmission Intermediate Shaft
Sensor Sensor Speed Sensor
Item
Function Detects the torque converter Detects the torque converter Detects the transmission
input shaft speed. output shaft speed. intermediate shaft speed.
Symptoms When abnormality is detected, When abnormality is detected, When abnormality is detected,
in control output from the sensor becomes output from the sensor becomes output from the sensor becomes
system when invalid. invalid. invalid.
trouble occurs
Symptoms The speed change feeling The speed change feeling Nothing special.
in machine becomes bad extremely during becomes bad extremely during
operation automatic speed shift. automatic speed shift.
when trouble Possible to judge if sensor is Possible to judge if sensor is
occurs faulty by switching sensor with faulty by switching sensor with
other sensor. other sensor.
Evaluation by TCU: 5140 TCU: 5150 TCU: 5160, 5660, 5665, 5670,
Fault Code 5675, 5680, 5685
Evaluation by TCU: Actual Engine Speed TCU: Torque Converter Output -
Monitoring Shaft Speed
Evaluation by - - -
Light Harness
Note Possible to judge if speed sensor Possible to judge if speed sensor Possible to judge if speed sensor
is faulty by switching pressure is faulty by switching pressure is faulty by switching pressure
sensor with other speed sensor. sensor with other speed sensor. sensor with other speed sensor.
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-16
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Machine Speed Sensor Pressure Sensor (Refrigerant

Pressure)
Item
Function Detects transmission output Detects air conditioner
shaft speed. refrigerant pressure.
Symptoms When abnormality is detected, When output is 0 V or 5 V, the
in control the following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms The speed meter continues to The fan speed is fixed to the
in machine display 0 km/h (0 mph). maximum.
operation The overrun alarm control is not The fan reverse rotation control is
when trouble effective. not activated.
occurs The ride control is not activated.
Evaluation by TCU: 5170 111207
Fault Code
Evaluation by MC: Vehicle Speed Pulse MC: Air Conditioner Refrigerant
Monitoring Pressure
Evaluation by - -
Light Harness
Note Possible to judge if speed sensor -
is faulty by switching pressure
sensor with other speed sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-17
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts 2-Spool Solenoid Valve Unit (SJ) 2-Spool Solenoid Valve Unit (SZ)

Item
Function Shifts ride control spool of the Shifts the selector valve of the lift
control valve. arm flow rate control valve.
Limits flow rate to the lift arm
cylinder during combined
operation of lift arm raise and
bucket.
Symptoms High current: The ride control is High current: Lift arm speed
in control always activated. becomes slow as the lift arm flow
system when Low current: The ride control is rate control valve (selector valve)
trouble occurs not activated. is always restricted.
Low current: The bucket
operation is not smooth during
combined operation of lift arm
and bucket as the lift arm flow
rate control valve (selector valve)
is always open.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 111422 111410
Fault Code
Evaluation by MC: Ride Control Solenoid Valve MC: Parallel/Tandem Control
Monitoring Output, Ride Control Solenoid Solenoid Valve Output, Parallel/
Valve Output FB Tandem Control Solenoid Valve
Output Feedback
Evaluation by Install light harness (ST 7226). Install light harness (ST 7226).
Light Harness Check output signals from MC Check output signals from MC
and harness condition. and harness condition.
Note - -
Descriptions T2-2, 2-4 T2-2, 2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-18
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Parking Brake Solenoid Valve Pump Torque Control Solenoid

Valve
Item
Function Applies and releases parking Supplies control pressure to the
brake by using pilot pressure oil. main pump.
Symptoms When closed: The parking brake High current: Pump torque of
in control is not released. (Pilot pressure oil main pump is kept maximum.
system when is not supplied to parking brake.)) The engine stalls or engine
trouble occurs When open: The parking brake lug-down is remarkable at high
is released. (Pilot pressure oil is loaded.
supplied to parking brake.) Low current: Pump torque of
main pump is kept minimum and
machine movement becomes
slow.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - 111413
Fault Code
Evaluation by - MC: Pump Swash Angle Solenoid
Monitoring Valve Output, Pump Swash Angle
Solenoid Valve Output FB
Evaluation by - -
Light Harness
Note - -
Descriptions T2-2, 2-4 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-19
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Fan Speed Control Solenoid Valve Fan Reverse Rotation Control
Solenoid Valve
Item
Function Controls fan rotation speed. Shifts fan reverse rotation spool
of the fan valve.
Symptoms High current: The fan speed is High current: The fan always
in control fixed to the minimum. rotates in reverse.
system when Low current: The fan speed is Low current: The fan does not
trouble occurs fixed to the maximum. rotate in reverse.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 111412 111411
Fault Code
Evaluation by MC: Oil Pressure Driving Fan MC: Oil Pressure Driving Fan
Monitoring Solenoid Valve Output, Oil Reverse Solenoid Valve Output,
Pressure Driving Fan Solenoid Oil Pressure Driving Fan Reverse
Valve Output Feedback Solenoid Valve Output Feedback
Evaluation by - -
Light Harness
Note - -
Descriptions T2-2, 2-4 T2-2, 2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-20
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Fast-Forward/Slow-Forward/ Speed Shift Solenoid Valves (1,

Reverse Clutch Solenoid Valves 2, 3)
Item
Function Engage/disengage the fast- Engage/disengage the speed
forward clutch, slow-forward clutches (1, 2, 3) of transmission.
clutch, and reverse clutch of
transmission.
Symptoms Refer to TCU Fault Code List (T5-5) Refer to TCU Fault Code List (T5-5)
in control
system when
trouble occurs
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by TCU: 5510, 5520, 5530, 5830 TCU: 5480, 5490, 5500, 5830
Fault Code
Evaluation by - -
Monitoring
Evaluation by - -
Light Harness
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-21
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Main Relief Valve (Front Overload Relief Valve Lift Arm Anti-Drift Valve
Attachment)
Item
Function Prevents pressure in main pump Prevents actuator circuit pressure
Forcibly opens check valve in
circuit from exceeding the set generated by external force from lift arm lower return circuit and
pressure when a control lever is exceeding the set pressure with lowers lift arm only when lift arm
operated. the control lever set in neutral.is lowered.
Prevents lift arm from drifting due
to oil leaks in control valve.
Symptoms If stuck in fully closed position, If stuck in fully closed position, If stuck in fully closed position, lift
in control hose of front attachment may be hose of front attachment may be arm does not lower smoothly.
system when damaged. damaged by external force. If stuck in fully open position, lift
trouble occurs If stuck in fully open position, If stuck in fully open position, arm lowers.
power is weak during digging power is weak during digging
operation. operation.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-4 T2-4 T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-22
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Bucket Anti-Drift Valve (Rod Side) Lift Arm Flow Rate Control Valve Pump Control Valve

Item
Function Prevents bucket from dumping Is shifted by pilot pressure from Supplies pressure oil from the
due to oil leaks in control valve.
2-spool solenoid valve unit (SZ). main pump to the regulator of
Restricts lift arm circuit and keeps pump device and increases/
bucket speed during combined decreases the pump delivery flow
operation of lift arm and bucket. rate.
Symptoms If stuck in fully closed position, If poppet valve or selector valve is Load is applied to the pump
in control the bucket does not dump. stuck in fully closed position, lift as the pump delivery flow rate
system when If stuck in fully open position, the arm does not move. does not decrease with the front
trouble occurs bucket dumps. If poppet valve or selector attachment control lever set in
valve is stuck in fully open neutral.
position, bucket tilt operation As pump torque increases,
is not smooth during combined acceleration is not smooth when
operation of lift arm lower and staring the vehicle. Vehicle speed
bucket tilt. does not increase. (Pump Torque
Increase)
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-4 T2-4 T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-23
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Parts Ride Control Spool (Control Valve) Fan Reversing Spool (Fan Valve) Main Relief Valve (Steering)

Item
Function Is shifted by pilot pressure from Is shifted by pilot pressure Prevents pressure in main pump
2-spool solenoid valve unit (SJ). from fan reverse rotation circuit from exceeding the set
Connects the lift arm cylinder control solenoid valve in fan pressure when a steering wheel is
bottom side circuit to the valve. Changes the fan rotation operated.
accumulator, and the hydraulic direction (in normal / reverse).
oil flows to and from the
accumulator.
Symptoms If stuck in neutral position, the If stuck in normal direction If stuck in fully closed position,
in control ride control is not activated. position, the fan always rotates in steering hose may be damaged.
system when If stuck in ride control operating normal direction. If stuck in fully open position,
trouble occurs position, digging operation is not If stuck in reverse direction steering wheel rotation speed
smooth. position, the fan always rotates in becomes slow.
reverse direction.
Overheating occurs easily.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation by - - -
Light Harness
Note - - -
Descriptions T2-4 T2-4 T2-4
of Control
(Operational
Principle
Section in
S/M)

TTNEM50-EN-01(20181109) T5-6-24
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

(Blank)

TTNEM50-EN-01(20181109) T5-6-25
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Correlation between Trouble Symptoms and

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

The marks / in this table indicate the influence to

trouble symptom.

: Related , required to check

: Related. However, in case this component fails, fault
code is displayed, or other trouble symptom will be
more noticeable. Thus this component will not be the
direct cause of the trouble concerned.

TTNEM50-EN-01(20181109) T5-6-26
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Engine System Troubleshooting

Trouble Symptom E-1 E-2 E-3

Starter does not rotate. Even if starter rotates, Engine starts with forward/
engine does not start. reverse lever set in the
Parts forward or reverse position.
MC
ECM  
TCU 
Monitor Controller
Monitor
Column Display Controller
MPDr.
Key Switch   
Accelerator Pedal Sensor
Forward/Reverse Lever  (Neutral) 
Forward/Reverse Selector  
Switch
Forward/Reverse Switch  (Neutral) 
Battery 
Battery Relay 
Fuse Box A  (#14)  (#1)
Fuse Box B  (#8, #10, #13)  (#8, #10, #13)  (#14)
Neutral Relay  
Starter Cut Relay 
Starter Relay 1 
ECM Main Relay  
Fuel Pump Relay 
Starter 
Engine Unit 
Coolant Temperature Sensor
Glow Plug (Heater) Relay
Glow Plug (Heater)
Pump Delivery Pressure Sensor
Remark

TTNEM50-EN-01(20181109) T5-6-27
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom E-4 E-5 E-6

Power mode is not shifted Even if key switch is turned Auto shut-down (idling stop)
when is set in the ON OFF, engine does not stop. is not activated.
Parts position. power mode
switch.
MC   
ECM  
TCU
Monitor Controller  
Monitor  
Column Display Controller
MPDr.   (Setup)
Key Switch  
Accelerator Pedal Sensor 
Power Mode Switch 
Parking Brake Switch 
Forward/Reverse Lever  (Neutral)
Forward/Reverse Selector 
Switch
Forward/Reverse Switch  (Neutral)
Manual Regeneration Switch 
Battery 
Battery Relay  
Fuse Box A
Fuse Box B  (#8, #13)
Key Switch ON Cut Relay 
ACC Cut Relay 
Auto Shut-Down Relay 
Starter Relay 1
ECM Main Relay  
Fuel Pump Relay 
Starter
Engine Unit
Coolant Temperature Sensor
Pump Delivery Pressure Sensor
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Parking Brake) 
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-28
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

All Actuator System Troubleshooting

Trouble Symptom A-1 A-2

Only actuators of the front Actuator speed of front
attachment do not work. attachment and steering are
Parts slow.
MC 
Battery
Fuse Box B  (#16)
Pilot Shut-Off Relay 
Front Control Lever Lock Switch 
Power Mode Switch 
Pilot Pump  
Brake Charge Valve 
Priority Valve (Brake)  
Pilot Relief Valve (Brake)
Manifold Valve 
Pilot Relief Valve  
Torque Control Solenoid Valve 
Pilot Shut-Off Solenoid Valve  
Pilot Valve  
Pressure Sensor (Primary Pilot  
Pressure)
Flow Regulator Valve
Pressure Sensor (Lift Arm Raise) 
Pressure Sensor (Bucket Dump) 
Pressure Sensor (Bucket Tilt) 
Spool (Control Valve)  
Main Relief Valve (Front 
Attachment)
Pump Control Valve 
Cylinder
Main Pump 
Pump Delivery Pressure Sensor 
Priority Valve 
Pump Regulator 
Pilot Filter 
Remark

TTNEM50-EN-01(20181109) T5-6-29
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom A-3

Actuator of front attachment
does not stop even if a
Parts control lever is set to neutral.
MC
ECM
TCU
Monitor Controller
Monitor
Key Switch
Accelerator Pedal Sensor
Forward/Reverse Lever
Forward/Reverse Selector
Switch
Forward/Reverse Switch
Pilot Shut-Off Relay
Front Control Lever Lock Switch
Manual Regeneration Switch
Battery
Engine Unit
Crank Revolution Sensor
Cam Angle Sensor
Coolant Temperature Sensor
Exhaust Temperature Sensor
Main Pump
Pilot Pump
Pump Regulator
Pump Delivery Pressure Sensor
Manifold Valve
Torque Control Solenoid Valve
Pilot Shut-Off Solenoid Valve
Pressure Sensor (Primary Pilot
Pressure)
Pilot Valve 
Control Valve 
Ride Control Spool (Control
Valve)
Pilot Filter
Pilot Relief Valve
Hydraulic Oil Temperature
Sensor
Torque Converter Oil
Temperature Sensor
Pressure Sensor (Parking Brake)
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-30
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom A-4 A-5

Fan speed does not change. Fan does not rotate in
reverse when fan reverse
Parts rotation switch is set in the
ON or AUTO position.
MC  
ECM 
TCU
Monitor Controller
Monitor
MPDr. 
Key Switch
Accelerator Pedal Sensor
Power Mode Switch
Fan Reversing Switch 
Battery
Fuse Box A
Fuse Box B
Fan Valve  
Fan Speed Control Solenoid 
Valve
Fan Reverse speed Control 
Solenoid Valve
Fan Control Valve  
Fan Motor  
Fan Pump  
Engine Unit
Crank Speed Sensor
Cam Angle Sensor
Coolant Temperature Sensor 
Boost Temperature Sensor 
Fan Pump Delivery Pressure  
Sensor
Hydraulic Oil Temperature 
Sensor
Torque Converter Oil 
Temperature Sensor
Pressure Sensor (Refrigerant 
Pressure)
Pressure Sensor (Parking Brake) 
Remark

TTNEM50-EN-01(20181109) T5-6-31
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Front Attachment System Troubleshooting

Trouble Symptom F-1 F-2

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

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-32
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom F-3 F-4

Front attachment drifts Shock is large when
remarkably. stopping lift arm raise/
Parts lower operation or dumping
bucket.
MC
Monitor Controller
Monitor
Lift Arm Angle Sensor
Pilot Pump
Brake Charge Valve
Manifold Valve
Pilot Valve  
Shockless Valve (Flow Regulator  (Lift Arm Raise)
Valve)
Shockless Valve (Flow Regulator  (Lift Arm Lower)
Valve)
Restriction Valve (Flow  (Bucket Dump)
Regulator Valve)
Pressure Sensor (Lift Arm Raise) 
Pressure Sensor (Bucket Dump) 
Pressure Sensor (Bucket Tilt)
Spool (Control Valve)  
Lift Arm Anti-Drift Valve 
(Control Valve)
Bucket Anti-Drift Valve (Control 
Valve)
Load Check Valve (Control 
Valve)
Cylinder 
Main Pump
Remark with the engine stopped

TTNEM50-EN-01(20181109) T5-6-33
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom F-5 F-6

Bucket auto leveler control is Lift arm float control is not
not activated. (Detent is not activated. (Detent is not
Parts held.) held.)
MC 
Monitor Controller 
Monitor
Battery
Battery Relay
Fuse Box B  (#16)  (#16)
Lift Arm Angle Sensor 
Bucket Proximity Switch 
Pilot Pump
Brake Charge Valve
Manifold Valve
Pilot Valve  (Bucket)  (Lift Arm)
Flow Regulator Valve
Spool (Control Valve)  (Bucket)  (Lift Arm)
Cylinder
Main Pump
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-34
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom F-7 F-8 F-9

The lift arm auto leveler The lift arm auto leveler The ride control is not
height kickout control is not lower kickout control is not activated.
Parts activated. activated.
MC   
TCU
Monitor Controller
Monitor  (Setting: ON)  (Setting: ON)  (Setting: ON)
MPDr. 
Fuse Box B  (#16)  (#16)
Lift Arm Angle Sensor   
Machine Speed Sensor 
Ride Control Switch 
Pilot Pump
Brake Charge Valve
Pilot Shut-Off Solenoid Valve
(Manifold Valve)
Pilot Valve  (Lift Arm)  (Lift Arm)
Lift Arm Raise Side Coil (Pilot 
Valve)
Lift Arm Lower Side Coil (Pilot 
Valve)
Pressure Sensor (Primary Pilot
Pressure)
Flow Regulator Valve
Pressure Sensor (Lift Arm Raise) 
Pressure Sensor (Bucket Dump)
Pressure Sensor (Bucket Tilt)
2-Spool Solenoid Valve Unit (SJ) 
Spool (Control Valve)  (Lift Arm)  (Lift Arm)  (Ride Control Spool)
Cylinder  (Lift Arm)
Accumulator (Ride Control) 
Main Pump
Pump Delivery Pressure Sensor 
Remark

TTNEM50-EN-01(20181109) T5-6-35
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Steering System Troubleshooting

Trouble Symptom S-1 S-2 S-3

Steering operation power is Steering operation speed is Shock of steering operation
Parts weak. slow. is large.
MC 
Pilot Pump  
Priority Valve (Brake Charge 
Valve)
Pilot Relief Valve (Brake Charge 
Valve)
Pilot Relief Valve (Manifold 
Valve)
Torque Control Solenoid Valve  
(Manifold Valve)
Steering Pilot Valve (Steering  
Wheel)
Pressure Sensor (Primary Pilot  
Pressure)
Stop Valve (Left, Right)  
Steering Valve (Spool)    (Orifice)
Overload Relief Valve (Steering
Valve)
Steering Pressure Switch 
Steering Cylinder (Left, Right)  
Steering Accumulator 
Main Pump  
Steering Relief Valve (Pump  
Device)
Pump Delivery Pressure Sensor 
Priority Valve (Pump Device)   
Pump Regulator 
Pilot Filter 
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-36
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom S-4

Emergency steering is
not operated. (Automatic
Parts operation check when the
engine starts)
MC 
TCU
Monitor Controller
Monitor  (Setup)
MPDr. 
Battery
Fuse Box B  (#20)
Emergency Steering Relay 
Machine Speed Sensor 
Pilot Pump
Brake Charge Valve
Manifold Valve
Steering Pilot Valve (Steering
Wheel)
Stop Valve (Left, Right)
Spool (Steering Valve)
Steering Pressure Switch 
Emergency Steering Pump 
Delivery Pressure Sensor
Steering Cylinder (Left, Right)
Steering Accumulator
Main Pump
Emergency Steering Motor 
Emergency Steering Pump 
Remark

TTNEM50-EN-01(20181109) T5-6-37
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Travel System Troubleshooting

Trouble Symptom T-1 T-2 T-3

Although forward/reverse Although forward/reverse Declutch control is
lever is operated, machine lever is set to neutral inoperable.
Parts does not travel forward/ position, machine travels.
reverse.
MC 
TCU   
Monitor Controller
Monitor 
Battery
Fuse Box B  (#9, #14)  (#9, #14)  (#9, #14)
Accelerator Pedal Sensor
Brake Pedal (Right) Switch
Brake Valve 
Forward/Reverse Lever  (Forward/Reverse)  (Neutral)  (Forward)
Forward/Reverse Selector  
Switch
Forward/Reverse Switch  
Declutch Position Switch 
Drive Unit   
Transmission Control Valve   
Torque Converter Input Speed 
Sensor
Torque Converter Output Speed 
Sensor
Transmission Intermediate Shaft
Speed Sensor
Machine Speed Sensor 
Slow-Speed Forward Clutch   
Solenoid Valve (Y5)
Fast-Speed Forward Clutch   
Solenoid Valve (Y1)
Reverse Clutch Solenoid Valve  
(Y2)
Propeller Shaft 
Axle 
Pressure Sensor (Brake 
Secondary Pressure)
Pressure Sensor (Parking Brake) 
Remark Neutral Control

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-38
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom T-4 T-5 T-6

Travel mode can not be Although shift switch is Although machine speed
selected. operated, transmission does changes, transmission
Parts not shift. will not shift change
automatically.
MC  
TCU  
Monitor Controller
Monitor
Battery
Fuse Box B  (#9, #14)
Brake Pedal (Right) Switch
Travel Mode Selector Switch   (Manual Mode)  (AUTO 1/AUTO 2 Mode)
Shift Switch 
Power Mode Switch 
Drive Unit  
Transmission Control Valve  
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Transmission Intermediate Shaft
Speed Sensor
Machine Speed Sensor  
Speed Shift Solenoid Valve (Y3,  
Y4, and Y6)
Pressure Sensor (Brake
Secondary Pressure)
Remark Manual Speed Shift Control Automatic Speed Shift Control

TTNEM50-EN-01(20181109) T5-6-39
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom T-7 T-8 T-9

Transmission does not Selected gear is not held Speed shift retard control is
downshift when pushing when pushing hold switch. not activated.
Parts downshift switch (DSS).
MC 
TCU   
Monitor Controller 
Monitor
Key Switch  (ON)
Battery 
Fuse Box A
Fuse Box B  (#9, #14)  (#9, #14)
Accelerator Pedal Sensor
Brake Pedal (Right) Switch
Travel Mode Selector Switch 
Power Mode Switch 
Forward/Reverse Lever 
Forward/Reverse Selector 
Switch
Forward/Reverse Switch 
Shift Switch
Downshift Switch (DSS) 
Hold Switch 
Drive Unit   
Transmission Control Valve   
Torque Converter Input Speed  
Sensor
Torque Converter Output Speed  
Sensor
Transmission Intermediate Shaft
Speed Sensor
Machine Speed Sensor   
Speed Shift Solenoid Valve   
Transmission Oil Filter
Transmission Oil Filter
Restriction Switch
Pressure Sensor (Parking Brake)
Lift Arm Angle Sensor 
Pressure Sensor (Lift Arm Raise) 
Pressure Sensor (Bucket Dump) 
Remark During automatic speed shift: During automatic speed shift:
Effective Effective

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-40
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Brake System Troubleshooting

Trouble Symptom B-1 B-2 B-3

Parking brake is not released Parking brake is not applied Service brake braking force
with the engine running. with the engine running is weak.
Parts
MC
Monitor Controller
Column Display Controller
Key Switch  (ON)
Battery
Fuse Box A  (#10)  (#10)
Fuse Box B  (#14)  (#14)
Parking Brake Switch  (Released)  (Operated)
Parking Brake Relay 1  (OFF)  (ON)
Parking Brake Relay 2  (ON) 
Parking Brake Solenoid Valve  
Parking Brake  
Parking Brake Accumulator
Brake Charge Valve  
Pressure Sensor (Parking Brake)  
Pilot Relief Valve (Brake Charge  
Valve)
Pressure Sensor (Brake Primary
Pressure)
Service Brake Accumulator 
Brake Valve 
Axle (Service Brake) 
Pressure Sensor (Brake
Secondary Pressure)
Pilot Pump  
Pilot Filter  
Engine
Remark The parking brake can not be The parking brake is applied
released as the parking brake as the parking brake release
release pressure is not supplied pressure is not supplied with
with the engine stopped. the engine stopped.

TTNEM50-EN-01(20181109) T5-6-41
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Other System Troubleshooting

Trouble Symptom O-1 O-2 O-3

Clearance lights, tail lights, Headlights are not ON. Headlights are not shifted to
and license plate light are high beam.
Parts not ON.
MC
Monitor Controller
Column Display Controller  (Indicator)  (Indicator)  (Indicator)
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#2, #6)
Fuse Box B  (#2, #11, #12)  (#2)  (#2, #19)
Light Switch   
High-Low Beam Switch  
Head Light Relay (Left) 
Head Light Relay (Right) 
High Beam Relay 
Head Light   (High Beam)
Clearance Light 
Tail Light 
License Plate Light 
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-42
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom O-4 O-5 O-6

Hazard lights are not Turn signal lights are not Horn does not sound.
operated. operated.
Parts
MC
Monitor Controller
Column Display Controller  (Indicator)  (Indicator)
Key Switch  (ON)
Battery  
Fuse Box A  (#8)
Fuse Box B  (#7)  (#7)  (#6)
Hazard Light Switch 
Turn Signal Lever 
Horn Switch 
Flasher Relay  
Turn Signal Light Relay (Left)  
Turn Signal Light Relay (Right)  
Horn Relay 
Turn Signal Light (Hazard Light)  
Diode P  
Diode K  
Horn 
Remark

TTNEM50-EN-01(20181109) T5-6-43
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom O-7 O-8 O-9

Reverse buzzer does not Brake lights are not ON. Work lights are not ON.
sound.
Parts
MC
TCU 
Monitor Controller
Column Display Controller  (Indicator)
Key Switch  (ON)  (ON)  (ON)
Battery
Fuse Box A  (#7)  (#8)  (#5)
Fuse Box B  (#13)  (#2, #17)
Forward/Reverse Lever  (R)
Forward/Reverse Selector
Switch
Forward/Reverse Switch  (R)
Brake Light Switch (Brake Pedal) 
Light Switch 
Work Light Switch 
Back Buzzer Relay 
Brake Light Relay 
Work Light (Front) Relay 
Work Light (Rear) Relay 
Back Buzzer 
Brake Light 
Work Light 
Remark

: Check required : Related

TTNEM50-EN-01(20181109) T5-6-44
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Trouble Symptom O-10 O-11 O-12

Wiper is not operated. Washer is not operated. Cab light is not ON.

Parts
MC
Monitor Controller
Column Display Controller 
Key Switch  (ON)  (ON)
Battery 
Fuse Box A  (#4)  (#4)
Fuse Box B  (#18)  (#18)  (#3)
Front Wiper/ Washer Switch  
Rear Wiper/ Washer Switch  
Cab Light Switch 
Rear Cab Light Switch 
Door Open/Close Switch (Cab) 
Front Wiper Relay 1 
Front Wiper Relay 2  (Fast Speed)
Rear Wiper Relay 
Front Washer Relay 
Rear Washer Relay 
Front Wiper Motor 
Rear Wiper Motor 
Front Washer Motor 
Rear Washer Motor 
Remark

TTNEM50-EN-01(20181109) T5-6-45
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Engine System Troubleshooting

E-1 Starter does not rotate.

Preparation
 Check that the forward/reverse lever is in the neutral  In case the radio with the key switch set in the ACC
position. position and the horn with the key switch set in the
 Check the wiring connections first. OFF position are operated normally, the harness
 Check that #14 fuse in fuse box A is not abnormal. between battery and key switch terminal B is
 Check that #8, #10, #13 fuses in fuse box B are not considered normal.
abnormal.  This trouble has nothing to do with the electronic
 Check that fusible link (70 A) is not abnormal. control system such as Main Controller (MC).

Procedure Inspection Method Condition Evaluation Cause

1 Measure battery voltage - The measured values are Faulty battery
and electrolyte density out of normal range
(Normal range: Voltage:
24 V or more, Electrolyte
density: 1.26 or more)
2 Measure voltage between - 0V Open circuit in harness
key switch harness end between battery and key
#4 and chassis switch
3 Check continuity Key switch: START ∞Ω Faulty key switch
between key switch
connector #4 and #6, #4
and #1
4 Replace the neutral relay Set the key switch to Starter: Rotating Faulty neutral relay
with other general relay START after replacing
relays
5 Measure voltage between Key switch: START 0V Open circuit in harness
neutral relay harness end between key switch and
#3 and chassis neutral relay
6 Replace the starter cut Set the key switch to Starter: Rotating Faulty starter cut relay
relay with other general START after replacing
relay relays
7 Measure voltage between Key switch: START 0V Open circuit in harness
starter cut relay harness between neutral relay
end #3 and chassis and starter cut relay
8 Measure voltage at Key switch: START 0V Open circuit in harness
starter relay harness end between starter cut relay
terminal S and starter relay
9 Measure voltage between Key switch: ON 0V Open circuit in harness
starter cut relay harness between starter cut relay
end #1 and chassis and ECM
10 Measure voltage at Key switch: ON 0V Faulty battery relay
battery relay terminal A Open circuit in harness
between starter terminal
B and battery relay
11 Measure voltage at Key switch: START 0V Faulty starter relay
starter terminal S Open circuit in harness
between starter relay and
starter terminal C

TTNEM50-EN-01(20181109) T5-6-46
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

E-1 Starter does not rotate.

Procedure Inspection Method Condition Evaluation Cause

12 Monitor Forward/Reverse Forward/reverse lever: N OFF is displayed Faulty forward/reverse
Lever (N) lever
13 Replace the ECM main Key switch: START Starter: Rotating Faulty ECM main relay
relay
14 Replace the ECM timer Key switch: START Starter: Rotating Faulty ECM timer relay
relay with other general
relay
15 - - The above checks Faulty starter
resulted all normal.

 Relay Connector (Harness Side)  Starter Relay Connector (E/S)

95Z7BTT05-06-08

90Z7B-05-05-CN03  Key Switch Connector (Harness Side)

 Key Switch Connector (Switch Side)

90Z7B-05-05-CN06

90Z7B-05-05-CN04

TTNEM50-EN-01(20181109) T5-6-47
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

E-2 Even if starter rotates, engine does not start.

Preparation
 Check that #1 fuses in fuse box A are not abnormal.  Check that the fuel filter is not clogged.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Check cranking sound Key switch: START No cranking sound Faulty starter
2 Replace the fuel pump Key switch: START The engine starts Faulty fuel pump relay
relay with other general
relay
3 - - The check (1) above Faulty ECM or engine unit
resulted normal.

TTNEM50-EN-01(20181109) T5-6-48
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

E-3 Engine starts with forward/reverse lever set in

the positions except N.

Preparation
 Even if the key switch is set to the START position
with the forward/reverse lever set in the positions
except N (neutral), the starter does not rotate.

 Check #14 fuse in fuse box B.

 Refer to SYSTEM / Electrical System / Neutral Engine

Start Circuit (p. T2-5-12).

 Refer to SYSTEM / Hydraulic System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Check continuity Forward/reverse lever: F ∞Ω Open circuit in harness
between neutral relay or R between key switch and
harness end #1 and rear neutral relay
chassis
2 Replace the neutral relay Set the key switch to Starter: Rotating Faulty neutral relay
with other general relay START after replacing
relays
3 - - The above checks Find out cause of trouble
resulted all normal. by tracing other trouble
symptoms

 Relay Connector (Harness Side)

90Z7B-05-05-CN03

TTNEM50-EN-01(20181109) T5-6-49
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

E-4 Power mode is not activated when pushing

power mode switch.

Preparation
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Power Mode Power mode switch: ON OFF is displayed Faulty power mode
Switch switch or open circuit in
harness between power
mode switch and Main
Controller (MC)
2 - - The check (1) above Faulty MC
resulted normal

E-5 Even if key switch is turned OFF, engine does

not stop.

Preparation
 Remove 70 A fusible link and stop the engine as
emergency procedures first.

 In case other trouble symptoms occur, perform

troubleshooting of these troubles first.

 If the fault code is not displayed, the key switch may

be faulty. 1 2
85Z7B-1-126-1
 Refer to SYSTEM / Electrical System.

 Check the wiring connections first. 1- Fusible Link (70 A, 140 A)

2- Fusible Link (70 A, 120 A)

TTNEM50-EN-01(20181109) T5-6-50
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

E-6 Auto shut-down (idling-stop) is not activated.

Preparation
 Check the auto shut-down setting with the monitor
or MPDr. first.

 Refer to SYSTEM / Control System and SYSTEM /

Electrical System / Auto Shut-Down Control (p. T2-2-
88).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Replace auto shut-down - The symptom disappears Faulty auto shut-down
relay with other general relay
relay
2 Replace key switch ON - The symptom disappears Faulty key switch ON cut
cut relay with other relay
general relay
3 Replace ACC cut relay - The symptom disappears Faulty ACC cut relay
with other general relay
4 Monitor Forward/Reverse Forward/reverse lever: N F or R is displayed Faulty forward/reverse
Lever (N) lever
5 Monitor Parking Brake Parking brake switch: ON The measured value is Stuck spool in parking
Pressure Engine: Running out of the specification. brake solenoid valve
(Normal range: 10.8 ~
17.0 MPa (1567 ~ 2465
PSI))
6 Monitor Pilot Primary Front control lever lock Pressure is not detected Faulty pilot shut-off
Pressure switch: UNLOCK position circuit
7 Monitor Aftertreatment Aftertreatment device ON is displayed Faulty aftertreatment
Device Switch manual regeneration device manual
switch: OFF regeneration switch
8 Monitor Accelerator Pedal Accelerator pedal: Not 0.5 ± 0.1 V Faulty accelerator pedal
applied
9 - - The above checks Faulty Main Controller
resulted all normal (MC)

TTNEM50-EN-01(20181109) T5-6-51
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

All Actuator System Troubleshooting

A-1 Actuator of only front attachment do not
work.

Preparation
 If other function (steering) is operated normally, the  Pilot valve and multiple control valve spools are
main pump is considered to be normal. unlikely to be faulty at the same time.
Check that the main circuit pressure increases in
the neutral status. If the pressure increases to the  Refer to SYSTEM / Electrical System.
specified level, the cause of trouble may exist in the
bleed-off compensation spool.  Check the wiring connections first.

 Check that #16 fuse in fuse box B is not abnormal.

Procedure Inspection Method Condition Evaluation Cause

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

 Pilot Shut-off Solenoid Connector (Harness Side)

1 2

85Z7B-05-05-CN01

 Relay Connector (Harness Side)

TNED-01-02-013

90Z7B-05-05-CN03 1- Pilot Shut-Off (Control Lever Lock) Solenoid Valve

2- Pressure Sensor (Primary Pilot Pressure)

TTNEM50-EN-01(20181109) T5-6-52
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

A-2 Actuator speed of front attachment and

steering are slow.

Normal Range Remark

MPa (PSI)
Pilot Primary 4.8±0.3 (696±43) Accelerator pedal:
Pressure Full stroke

 If actuator speed of only front attachment is slow, the

Preparation
pilot system may be faulty (A-1) or the downstream
 The pump flow rate is minimized due to some circuit of the pilot valve may be faulty (F-2).
reasons.  If actuator speed of only steering is slow, the
 Even if speed is satisfactory, in case power is weak, downstream circuit of the steering pilot valve may
refer to the troubleshooting for faulty main relief be faulty (S-3).
valve (F-1/S-1).  Refer to SYSTEM/Hydraulic System.
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Lift Arm Raise Lift arm relief operation The measured value is Faulty pilot relief valve in
Pilot Pressure out of the specification. manifold valve
(Normal range: 3.4~4.2
MPa (493~609 PSI))
2 Monitor Pilot Primary - The measured value is Clogged pilot filter
Pressure out of the specification.
(Normal range: 4.5~5.1
MPa (653~740 PSI))
3 Disassemble and inspect - There is abnormality Faulty priority valve
the priority valve (brake) (brake) (stuck spool)
4 Measure pressure at port Accelerator pedal: Fully The measured value is Faulty priority valve
LS of priority valve (main depressed without load out of the specification. (pump device) (stuck
pump) (Control lever: Neutral) (Normal range: 1.5~3.0 spool)
MPa (218~435 PSI))
5 - - The above checks Faulty pump device
resulted all normal

TNED-05-01-003

a- Drive Unit Side b- Port LS

TTNEM50-EN-01(20181109) T5-6-53
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

A-3 Actuator of front attachment does not stop

even if a control lever is set to neutral.

Preparation
 Stuck spool in the pilot valve or stuck main spool in
the multiple control valve is suspected.

Procedure Inspection Method Condition Evaluation Cause

1 Set the front control - Actuator stops Faulty pilot valve (stuck
lever lock switch to LOCK spool)
position
2 - - Actuator does not stop. Faulty multiple control
valve (stuck spool)

TTNEM50-EN-01(20181109) T5-6-54
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

A-4 Fan speed does not change.

Preparation
 The sensors detect the conditions necessary to  Refer to SYSTEM/Control System/Fan Speed Control
operate fan speed control. Therefore, if these sensors (p. T2-2-62).
fail, fan speed control becomes ineffective.
 Accelerator pedal sensor, coolant temperature
sensor, boost temperature sensor, hydraulic
oil temperature sensor, torque converter oil
temperature sensor, and pressure sensor (refrigerant
pressure) are also engaged in the fan speed control.
However, if these sensors fail, other operating
functions will be also affected.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Target Hydraulic Engine: Running Fan speed does not Find out cause of trouble
Fan Speed change according by tracing other trouble
to accelerator pedal symptoms.
depressing amount
2 Monitor Hydraulic Fan Engine: Running Fan pump delivery Faulty fan pump
Circuit Pressure pressure does not
change according
to accelerator pedal
depressing amount
3 Disassemble and inspect the - There is abnormality Faulty fan speed control
fan speed control solenoid solenoid valve
valve
4 Disassemble and inspect the - There is abnormality Faulty fan control valve
fan control valve
5 - - The above checks Faulty fan motor
resulted all normal

1- Fan Reverse Rotation Control Solenoid Valve

85Z7BTT05-05-09 2- Fan Speed Control Solenoid Valve
3- Fan Control Valve

fNOTE: The fan speed control solenoid valve is installed

to the fan control valve. (Refer to F&S S/M p. T3-3-3 Fan
Valve.)

TTNEM50-EN-01(20181109) T5-6-55
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

A-5 Fan does not rotate in reverse when pushing

fan reverse rotation switch.

Preparation
 Refer to SYSTEM / Control System / Fan Reverse
Rotation Control (p. T2-2-64).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Fan Reversing Parking brake is applied OFF is displayed Faulty fan reverse
Switch Fan reverse rotation rotation switch
switch: ON
2 Measure resistance - 0/∞ Ω (Normal value: 22 Faulty fan reverse
between fan reverse Ω) rotation control solenoid
rotation control solenoid valve
valve connector #1 and
#2
3 Measure voltage Key switch: ON 0V Open circuit in harness
between fan reverse between fan reverse
rotation control solenoid rotation control solenoid
valve harness end #1 and valve and Main Controller
chassis (MC)
4 - - The above checks Faulty MC
resulted all normal.

Connector (Harness End)

 Fan Reverse Rotation Control Solenoid Valve

90Z7B-05-05-CN01

85Z7BTT05-05-09

1- Fan Reverse Rotation Control Solenoid Valve

2- Fan Speed Control Solenoid Valve
3- Fan Control Valve

fNOTE: The fan reverse control solenoid valve is installed

to the fan control valve. (Refer to F&S S/M p. T3-3-3 Fan
Valve.)

TTNEM50-EN-01(20181109) T5-6-56
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Front Attachment System Troubleshooting

F-1 All front attachment actuator power are weak.

Main Relief Valve Set Specification Remark

Pressure
Lift arm and bucket 29.4 to 31.3 MPa
relief operation (4264 to 4540 psi)

Preparation
 If operating speeds are extremely slow, pump control
may be faulty.
Faulty pilot system may also cause this trouble.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Pump Delivery Lift arm relief operation The measured values Faulty main relief valve
Pressure are out of the specified (readjust)
range.
2 - - The check (1) above Find out cause of trouble
resulted normal. by tracing other trouble
symptoms

1 2
85Z7BTT05-06-03

1- Main Relief Valve

2- Overload Relief Valve (Bucket Bottom Side, Roll Back)
3- Overload Relief Valve (Lift Arm Bottom Side, Raise)
4- Overload Relief Valve (Bucket Rod Side, Dump)

TTNEM50-EN-01(20181109) T5-6-57
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-2 Some cylinders are not operated or speeds

are slow.

Overload Relief Specification Remark

Valve Set Pressure
Lift Arm Raise 36.8 ± 0.5 MPa
(5338 ± 73 psi)
Bucket 32.8 ± 0.5 MPa
(4757 ± 73 psi)

Preparation
 When parking brake is released normally, the
primary pilot pressure is considered to be normal.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Bucket Roll Back Full operation of bucket The measured values Faulty pilot valve
Pilot Pressure, Bucket roll back/dump and lift are out of the specified
Dump Pilot Pressure, Lift arm raise range.
Arm Raise Pilot Pressure (Normal range: 3.4 ~ 4.2
MPa (493 ~ 609 psi))
2 Replace overload relief - Symptom is observed Faulty overload relief
valves, of which the set with the replaced relief valve
pressure are the same valve.
3 - - The above checks Faulty control valve spool
resulted all normal. (stuck)
Faulty cylinder (faulty
seal kit)
4

1 2
85Z7BTT05-06-03

1- Main Relief Valve

2- Overload Relief Valve (Bucket Bottom Side, Roll Back)
3- Overload Relief Valve (Lift Arm Bottom Side, Raise)
4- Overload Relief Valve (Bucket Rod Side, Dump)

TTNEM50-EN-01(20181109) T5-6-58
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-3 Front attachment drifts remarkably.

Procedure Inspection Method Condition Evaluation Cause

1 Set the front control lever - The symptom disappears Faulty pilot valve
lock switch to LOCK position
2 Replace the anti-drift valves - The symptom disappears Faulty anti-drift valve
(lift arm, bucket)
3 Disassemble and inspect - Abnormality found Faulty anti-drift valve housing
the anti-drift valves (lift arm,
bucket)
4 Disassemble and inspect the - Abnormality found Faulty cylinder (seal kit)
cylinder
5 - - The above checks resulted all Damaged control valve spool
normal. Broken spring
Loosened spool end

Leakage Check Within the Lift Arm Cylinder

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

2 1 3 4

A1 B1

A2 B2

Bucket Spool TNED-03-02-005

Lift Arm Spool TNED-03-02-006

1- Bucket Anti-Drift Valve 2- Bucket Anti-Drift Valve 3- Lift Arm Anti-Drift Valve 4- Lift Arm Anti-Drift Valve
(Check Valve) (Selector Valve) (Selector Valve) (Check Valve)

TTNEM50-EN-01(20181109) T5-6-59
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-4 Shock during bucket dump operation is

large when stopping lift arm raise / lower
operation.

Preparation
 Check that control levers are not abnormal first.

 The flow regulator valve may be faulty. Refer to

COMPONENT OPERATION / Others / Flow Regulator
Valve (p. T3-11-9).

 Refer to SYSTEM / Hydraulic System.

Procedure Inspection Method Condition Evaluation Cause

1 Replace the port at abnormal - Abnormality found Faulty shockless valve poppet
shockless valve with normal at corresponding port
shockless valve.
2 Disassemble and inspect the - Abnormality found Faulty shockless valve (in the
shockless valve. flow regulator valve)
3 Disassemble and inspect the - Abnormality found Faulty restriction valve in flow
restriction valve regulator valve
4 - - The above checks resulted all Stuck control valve spool, or
normal. faulty cylinder (faulty seal kit)

TTNEM50-EN-01(20181109) T5-6-60
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-5 Bucket auto leveler control is not activated.

(Detent is not held.)

Preparation
 Refer to SYSTEM / Control System / Bucket Auto
Leveler Control (p.T2-2-96).

 Check #16 fuse in fuse box B.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage between Key switch: ON 0V Open circuit in harness
pilot valve bucket roll between #16 fuse in fuse
back side coil harness box B and pilot valve
end #1 and chassis bucket roll back side coil
2 Measure resistance Bucket tilt detent control Bucket proximity switch: Faulty pilot valve bucket
between pilot valve lever operation ON: ∞ Ω roll back side coil
bucket roll back side Bucket proximity switch:
coil harness end #2 and OFF: 0 Ω
chassis.
3 Measure voltage Key switch: ON 0V Open circuit in wire
between bucket leveler harness between bucket
relay harness end #2 and proximity switch and
chassis bucket leveler relay
4 - - The above checks Faulty bucket proximity
resulted all normal. switch

Connector (Harness End)

 Bucket leveler relay connector (Harness Side)

90Z7B-05-05-CN03

TTNEM50-EN-01(20181109) T5-6-61
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-6 Lift arm float control is not activated. (Detent

is not held.)

Preparation
 Refer to SYSTEM / Control System / Lift Arm Float
Control (p.T2-2-98).

 Check #16 fuse in fuse box B.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage between pilot Key switch: ON 0V Open circuit in harness
valve lift arm lower side coil between #16 fuse in fuse
harness end #1 and chassis box B and pilot valve lift
arm lower side coil
2 Check continuity between pilot Lift arm lower control 0Ω Faulty ground in pilot
valve lift arm lower side coil lever operation valve lift arm lower side
harness end #2 and chassis coil
3 - - The above checks Faulty pilot valve lift arm
resulted all normal. lower side coil

TTNEM50-EN-01(20181109) T5-6-62
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-7 Lift arm auto leveler height kickout control is

not activated.

Preparation
 Check the lift arm auto leveler height kickout setting  Check #16 fuse in fuse box B.
with the monitor first. The activating conditions
for lift arm auto leveler height kickout control are  Check the wiring connections first.
different according to the settings.

 Refer to SYSTEM / Control System / Lift Arm Auto

Leveler Height Kickout Control (p.T2-2-82).

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage between Key switch: ON 0V Open circuit in harness
pilot valve lift arm raise side between #16 fuse in fuse
coil harness end #1 and box B and pilot valve lift arm
chassis raise side coil
2 Check continuity between Lift arm raise, 0Ω Faulty ground in pilot valve
pilot valve lift arm raise side detent control lever lift arm raise side coil
coil harness end #2 and operation
chassis
3 - - The above checks Faulty pilot valve lift arm
resulted all normal. raise side coil

TTNEM50-EN-01(20181109) T5-6-63
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-8 Lift arm auto leveler lower kickout control is

not activated.

Preparation
 Check the lift arm auto leveler lower kickout setting  Check the wiring connections first.
with the monitor first. The activating conditions  Check #16 fuse in fuse box B.
for lift arm auto leveler lower kickout control are
different according to the settings.
 Refer to SYSTEM / Control System / Lift Arm Auto
Leveler Lower Kickout Control (p.T2-2-84).

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage between Key switch: ON 0V Open circuit in harness
pilot valve lift arm lower between #16 fuse in fuse
side coil harness end #1 and box B and pilot valve lift arm
chassis lower side coil
2 Check continuity between Lift arm lower, 0Ω Faulty ground in pilot valve
pilot valve lift arm lower detent control lever lift arm lower side coil
side coil harness end #2 and operation
chassis
3 - - The above checks Faulty pilot valve lift arm
resulted all normal. lower side coil

TTNEM50-EN-01(20181109) T5-6-64
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

F-9 Ride control is not activated.

Preparation
 Check the ride control setting with the monitor or  When the parking brake is released normally, the
MPDr. first. The activating conditions for ride control primary pilot pressure is considered to be normal.
are different according to the settings.
 Check the wiring connections first.
 Refer to SYSTEM / Control System / Ride Control.

Procedure Inspection Method Condition Evaluation Cause

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

3 2

85Z7BTT05-05-10

1- 2-spool Solenoid Valve 3- Multiple Control Valve

Unit (SJ)
2- Ride Control Accumulator

TTNEM50-EN-01(20181109) T5-6-65
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Steering System Troubleshooting

S-1 Steering operation is weak.

Main Relief Valve Specification Remark

Set Pressure
Steering relief 29.4 to 31.3 MPa
operation (4264 to 4540) psi)

Preparation
 If operating speeds are extremely slow, pump control
may be faulty. Faulty pilot system may also cause this
trouble.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Pump Delivery Steering relief operation The measured values Faulty steering relief
Pressure are out of the specified valve (readjust)
range.

2 - - The check (1) above Find out cause of trouble

resulted normal. by tracing other trouble
symptoms

fNOTE: Refer to p. T4-5-14 for the steering relief pressure

measurement and adjustment.

TTNEM50-EN-01(20181109) T5-6-66
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

S-2 Steering operation is slow.

Specification Remark
Steering cylinder 2.7 ± 0.4 Accelerator pedal: Fully depressed
operation time Power mode switch: ON
(sec) Bucket: Empty

Preparation
 If speed of front attachment is also slow, the pilot  Check that the steering wheel is not abnormal first.
system or main system may be faulty (A-2).  Refer to SYSTEM / Hydraulic System.
 If the pilot system is faulty, the circuit after the
steering pilot valve may be faulty.

Procedure Inspection Method Condition Evaluation Cause

1 Measure Steering Relief - The measured value is Faulty main relief valve
Pressure out of the specification. (steering)
(Normal range: 29.4 to
31.3 MPa (4264 to 4540
PSI))
2 Measure pressure at stop Engine: Running The measured value is Faulty steering pilot valve
valves (left/right) port A Operate steering left (or out of the specification.
right) (Normal range: 4.5 to 5.1
MPa (653 to 740 PSI))
3 Measure pressure at stop Engine: Running The measured value is Faulty stop valve
valves (left/right) port B Operate steering left (or out of the specification.
right) (Normal range: 4.5 to 5.2
MPa (653 to 754 PSI))
4 - - The above checks Stuck steering valve spool
resulted all normal. or faulty steering cylinder
(faulty seal kit)

 Stop Valve
2 3

TNED-05-06-007

1- Front Side of Machine 3- Port A

2- Port B

TTNEM50-EN-01(20181109) T5-6-67
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

S-3 Shock of steering operation is large.

Preparation
 Check that the steering wheel is not abnormal first.  Set machine to driving position before checking
gas pressure in the accumulator. Stop the engine,
 The steering valve and stop valve may be faulty. operate the steering wheel, and release remaining
pressure from the accumulator.
 Refer to SYSTEM / Hydraulic System.

Procedure Inspection Method Condition Evaluation Cause

1 Disassemble and inspect the - There is abnormality Faulty stop valve
stop valve
2 Disassemble and inspect the - There is abnormality Faulty steering valve (stuck
steering valve spool, clogged orifice)
3 - - The above checks resulted all Faulty steering cylinder (faulty
normal. seal kit)

2
MNEC-07-114

1- Steering Cylinder
2- Steering Accumulator

fNOTE: Steering Accumulator Gas Pressure:

8.0 MPa (1160 PSI)

TTNEM50-EN-01(20181109) T5-6-68
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

S-4 Emergency (secondary) steering is not

operated. (Automatic operation check when the
engine starts)

Preparation
 Check the wiring connections first.
 Check the emergency steering control setting with
the monitor first.  The emergency steering check switch may be faulty
when emergency steering operation cannot be
 Refer to SYSTEM / Control System / Emergency checked manually.
Steering Control (p. T2-2-90).

 Check that #20 fuse in fuse box B is not abnormal.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Emergency Steering Engine starts The measured values are Faulty emergency steering
Pump Delivery Pressure not at the normal level (4.8 pump unit
MPa) (696 psi) or more
2 Replace emergency steering Emergency Emergency steering works Faulty emergency steering
relay (general) with other steering check normally relay (general)
general relay switch: ON
3 - - The above checks resulted Faulty main controller (MC)
all normal.

TTNEM50-EN-01(20181109) T5-6-69
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Travel System Troubleshooting

T-1 Although forward/reverse lever is operated,
machine does not travel forward/reverse.

Preparation fNOTE: If TCU error codes are accompanied,

troubleshoot them first.
 The transmission may be faulty when the
transmission warning indicator lights.

 Refer to SYSTEM / Control System / Forward/Reverse

Lever Priority Control (p. T2-2-46).

 Check the wiring connections first.

 Check that #15 fuse in fuse box B is not abnormal.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Forward/Reverse Forward/reverse OFF is displayed (0 is Faulty forward/reverse
Lever (F) or (R) lever: F, R displayed on the monitor) lever, or open circuit in wire
harness between forward/
reverse lever and TCU
2 Measure transmission clutch Forward/reverse The measured values Faulty transmission control
pressure lever: F, R are out of normal range valve
(Normal range: 1.6 ~ 1.8
MPa (232 ~ 261 psi))
3 - - The above checks resulted Faulty TCU
all normal.

TTNEM50-EN-01(20181109) T5-6-70
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-2 Although forward/reverse lever is set to

neutral position, machine travels.

Preparation
 Refer to SYSTEM / Control System / Neutral Control
(p. T2-2-44).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

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

TTNEM50-EN-01(20181109) T5-6-71
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-3 Declutch is not operated.

Declutch Position Switch Brake pedal angle: Brake pedal angle:

Lightly applied (N) Fully applied (D)
Speed Shift: 1st 1.5 MPa (218 psi) or more 3.0 MPa (435 psi) or more
Speed Shift: 2nd 0.8 MPa (115 psi) or more 2.5 MPa (363 psi) or more

Preparation
 Refer to SYSTEM / Control System / Declutch Control  When other actuator (steering) is operated normally,
(p. T2-2-56). the pilot pump (primary pilot pressure) is considered
 Check the wiring connections first. to be normal.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Declutch Declutch position OFF is displayed Faulty declutch position switch
Position Switch switch: N, D (0 is displayed on the Open circuit in harness between
monitor) declutch position switch and
main controller (MC)
2 Monitor Service Brake Brake pedal (right) The measured values are Faulty brake system (brake
Secondary Pressure operation out of the specified range valve) or faulty pressure sensor
(For Declutch) (brake secondary pressure)
3 Measure transmission - The measured value is out Faulty transmission control valve
clutch pressure of the specification.
(Normal range: Declutch: 0
to 0.3 MPa (0 to 43.5 PSI))
4 - - The above checks resulted Faulty MC
all normal.

85Z7BT01-02-13

1- Service Brake Secondary Pressure (for Declutch)

TTNEM50-EN-01(20181109) T5-6-72
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-4 Travel mode cannot be changed.

Preparation
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

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

TTNEM50-EN-01(20181109) T5-6-73
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-5 Although shift switch is operated, speed shift

does not change.

Preparation
 Check that the travel mode is Manual mode. fNOTE: If MC error codes are accompanied, troubleshoot
them first.
 Refer to SYSTEM / Control System / Manual Speed
Shift Control (p. T2-2-48).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Operate and monitor Shift switch: 2/3/4/5 The position of shift switch is Faulty shift switch or open
Shift Switch position not identical to the displayed circuit in harness between
range on monitor shift switch and TCU
2 Measure - The measured values are out Faulty transmission control
transmission clutch of the specification. valve
pressure (Normal range: Clutch ON: 1.6
to 1.8 MPa (232 to 261 PSI))
3 - - The above checks resulted all Faulty TCU
normal.

TTNEM50-EN-01(20181109) T5-6-74
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-6 Although vehicle speed changes, speed shift

does not change automatically.

Preparation fNOTE: If MC error codes are accompanied, troubleshoot

them first.
 Check that the travel mode is AUTO 1/AUTO 2 mode.

 Refer to SYSTEM / Control System / Automatic Speed

Shift Control (p. T2-2-50).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Travel Mode Driving mode switch: Manual mode is always Faulty driving mode switch
Selector Switch AUTO 1/ AUTO 2 displayed (0 is displayed on Open circuit in harness
mode the monitor). between driving mode switch
and main controller (MC)
2 Monitor Power Mode Power mode switch: OFF is displayed. Faulty power mode switch
Switch ON Open circuit in harness
between power mode switch
and MC
3 Monitor actual While driving 0 km/h or 0 mph is displayed Faulty machine speed sensor
machine speed on the speedometer. Open circuit in harness
between MC and machine
speed sensor
4 - - The check (1) above resulted Faulty MC
normal.

TTNEM50-EN-01(20181109) T5-6-75
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-7 Speed shift is not shifted down when pushing

downshift switch (DSS).

Preparation
 Check that the travel mode is AUTO 1/AUTO 2 mode.

 Refer to SYSTEM / Control System / Downshift

Control (p. T2-2-52).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor DSS Switch Downshift switch OFF is displayed Faulty downshift switch (DSS), or
(DSS): ON open circuit in wire harness between
While machine is downshift switch (DSS) and TCU
travelling
2 - - The check (1) above Faulty TCU
resulted normal.

TTNEM50-EN-01(20181109) T5-6-76
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-8 Speed shift is not held when pushing hold

switch.

Preparation
 Check that the travel mode is AUTO 1/AUTO 2 mode.

 Refer to SYSTEM / Control System / Shift Holding

Control (p. T2-2-58).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Shift Hold Hold switch: ON OFF is displayed Faulty shift hold switch
Switch Open circuit in harness
between shift hold switch and
TCU
2 - - The check (1) above resulted Faulty TCU
normal.

TTNEM50-EN-01(20181109) T5-6-77
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

T-9 Speed shift delay control is not activated.

Preparation
 Check the speed shift delay control setting with the
monitor first.

 Check the parking brake is OFF (not applied).

 Refer to SYSTEM / Control System / Speed Shift Delay

Control (p. T2-2-54).

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Forward/ Forward/reverse N is displayed Faulty forward/reverse lever
Reverse Lever (F), (R) lever: F and R Open circuit in wire harness
between forward/reverse
lever and TCU
2 Monitor Travel Mode Travel mode: AUTO Manual mode is displayed (0 Faulty driving mode switch
Selector Switch 1/AUTO 2 mode is displayed on the monitor) Open circuit in harness
between travel mode selector
switch and MC
3 Monitor Actual Travel operation Speedometer: 0 km/h (mph) Faulty machine speed sensor,
Machine Speed or open circuit in wire harness
between machine speed
sensor and monitor controller
4 Monitor Shift Switch Shift switch: Third or 1st or 2nd is displayed Faulty shift switch, or open
Fourth circuit in wire harness
between shift switch and TCU
5 - - The above checks resulted all Find out cause of trouble
normal. by tracing other trouble
symptoms

TTNEM50-EN-01(20181109) T5-6-78
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Brake System Troubleshooting

B-1 Parking brake is not released with the engine
running.

Preparation
 When steering is operated normally, the pilot pump  Check fuse #14 in fuse box B and fuse #10 in fuse box
(primary pilot pressure) is considered to be normal. A.
 Refer to SYSTEM/Electrical System.  Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Parking Parking brake The measured values Stuck spool in parking brake solenoid
brake switch. switch: ON are not within the valve
(Release) specification. (Normal
Engine: Running range: 10.8 ~ 17 MPa
(1566 ~ 2466 psi))
2 Measure voltage at Key switch: ON 0V Open circuit in wire harness between
parking brake relay 1 fuse #14 in fuse box B and parking
harness end #1 and brake relay 1 harness end #1 or #3
#3.
3 Measure resistance Parking brake ∞Ω Faulty OFF circuit between terminals
between parking switch: OFF #1 and #6 in parking brake switch, or
brake relay 1 harness open circuit in wire harness between
end #2 and chassis. parking brake relay 1 harness end #2
and parking brake switch harness end
#1, and open circuit in wire harness
between parking brake switch harness
end #6 and the ground
4 Measure voltage Key switch: ON 0V Open circuit in wire harness between
at parking brake Parking brake fuse #10 in fuse box A and parking
solenoid valve switch: OFF brake solenoid valve harness end #1
harness end #1.
5 Measure resistance - ∞Ω Open circuit in wire harness between
between parking parking brake solenoid valve harness
brake solenoid valve end #2, diode, and parking brake relay
harness end #2 and 2 harness end #3, or open circuit in
chassis. wire harness between parking brake
relay 2 harness end #5 and the ground
6 - - The above checks resulted Faulty parking brake
all normal.

Connector (Wire harness end)

 Parking Brake Relay 1
 Parking Brake Relay 2
 Parking Brake Solenoid Valve  Parking Brake Switch

90Z7B-05-05-CN03 90Z7B-05-05-CN05 85Z7BTT05-06-01

TTNEM50-EN-01(20181109) T5-6-79
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

B-2 Parking brake is not applied.

Wear amount of Specification Allowable Limit

parking brake mm (in) mm (in)
Brake Disc 2.2 (0.09) 1.9 (0.07)
Brake Friction Pad 6.0 (0.24) 4.5 (0.18)

Preparation
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Parking Brake Parking brake switch: OFF ON is displayed Faulty parking brake
Signal Output (Apply) switch
Engine: Running
2 Monitor Parking Brake Key switch: ON Pressure is detected Stuck spool in parking
Pressure Parking brake switch: OFF brake solenoid valve
3 Check the wear amount - Allowable limit or less Faulty brake disc and
of parking brake faulty brake friction pad
4 - - The above checks Faulty main controller
resulted all normal. (MC)

TTNEM50-EN-01(20181109) T5-6-80
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

B-3 Service brake function lowers.

Wear amount of Specification Allowable Limit

service brake mm (in) mm (in)
Brake Disc 6.2 (0.244) 5.3 (0.209)
Brake Ring 11.9 (0.469) 10.4 (0.409)
Brake Ring 6.5 (0.256) 6.0 (0.236)
Brake Ring 6.9 (0.272) 6.4 (0.252)

Preparation
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Service Brake - The measured value is Faulty brake charge valve
Primary Pressure out of the specification.
(Normal range: 10.8 ~
17.0 MPa (1566 ~ 2466
psi))
2 Monitor Service Brake Brake pedal: Fully The measured value is Faulty brake valve
Secondary Pressure depressed out of the specification.
(Normal range: 4.6 +0.8/-0
MPa (667 +116/-0 PSI))
3 Check the wear amount Refer to page T4-4-6. ≤ Allowable limit The wear amount of
of service brake brake disc is beyond the
allowable limit of use
4 - - The above checks Faulty service brake (in
resulted all normal. the axle)

fNOTE: The service brake primary pressure sensor is

installed to the brake charge valve (see p. T5-4-22 #6).
The service brake secondary pressure sensor is installed
to the front axle (see p. T5-4-11).

TTNEM50-EN-01(20181109) T5-6-81
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

(Blank)

TTNEM50-EN-01(20181109) T5-6-82
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Other System Troubleshooting

O-1 Clearance light, tail light, and license plate
light are not ON.

Preparation
 Check that the clearance light, tail light, and license  Failure of the clearance light indicator lighting will be
plate light are not broken first. also affected.

 Check #2 fuse in fuse box B when the clearance  Refer to SYSTEM / Electrical System.
lights, tail light, and license plate light on both sides
are not ON at the same time.  Check the wiring connections first.

 Check #11 or #12 fuse in fuse box B when only the

lights on left or right side is ON.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Lighting Light switch: Clearance OFF is displayed. Faulty lighting switch
Switch light position (or Head Open circuit in harness between
light position) light switch and fuse #11 or #12
in fuse box B
2 Measure voltage - 0V Open circuit in harness between
between light switch light switch and fuse #2 in fuse
harness end #6 and box B
chassis
3 Measure voltage Light switch: Clearance 0 V Faulty lighting switch
between chassis and light position (or Head Open circuit in harness between
fuses #11 and #12 in light position) light switch and fuse #11 or #12
fuse box B in fuse box B
4 - - The check (1) above Open circuit in harness between
resulted normal. fuse #11 or "12 in fuse box B and
clearance light/tail light/license
plate light
Faulty clearance light, tail light,
or license plate light

TTNEM50-EN-01(20181109) T5-6-83
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-2 Head light is not ON.

Preparation
 Check that the head lights are not broken first.  Check that the light switch is the head light position.

 The light switch may be faulty (O-1) or the dimmer  Refer to SYSTEM / Electrical System.
switch may be faulty when the head lights on both
sides are not ON at the same time.  Check the wiring connections first.

 Check #2 or #6 fuse in fuse box A when only the light

on right or left side is ON.

Procedure Inspection Method Condition Evaluation Cause

1 Replace head light relay Key switch: ON The head lights (left/ Faulty head light relay (left/right)
(left/right) with other Dimmer switch: Low right) are ON
general relay beam position
2 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: Low head light relay (left/right) and
relay (left/right) harness beam position light switch
end #1 and chassis Faulty dimmer switch
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: Low head light relay (left) and #6 fuse
relay (left) harness end beam position in fuse box A
#3 and chassis Faulty #6 fuse in fuse box A
4 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: Low head light (left) and head light
(left) harness end #1 beam position relay (left)
and chassis
5 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: Low head light relay (right) and #2
relay (right) harness end beam position fuse in fuse box A
#3 and chassis Faulty #2 fuse in fuse box A
6 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: Low head light (right) and head light
(right) harness end #1 beam position relay (right)
and chassis
7 - - The check (1) above Open circuit in harness between
resulted normal. head light (right/left) harness
end #3 and chassis
Faulty head light (right/left)

Connector (Harness end)

 Head Light Relay (Left/Right)  Head Light (Left/Right)

90Z7B-05-05-CN03 90Z7-05-06CN01

TTNEM50-EN-01(20181109) T5-6-84
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-3 Head light is not shifted to high beam.

Preparation
 Check #19 fuse in fuse box B when the high beams at  Failure of the high beam indicator lighting will be
both sides are not ON. also affected.

 Check that the light switch is the head light position.  Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Replace high beam Key switch: ON High beam is ON Faulty high beam relay
relay with other general Dimmer switch: High
relay beam position
2 Measure voltage Key switch: ON 0V Open circuit in harness between
between high beam Dimmer switch: High high beam relay and dimmer
relay harness end #1 beam position switch
and chassis Faulty dimmer switch
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between high beam Dimmer switch: High high beam relay and #19 fuse in
relay harness end #3 beam position fuse box B
and chassis Faulty #19 fuse in fuse box B
4 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: High head light (left) and high beam
(left) harness end #2 beam position relay
and chassis
5 Measure voltage Key switch: ON 0V Open circuit in harness between
between head light Dimmer switch: High head light (right) and high beam
(right) harness end #2 beam position relay
and chassis
6 - - The above checks Open circuit in harness between
resulted all normal. head light (right/left) harness
end #3 and chassis
Faulty head light (right/left)

Connector (Harness end)

 High Beam Relay  Head Light (Left/Right)

90Z7B-05-05-CN03 90Z7-05-06CN01

TTNEM50-EN-01(20181109) T5-6-85
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-4 Hazard light is not operated.

Preparation
 Check that the turn signal lights (hazard lights) are  Failure of blinking of the turn signal light indicators
not broken first. at both sides will be also affected.
 Check #7 fuse in fuse box B when all turn signal lights  Refer to SYSTEM / Electrical System.
do not blink at the same time.  Check the wiring connections first.
Faulty flasher relay may also cause this trouble.

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage between Key switch: OFF 0V Open circuit in harness between
hazard light switch harness hazard light switch and #7 fuse in
end #7 and chassis fuse box B
Faulty #7 fuse in fuse box B
2 Measure voltage between Key switch: OFF 0V Open circuit in harness between
flasher relay harness end #4 flasher relay and #7 fuse in fuse
and chassis box B
3 Replace turn signal light relay Hazard light Symptom is observed Faulty turn signal light relays
(left) with turn signal light switch: ON on the opposite side. (left/right)
relay (right)
4 Measure voltage between Hazard light 0V Open circuit in harness between
turn signal light relay (left/ switch: ON turn signal light relay (left/right)
right) harness end #1 and and hazard light switch
chassis Faulty diode (Flasher 1, 2)
Faulty hazard light switch
5 Measure voltage between Hazard light 0V Open circuit in harness between
turn signal light relay (left/ switch: ON turn signal light relay (left/right)
right) harness end #3 and and flasher relay
chassis Faulty flasher relay
6 Measure voltage between Hazard light 0V Open circuit in harness between
hazard lights (right front/ switch: ON hazard lights (right front/ right
right rear) harness end #530 rear) and turn signal light relay
and chassis (right)
7 Measure voltage between Hazard light 0V Open circuit in harness between
hazard lights (left front/ left switch: ON hazard lights (left front/ left rear)
rear) harness end #531 and and turn signal light relay (left)
chassis
8 - - The above checks Faulty hazard lights (left front/
resulted all normal. left rear)

Connector (Harness end)

 Turn Signal Light Relay  Hazard Light (Front)  Flasher Relay
(Left/Right)
#530
#531

90Z7-05-06CN02 90Z6-05-06-02

 Hazard Light (Rear)  Hazard Light Switch

90Z7B-05-05-CN03 #530
#531
90Z7-05-06CN03 90Z7B-05-SW1

TTNEM50-EN-01(20181109) T5-6-86
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-5 Turn signal light is not operated.

Preparation
 Check #8 fuse in fuse box A when all turn signal
lights do not blink.
fNOTE: Turn signal light circuit and hazard light circuit
are branched from the same circuit. Check the hazard
light circuit first by referring to the previous section O-4.
 Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Measure voltage Key switch: ON 0V Open circuit in harness between
between turn signal turn signal lever and #8 fuse in
lever harness end #2 and fuse box A
chassis Faulty #8 fuse in fuse box A
2 Measure voltage Key switch: ON 0V Open circuit in harness between
between turn signal Turn signal lever: Left turn signal light relay (left) and
light relay (left) harness position turn signal lever
end #1 and chassis Faulty diode (Flasher 2)
Faulty turn signal lever
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between turn signal Turn signal lever: Right turn signal light relay (right) and
light relay (right) harness position turn signal lever
end #1 and chassis Faulty diode (Flasher 1)
Faulty turn signal lever
4 - - The above checks Faulty turn signal light
resulted all normal.

Connector (Harness end)

 Turn Signal Light Relay  Turn Signal Lever
(Left/Right)

90Z7B-05-05-CN03 90Z7B-05-05-CN08

TTNEM50-EN-01(20181109) T5-6-87
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-6 Horn does not sound.

Preparation
 Check that the horn is not broken first.

 Check #6 fuse in fuse box B when the horn does not

sound by pushing two horn switches.

 Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Switch horn relay with other Horn switch: ON Horn sounds Faulty horn relay
general relay
2 Measure voltage between - 0V Open circuit in harness between
horn relay harness end #1 horn relay and #6 fuse in fuse
and chassis box B
Faulty #6 fuse in fuse box B
3 Measure voltage between Horn switch: ON 0V Open circuit in harness between
horn central connector #1 horn relay and horn central
and chassis connector
4 - - The above checks Open circuit in harness between
resulted all normal. horn and horn central connector
Faulty horn

Connector (Harness end)

 Turn Signal Light Relay  Horn Central Connector
(Left/Right)

90Z7B-05-05-CN03 90Z6-05-CN05

TTNEM50-EN-01(20181109) T5-6-88
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-7 Reverse light is not ON. Reverse buzzer does

not sound.

Preparation
 Check that the reverse light and reverse buzzer  Check that the machine drives in reverse direction
(backup lamp and alarm) are not broken first. when forward/reverse lever is in the R position.

 Check #7 fuse in fuse box A when the reverse lights  Refer to SYSTEM / Electrical System.
at both sides and reverse buzzer are not operated at
the same time.  Check the wiring connections first.
Faulty forward/reverse lever (T-1) may also cause this
trouble.

Procedure Inspection Method Condition Evaluation Cause

1 Switch reverse light/buzzer Key switch: ON Reverse light is ON Faulty reverse light/buzzer relay
relay with other general and reverse buzzer
relay sounds.
2 Measure voltage between Key switch: ON 0V Open circuit in harness between
reverse light/buzzer relay reverse light/buzzer relay and #7
harness end #3 and chassis fuse in fuse box A
Faulty #7 fuse in fuse box A
3 Measure voltage between Key switch: ON 0V Open circuit in harness between
reverse lights (left/right) Forward/reverse reverse lights (left/right) and
harness end #2 and chassis lever: R reverse light/buzzer relay
Faulty reverse light/buzzer relay
control (MC)
4 Measure voltage between Key switch: ON 0V Open circuit in harness between
reverse buzzer harness end Forward/reverse reverse buzzer and reverse light/
#1 and chassis lever: R buzzer relay
Faulty reverse light/buzzer relay
control (MC)
5 Measure voltage between Key switch: ON 0V Open circuit in harness between
reverse light/buzzer relay reverse light/buzzer relay and #13
harness end #1 and chassis fuse in fuse box B, or faulty #13
fuse
6 Measure voltage between Key switch: ON Other than 0 V Open circuit in harness between
reverse light/buzzer relay Forward/reverse reverse light/buzzer relay and MC
harness end #2 and chassis lever: R Faulty reverse light/buzzer relay
control (MC)
7 - - The above checks Faulty reverse lights (left/right)
resulted all normal. Faulty grounding

Connector (Harness end)

 Reverse Light/Buzzer Relay  Reverse Buzzer  Reverse Light (Left/Right)

90Z7-05-CN10 90Z7-05-06CN03
90Z7B-05-05-CN03

TTNEM50-EN-01(20181109) T5-6-89
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-8 Brake light is not ON.

Preparation
 Check that the brake lights are not broken first.

 Check #8 fuse in fuse box A when the brake lights at

both sides are not ON.

 Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Replace brake light Brake light switch: ON The symptom Faulty brake light relay
relay with other general (Brake pedal is applied) disappears
relay
2 Measure voltage Key switch: ON 0V Open circuit in harness between
between brake light brake light relay and #8 fuse in
relay harness end #1 or fuse box A
#3 and chassis Faulty #8 fuse in fuse box A
3 Measure voltage Brake light switch: ON 0V Open circuit in harness between
between brake light (Brake pedal is applied) brake light relay and brake light
(left/right) harness end (left/right)
#5 and chassis Faulty brake light switch
4 Check continuity Brake light switch: ON Other than 0 Ω Open circuit in harness between
between brake light (Brake pedal is applied) brake light relay and brake light
relay harness end #2 Key switch: OFF switch
and chassis Faulty brake light switch
5 - - The above checks Faulty brake light
resulted all normal. Faulty grounding

Connector (Harness end)

 Reverse Light/Buzzer Relay  Reverse Light (Left/Right)

90Z7B-05-05-CN03 90Z7-05-06CN03

TTNEM50-EN-01(20181109) T5-6-90
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-9 Work light does not light.

Preparation
 Check that the work lights are not broken first.  The work light indicator may not turn ON.

 The light switch may be faulty (O-1) or #2 fuse in fuse  Refer to SYSTEM / Electrical System.
box B when the width/tail lights are not ON at the
same time.  Check the wiring connections first.

 Check #5 fuse in fuse box A when only the light at

rear side is ON, and #17 fuse in fuse box B when only
fNOTE:
Work light switch (ON2: front) (ON1: front/rear)
the light at front side is ON.

Procedure Inspection Method Condition Evaluation Cause

1 Replace work light relays Key switch: ON Work light on the Faulty work light relay (front/
(front/rear) each other opposite side is ON. rear)
2 Measure voltage between Light switch: ON 0V Open circuit in harness between
work light relay (front/rear) work light relay (front/rear) and
harness end #1 and chassis work light switch
Work light switch: Faulty work light switch
ON 1 position Open circuit in harness between
work light switch and light
switch
3 Measure voltage between 0V Open circuit in harness between
work light relay (front) work light relay (front) and #5
harness end #3 and chassis fuse in fuse box A
Faulty #5 fuse in fuse box A
4 Measure voltage between 0V Open circuit in harness between
work light relay (front) work light (front) and work light
harness end #515 and relay (front)
chassis
5 Measure voltage between 0V Open circuit in harness between
work light relay (rear) work light relay (right) and #17
harness end #3 and chassis fuse in fuse box B
Faulty #17 fuse in fuse box B
6 Measure voltage between 0V Open circuit in harness between
work light (rear) harness work light (rear) and work light
end #517 and chassis relay (rear)
7 - - The above checks Faulty work light relay (front/
resulted all normal. rear)
Faulty grounding

Connector (Harness end)

 Work Light Relay  Work Light (Front)  Work Light (Rear)

#515 #517
+

90Z7-05-06CN02 90Z7-05-06CN04

90Z7B-05-05-CN03

TTNEM50-EN-01(20181109) T5-6-91
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-10 Wiper is not operated.

Preparation
 The wiper is driven by electric power routed via
the relay circuit. The relay circuit of front wiper is  Refer to SYSTEM / Electrical System.
controlled by the column display controller.  Check the wiring connections first.
 In case the wiper is not operated, first check if the
wiper relay is activated. Next, check if electric power
is routed to the wiper motor.

 Front Wiper
 In case the front washer is also not operated, check
#4 fuse in fuse box A.

Procedure Inspection Method Condition Evaluation Cause

1 Monitor Front Wiper Key switch: ON OFF is displayed. Open circuit in harness between
Relay 1 Output Front wiper/ washer front wiper relay 1 and column
switch: LOW display controller
2 Monitor Front Wiper Key switch: ON OFF is displayed. Open circuit in harness between
Relay 2 Output Front wiper/ washer front wiper relay 2 and column
switch: HI display controller
3 Monitor Front Wiper Key switch: ON The position of front Faulty front wiper/ washer switch
Switch Front wiper/ washer wiper/ washer switch Open circuit in harness between
switch: LOW/HI is not identical to the front wiper/ washer switch and
display on monitor. column display controller
4 Replace front wiper Key switch: ON The front wiper is Faulty front wiper relay 1, 2
relay 1, 2 with other Front wiper/ washer operated.
general relay switch: LOW
5 Measure voltage Key switch: ON 0V Open circuit in harness between
between front wiper front wiper motor and #4 fuse in
motor harness end #5 fuse box A
and chassis
6 Measure voltage Key switch: ON 0V Open circuit in harness between
between front wiper front wiper relay 1, 2 and #4 fuse
relay 1, 2 harness end in fuse box A
#1 and chassis
7 - - The above checks Faulty column display controller
resulted all normal. Faulty front wiper motor

Connector (Harness end)

 Front Wiper Relay  Front Wiper Motor

90Z7B-05-05-CN03 90Z7B-05-05-CN06

TTNEM50-EN-01(20181109) T5-6-92
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

 Rear Wiper

Preparation
 In case the rear washer is also not operated, check
#18 fuse in fuse box B.

Procedure Inspection Method Condition Evaluation Cause

1 Replace rear wiper relay Key switch: ON Rear wiper is operated. Faulty rear wiper relay
with other general relay Rear wiper/ washer
switch: LOW
2 Check continuity Key switch: OFF ∞Ω Open circuit in harness
between rear wiper Rear wiper/ washer between rear wiper relay
relay harness end #2 and switch: LOW and rear wiper/ washer
chassis switch
Faulty rear wiper/ washer
switch
3 Measure voltage between Key switch: ON 0V Open circuit in harness
rear wiper relay harness between rear wiper relay
end #1 and chassis and #18 fuse in fuse box B
Faulty #18 fuse in fuse
box B
4 Measure voltage between Key switch: ON 0V Open circuit in harness
rear wiper motor harness Rear wiper/ washer between rear wiper relay
end #1 and chassis switch: LOW and rear wiper motor
5 - - The above checks Faulty rear wiper motor
resulted all normal.

Connector (Harness end)

 Rear Wiper Relay  Rear Wiper Motor

90Z7B-05-05-CN03 90Z6-05-06-02

TTNEM50-EN-01(20181109) T5-6-93
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-11 Washer is not operated.

Preparation
 Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

 Front Washer
 In case the front wiper is also not operated, check #4
fuse in fuse box A.

Procedure Inspection Method Condition Evaluation Cause

1 Replace the front Front wiper/washer Front washer is Faulty front washer relay
washer relay with other switch: ON position operated.
general relay
2 Check continuity Front wiper/washer ∞Ω Open circuit in harness between
between front washer switch: ON position front washer relay and front
relay harness end #2 wiper/washer switch
and chassis Faulty front wiper/washer switch
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between front washer front washer relay and #4 fuse in
relay harness end #1 fuse box A
and chassis Faulty #4 fuse in fuse box A
4 Monitor Front Washer Front wiper/washer OFF is displayed Faulty front wiper/washer switch
Switch switch: Washer ON Open circuit in harness between
front wiper/washer switch and
column display controller
5 Measure voltage Key switch: ON 0V Open circuit in harness between
between front washer front washer relay and #4 fuse in
relay harness end #3 fuse box A
and chassis
6 Measure voltage Front wiper/washer 0V Open circuit in harness between
between front washer switch: ON position front washer relay and front
motor harness end #1 washer motor
and chassis
7 - - The above checks Faulty front washer motor
resulted all normal. Faulty grounding

Connector (Harness end)

 Front Washer Relay  Front Washer Motor

90Z7B-05-05-CN03 95Z7BTT05-06-06

TTNEM50-EN-01(20181109) T5-6-94
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

 Rear Washer

Preparation
 In case the rear wiper is also not operated, check #18
fuse in fuse box B.

Procedure Inspection Method Condition Evaluation Cause

1 Replace the rear washer Key switch: ON Rear washer is Faulty rear washer relay
relay with other general Rear wiper/washer operated
relay switch: Washer ON
2 Check continuity Key switch: OFF ∞Ω Open circuit in harness between
between rear washer Rear wiper/ washer rear washer relay and rear wiper/
relay harness end #2 switch: Washer ON washer switch
and chassis Faulty rear wiper/washer switch
3 Measure voltage Key switch: ON 0V Open circuit in harness between
between rear washer rear washer relay and #18 fuse in
relay harness end #1 fuse box B
and chassis
4 Measure voltage Key switch: ON 0V Open circuit in harness between
between rear washer rear washer relay and #18 fuse in
relay harness end #3 fuse box B
and chassis
5 Measure voltage Key switch: ON 0V Open circuit in harness between
between rear washer Rear wiper/washer rear washer relay and rear washer
motor harness end #1 switch: Washer ON motor
and chassis
6 - - The above checks Faulty rear washer motor
resulted all normal. Faulty grounding

Connector (Harness end)

 Rear Washer Relay  Rear Washer Motor

90Z7B-05-05-CN03 95Z7BTT05-06-06

TTNEM50-EN-01(20181109) T5-6-95
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

O-12 Cab dome light is not ON.

Preparation
 Check #3 fuse in fuse box B when the cab dome light
and rear cab dome light are not ON at the same time.

 Refer to SYSTEM / Electrical System.

 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause

1 Set cab dome light switch Door open/close Cab dome light is not ON. Faulty door open/close
to Door Interlocking switch: ON switch
Position
2 Set cab dome light switch - Cab dome light is not ON. Faulty cab dome bulb
to ON position Open circuit in harness
between cab light and #3
fuse in fuse box B
3 Set cab rear dome light - Cab rear dome light is not Faulty cab dome bulb
switch to ON position ON. Open circuit in harness
between cab rear dome light
and #3 fuse in fuse box B
4 - - The above checks Faulty #3 fuse in fuse box B
resulted all normal.

TTNEM50-EN-01(20181109) T5-6-96
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Exchange Inspection
1 Machine Front Side
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging
the suspected part / component with another part /
component having identical characteristics.

Many sensors and solenoid valves used on this machine

2
are identical. Therefore, by using this switch-check
method, faulty part /component, and/or harness can be
easily found. 3

Example: Lift Arm Raise Pilot Pressure Sensor High Input

4
(MC Fault Code 111200-3)
TNED-01-02-022
Check Method:
1. Switch connectors of pressure sensor (lift arm raise)
1- Flow Regulator Valve 4- Pressure Sensor (Bucket
and pressure sensor (bucket dump). 2- Pressure Sensor (Lift Arm Dump)
2. Retry troubleshooting. Raise)
3- Pressure Sensor (Bucket
Rollback)
Result:
In case Bucket Dump Pilot Pressure Sensor High Input
(MC fault code 111203-3) is displayed, the pressure sensor
(lift arm raise) is considered to be faulty.

In case Lift Arm Raise Pilot Pressure Sensor High Input

(MC fault code 111200-3) is displayed, the pressure sensor
(lift arm raise) harness is considered to be faulty.

TTNEM50-EN-01(20181109) T5-6-97
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Applicability of Switch-Check Method

Fault Code Trouble Remedy

111204-3 Pump Delivery Pressure Sensor Circuit High Input Compatible Harness / Sensor
111204-4 Pump Delivery Pressure Sensor Circuit Low Input
111206-3 Hyd. Fan Circuit Pressure Sensor Circuit High Input
111206-4 Hyd. Fan Circuit Pressure Sensor Circuit Low Input
111311-3 Service Brake Primary Pressure Sensor Circuit High Input
111311-4 Service Brake Primary Pressure Sensor Circuit Low Input
111208-3 Emergency Steering Check Pressure Sensor Circuit High Input
111208-4 Emergency Steering Check Pressure Sensor Circuit Low Input
111217-3 Pilot Pressure Sensor Circuit High Input Compatible Harness / Sensor
111217-4 Pilot Pressure Sensor Circuit Low Input
111200-3 Lift Arm Raise Pilot Pressure Sensor Circuit High Input
111200-4 Lift Arm Raise Pilot Pressure Sensor Circuit Low Input
111203-3 Bucket Dump Pilot Pressure Sensor Circuit High Input
111203-4 Bucket Dump Pilot Pressure Sensor Circuit Low Input
111202-3 Bucket Roll Back Pilot Pressure Sensor Circuit High Input
111202-4 Bucket Roll Back Pilot Pressure Sensor Circuit Low Input
111313-3 Parking Brake Pressure Sensor Circuit High Input
111313-4 Parking Brake Pressure Sensor Circuit Low Input

TTNEM50-EN-01(20181109) T5-6-98
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

Air Bleeding Procedures for Brake (Axle)

IMPORTANT: If air is mixed in the brake system, the
brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and
replacing hydraulic oil.
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 L (0.13 gal)) is drawn from
each wheel (4 places) after bubbles stops.

fNOTE: Perform this work on all wheels (4 places) by two

or more persons. Air bleed plug (1) is located around the
center on front and rear axles.
1
85Z7BTT05-06-02

1. Set the parking brake switch of front console to the

ON position, start the engine, and increases service
brake oil pressure.

2
2. Connect clear vinyl tube (2) to either one of two air
bleed plugs (1). 1
Insert the other end of clear vinyl tube (2) into clear
container (3) filled with hydraulic oil.

T4GB-05-04-005

TTNEM50-EN-01(20181109) T5-6-99
 SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B

3. Depress brake pedal (4) several times.

Then, depress and hold brake pedal (4) to the stroke
end.
4. Loosen air bleed plug (1) under condition in step 3
and drain hydraulic oil and air for several seconds.
5. Tighten air bleed plug (1).
6. Drain hydraulic oil after bubbles stops in steps 3 to 5
repeatedly.

fNOTE: When bubbles do not disappear after hydraulic

oil (about 0.5 L (0.13 gal)) is discharged, repeat step 3 to
step 5. 4
T4GB-05-04-006

7. Bleed air at other 3 places in the same way as step 3

to step 5.

IMPORTANT: After air bleeding is completed at 4

places, bleed air at 4 places again.
Bleed air in the same way as step 3 to step 5 twice
and check that no air remains inside.

TTNEM50-EN-01(20181109) T5-6-100
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Outline
Configuration layout of the air conditioning system is The vents (operator’s front/rear vent, foot vent, and the
illustrated below. front window) can be simultaneously or independently
Either fresh or re-circulated air is induced into the air selected by air vent damper servo motor (1) in accordance
conditioner unit by operating fresh/re-circulated air with the set-ventilation mode.
damper servo motor (6). The front widow and operator’s front vents are manually
The induced air flows out of the vents through evaporator selectable. The air conditioning controller controls the
(5) or heater (15) by blower motor (11). Evaporator (5) is air conditioning system. The air conditioner controller
a device used to cool the air. Heater (15) is a device used controls the damper operation by corresponding to the
to warm the air. In the air conditioning system, after the job site conditions such as atmospheric and cab inside
refrigerant is compressed by the compressor, it is sent to air temperatures, coolant temperature, operator’s set-
evaporator (5) in which the refrigerant expands to cool temperature, and the set-ventilation mode. In addition,
the air. Heater (15) warms air by absorbing heat from the air conditioning controller displays the air conditioner
warmed engine coolant. The temperature is kept at the system operation status on the monitor.
set temperature by adjusting evaporator (5) and heater
(15).

8
7

1 5
10 9
2 3

16

TDAA-05-07-001
15 14 13 12 11

1- Air Vent Damper Servo Motor 6- Fresh/Re-circulated Air 9- Re-circulated Air Filter 13- Frost Sensor
2- Defroster Vent Damper Servo Motor 10- Re-circulated Air Induction 14- Air Mix Damper Servo Motor
3- Rear Vent 7- Re-circulated Air Temperature Port 15- Heater Core
4- Front Vent Sensor 11- Blower Motor 16- Foot Vent
5- Evaporator 8- Fresh Air Induction Port 12- Power Transistor

TTNEM50-EN-01(20181109) T5-7-1
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Component Layout

1 2 6

3
7

5
9

11

TNEK-05-07-002
View A

8 A

10

TNEK-05-07-001

12

28

14

13 27 TNEK-05-07-003

1- Solar Radiation Sensor 4- AUTO/OFF Switch / Blower 8- Air Conditioner Unit 12- High/Low Pressure Switch
2- Column Display Controller Switch 9- Fresh Air Filter 13- Air Conditioner Condenser
3- Temperature Control Switch/ 5- Accelerator Pedal 10- Air Conditioner Controller 14- Receiver Tank
Mode Switch 6- Key Switch 11- Outdoor Ambient 27- Compressor
7- Monitor Controller Temperature Sensor 28- Engine

TTNEM50-EN-01(20181109) T5-7-2
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

19

18
17
16

15

20

21

22

23
24
25

TDAA-05-07-028
26

15- Re-circulated Air Filter 18- Fresh/Re-circulated Air 21- Heater Core 25- Power Transistor
16- Compressor Relay Damper Servo Motor 22- Air Mix Damper Servo Motor 26- Blower Motor
17- Re-circulated Air Temperature 19- Frost Sensor 23- Air Vent Damper Servo Motor
Sensor 20- Evaporator 24- Blower Motor Relay

TTNEM50-EN-01(20181109) T5-7-3
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Functions of Main Parts

The functions of the main parts for the air conditioner
are described below. The connector No. is shown in the
parentheses after the part name.

 Controller
Controls the air conditioning system. The controller has
the following functions.
 The operator’s instructions are input by the switches.
 The air and coolant temperature are detected by the
sensors.
 Input the air conditioner unit conditions.
 The blower motor and compressor are controlled by
operating the relays.
 The air conditioner operating conditions are TDC1-05-07-002
displayed on the monitor panel.

 Power Transistor (CN7)

An electric switch to control blower motor voltage.

TDC1-05-07-003

 Blower Motor Relay (CN3)

Supplies 24 volts of electricity to the blower motor when
the air conditioner is operated. The blower motor relay
is turned ON when excited by the current from terminal
#30B in controller.

TDC1-05-07-004

 Compressor Relay (CN4)

Supplies 24 volts of electricity to the compressor clutch
when the air conditioner is operated. The compressor
relay is turned ON when excited by the current from
terminal #29B in controller.

TDC1-05-07-005

TTNEM50-EN-01(20181109) T5-7-4
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

 Frost Sensor (CN12)

Monitors the fin temperature which is cooled by the
evaporator. When the temperature is higher than
3°C (37°F) (approx. 4.2 kΩ), the controller turns the
compressor relay ON. When the temperature is lower
than 2°C (36°F) (approx. 4.5 kΩ), the controller turns the TDC1-05-07-006
compressor relay OFF. Therefore, the evaporator in the air
conditioner unit is prevented from freezing. The electrical
resistance in the frost sensor is 100 Ω to 115 kΩ.

 High/Low Pressure Switch (CN14)

Controls the compressor clutch solenoid while
monitoring the compressor circuit pressure.
The high/low pressure switch consists of a pressure
gauge and a switch. The pressure gauge detects the lower
pressure range (0.196 ~ 0.225 MPa) (28.4 ~ 32.6 PSI) and TDC1-05-07-007
the surge pressure range (2.55 ~ 3.14 MPa) (370 ~ 455
PSI). When the circuit pressure is reduced to the lower
pressure range or increases to the surge pressure range,
the pressure gauge turns the switch OFF so that the
compressor operation stops. If the pressure is reduced to
the lower range, a lack of refrigerant is suspected.
Therefore, damage to the compressor due to a lack of TDAA-05-07-014
refrigerant is prevented. In case the pressure increases
to the surge range, damage to the air conditioner circuit
parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Temperature Sensor (CN11)

Monitors the temperature 0 ~ 25°C (32 ~ 77°F) around the
re-circulated air inlet as the interior air temperatures and
converts them to the electrical resistance values.
The temperature 0 ~ 25°C (32 ~ 77°F) corresponds to a
resistance of 1.645 kΩ (0°C) (32°F) to 5 kΩ (25°C) (77°F)
TDC1-05-07-008
respectively.
The electrical resistance in the air circulation sensor is 300
Ω to 430 kΩ.

 Ambient Temperature Sensor (CN15)

Monitors the temperature around the front side of the
machine as the fresh air temperature, and converts the
temperature to the electrical resistance value.
The electrical resistance in the fresh air sensor is 100 Ω to
210 kΩ. TDC1-05-07-009

TTNEM50-EN-01(20181109) T5-7-5
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

 Solar Radiation Sensor (CN16)

Converts the amount of solar radiation (illumination
intensity) at the cab front to the current values.
TDC1-05-07-010

 Fresh/Re-circulated Air Damper Servo Motor (CN10)

Opens or closes the fresh/re-circulated air selection
louvers. The damper consists of a motor, link mechanism,
and position sensing switch. The motor opens or closes
the fresh/re-circulated air selection louvers via the link
mechanism.

TDC1-05-07-011

TTNEM50-EN-01(20181109) T5-7-6
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

 Air Mix Damper Servo Motor (CN9)

Controls opening/closing of the air mixing door in
response to the set temperature.
The damper consists of a motor, link mechanism, and
potentiometer.
The motor opens or closes the air mix door via the link
mechanism.
The potentiometer converts the link movements (the TDC1-05-07-012
mix door strokes) to the voltage. Both ends of the
potentiometer are energized by 5 V from terminals #7D
(+) and #25E (-) in controller so that the potentiometer
outputs voltage of 0.5 to 4.5 V from the center terminal
to terminal #19B in controller corresponding to the link
movement.
When the set temperature is determined by temperature
UP/DOWN signal from the controller, the controller
calculates voltage (Vr) corresponding the link position.
Further more, the controller checks the air mix door
position by voltage (Vf ) from the potentiometer.
Then, after the controller decides the motor rotational
direction (polarity of motor) based on the differential
voltage between Vr and Vf, the controller sends out the
current from terminals #15B and #16B.
The controller drives the motor until voltage (Vf )
becomes equal to voltage (Vr).

TTNEM50-EN-01(20181109) T5-7-7
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

 Air Vent Damper Servo Motor (CN8)

Opens or closes the front and rear air vent, foot vent, and
defroster vent louvers.
The damper consists of a motor, link mechanism, and
potentiometer.
The motor opens or closes vent louvers via the link
mechanism.
The potentiometer converts the link movements TDC1-05-07-013
(vent louvers strokes) to the voltage. Both ends of the
potentiometer are energized by 5 V from terminals #7C
(+) and #25D (-) in controller so that the potentiometer
outputs voltage of 0.5 to 4.5 V from the center terminal to
terminal #20B in controller.

Depending on the MODE switch set position, vent louvers

are operated as shown below:

MODE switch Front air Rear air Foot air Defroster

position vent vent vent vent
   

TNED-05-07-005
   

TNED-05-07-006
   

TNED-05-07-007
   

TNED-05-07-008
   

TNED-05-07-009
   

TNED-05-07-010

: Open : Closes

When the front and rear air vent louvers positions

are selected, the controller calculates potentiometer
voltage (Vr). Furthermore, the controller checks the vent
louvers positions by receiving voltage (Vf ) from the
potentiometer. Then, after the controller decides the
motor rotational direction (polarity of motor) based on
the differential voltage between Vr and Vf, the controller
sends out the current from terminals #31B and #32B.
The controller drives the motor until voltage (Vf )
becomes equal to voltage (Vr).

TTNEM50-EN-01(20181109) T5-7-8
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Troubleshooting
IMPORTANT:
When replacing the compressor due to the

breakage of compressor from internal lock,
sufficiently clean the air conditioner circuit or
replace all the parts.
When cleaning is insufficient or all the parts are

not replaced, the air conditioner may be broken
due to contaminants remaining in the circuit.
Using deteriorated LLC (coolant) or low-

concentration LLC, the heater core will receive
a bad influence and it may lead water leaks
and shorten the service life of machine.
Replace coolant and manage LLC concentration
according to the Operator's Manual.
fNOTE: The fault code of the air conditioner controller
is displayed only on the monitor. It is not displayed on
MPDr..

TTNEM50-EN-01(20181109) T5-7-9
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Air Conditioner Controller Fault Code List

Fault Code Trouble Cause Symptoms in Machine Remedy

Operation When Trouble Occurs.
11 Open circuit in Voltage: more than Operation is controlled under Check the wire
re-circulated air 4.95 V such circumstances as no re- harness.
temperature sensor circulated air temperature Replace the re-
sensor is provided. circulated air
temperature sensor.
12 Shorted circuit in Voltage: less than 0.3 V Operation is controlled under Check the wire
re-circulated air such circumstances as no re- harness.
temperature sensor circulated air temperature Replace the re-
sensor is provided. circulated air
temperature sensor.
13 Open circuit in Voltage: more than Operation is controlled under Check the wire
ambient temperature 4.88 V such circumstance as no harness.
sensor ambient temperature sensor is Replace the ambient
provided. temperature sensor.
14 Short circuit in Voltage: less than Operation is controlled under Check the wire
ambient temperature 0.096 V such circumstance as no harness.
sensor ambient temperature sensor is Replace the ambient
provided. temperature sensor.
18 Short circuit in solar Voltage: more than Operation is controlled under Check the wire
radiation sensor 5.04 V such circumstance as no solar harness.
radiation sensor is provided. Replace the solar
radiation sensor.
21 Open circuit in frost Voltage: more than The compressor clutch is Check the wire
sensor 4.79 V disengaged. (The compressor harness.
stops.) Replace the frost
sensor.
22 Short circuit in frost Voltage: less than The compressor clutch is Check the wire
sensor 0.096 V disengaged. (The compressor harness.
stops.) Replace the frost
sensor.
43 Abnormal air vent Short circuit: Voltage: Air vent damper servo motor Check the wire
damper servo motor 0V becomes inoperable. harness.
Open circuit: Voltage: Replace the air vent
more than 5 V damper servo motor.
44 Abnormal air mix Short circuit: Voltage: Air mix damper servo motor Check the wire
damper servo motor less than 0.2 V servo motor becomes harness.
Open circuit: Voltage: inoperable. Replace the air mix
more than 4.8 V damper servo motor.
51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the wire
refrigerant pressure disengaged. (The compressor harness.
stops.) Replace the high/low
pressure switch.
91 CAN communication Faulty CAN2 harness Air conditioner stops. Check the CAN2
error between monitor harness.
controller and air Replace the air
conditioner controller conditioner controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN2
controller harness.
Faulty CAN2 harness Replace the air
conditioner controller.

TTNEM50-EN-01(20181109) T5-7-10
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Air Conditioner Controller Fault Codes 11 to 22

Preparation
 Check the wiring connections first.
 Before inspection, set the key switch to the ON position.

Fault Code Trouble Procedure Inspection Method Evaluation Cause

11 Open circuit in 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
re-circulated between sensor #25H 300 to 430 kΩ) NO: Go to Procedure No. 2
air temperature and #6B
sensor 2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #25H
end #25H and the body. NO: Open circuit in wire
harness #6B
12 Short circuit in 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
re-circulated between sensor #25H 300 to 430 kΩ) NO: Short circuit in wire
air temperature and #6B harness #25H and #6B
sensor
13 Open circuit 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
in ambient between sensor #A251 100 to 210 kΩ) NO: Go to Procedure No. 2
temperature and #A41
sensor 2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #A251
end #A251 and the body. NO: Open circuit in wire
harness #A41
14 Short circuit 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
in ambient between sensor #A251 100 to 210 kΩ) NO: Short circuit in wire
temperature and #41 harness #A251 and #A41
sensor
18 Short circuit in 1 Check continuity 0Ω YES: Short circuit in wire
solar radiation between sensor harness harness #A71 and #31
sensor end #A71 and #A31. NO: Faulty sensor
21 Open circuit in 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
frost sensor between sensor #25C 100 to 115 kΩ) NO: Go to Procedure No. 2
and #5B
2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #25C
end #25C and the body. NO: Open circuit in wire
harness #5B
22 Short circuit in 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
frost sensor between sensor #25C 100 to 115 kΩ) NO: Short circuit in wire
and #5B harness #25C and #5B

TTNEM50-EN-01(20181109) T5-7-11
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Air Conditioner Controller Fault Codes 43 to 92

Preparation
 Check the wiring connections first.
 Before inspection, set the key switch to the ON position.

Fault Code Trouble Procedure Inspection Method Evaluation Cause

43 Abnormal air vent 1 Measure voltage between 0 V YES: Faulty controller or
damper servo air vent damper servo open circuit in wire harness
motor motor harness end 7C between controller and air
and the body. (AUTO/OFF vent damper servo motor
switch / blower switch: NO: To Procedure No. 2
ON)
2 Measure voltage between 0 V YES: Faulty controller or
air vent damper servo open circuit in wire harness
motor harness end 7C and between controller and air
25D. (AUTO/OFF switch / vent damper servo motor
blower switch: ON) NO: Faulty air vent damper
servo motor
44 Abnormal air mix 1 Measure voltage 0V YES: Faulty controller or
damper servo between air mix damper open circuit in wire harness
motor servo motor harness end between controller and air
7D and the body. (AUTO/ mix damper servo motor
OFF switch / blower NO: To Procedure No. 2
switch: ON)
2 Measure voltage between 0 V YES: Faulty controller or
air mix damper servo open circuit in wire harness
motor harness end 7D and between controller and air
25E. (AUTO/OFF switch / mix damper servo motor
blower switch: ON) NO: Faulty air mix damper
servo motor
51 Abnormal high/ 1 Measure voltage between 0 V YES: Faulty controller or
low refrigerant high/low pressure switch open circuit in harness
pressure harness end A211 and between controller and
A052. (AUTO/OFF switch / high/low pressure switch
blower switch: ON) NO: Faulty high/low
pressure switch
91 CAN 1 Check continuity in CAN2 Normal YES: Faulty controller
communication harness. NO: Faulty CAN2 harness
error
92 CAN bus off error 1 Check continuity in CAN2 Normal YES: Faulty controller
harness. NO: Faulty CAN2 harness

TTNEM50-EN-01(20181109) T5-7-12
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

(Blank)

TTNEM50-EN-01(20181109) T5-7-13
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty cooling (1)

Condition:
 Fault code: Un-displayed
 Airflow volume: faulty
Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
rotates Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles
Deformation or breakage of blower Replace the blower
Frosted evaporator Go to A
Adhered dirt on evaporator surface Evaporator surface cleaning
Slow speed Power source decreases Check the battery charging
system
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Faulty blower motor relay Replace
does not rotate Faulty blower motor Replace
Faulty power transistor Replace
Blower interferes with case Repair
Faulty controller Replace the controller
Faulty ground in body Make sure to ground
Faulty wire harness, disconnection of connector Check the wire harness
Blowout of power transistor thermal fuse due to locked motor Replace the motor
Blowout of fuse Replace with the Blower motor is locked Replace the blower motor
same capacity fuse Faulty wire harness Refer to wire harness
diagram and check
Short circuit Check the wire harness

TTNEM50-EN-01(20181109) T5-7-14
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wire harness of Short circuit check Repair
frost sensor
Faulty frost sensor Characteristic check Replace the frost
characteristics sensor.
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator range mm or less)
(faulty sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch

TTNEM50-EN-01(20181109) T5-7-15
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty cooling (2)

Condition:
 Fault Code: Un-displayed
 Airflow volume: Normal
 Compressor: Compressor rotates normally
 Compressor pressure: Normal
Fresh air enters Close the window and door.
Readjust the fresh/re-circulated
air selection damper.
Disconnection of A/M Set the link again.
link

TTNEM50-EN-01(20181109) T5-7-16
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

(Blank)

TTNEM50-EN-01(20181109) T5-7-17
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty cooling (3)

Condition:
 Fault Code: Un-displayed
 Airflow volume: Normal
 Compressor: Compressor rotates normally
 Compressor pressure: Abnormal
Pressure on low- Overcharge of air Remove refrigerant thoroughly and recharge refrigerant to proper
pressure side is conditioner with refrigerant level after purging
too high (approx. Faulty compressor Breakage of head gasket Replace the compressor.
0.29 MPa (42 PSI) or Breakage of inlet valve Replace the compressor.
more)
Foreign matter is caught in inlet Replace the compressor.
valve
Excessive open of Faulty valve Replace the valve.
expansion valve
Pressure on high- Abnormally low ambient temperature
pressure side is too Lack of refrigerant To B
low (pressure is not Faulty compressor Swash plate shoe is locked Replace the compressor.
approx. 0.98 MPa
Piston is locked Replace the compressor.
(142 PSI) or more)
Faulty suction discharge valve Replace the compressor.
Faulty expansion valve Clogged valve (foreign matter) Replace the valve
Temporary clogged due to freezing Thoroughly perform purging
valve (water intrusion) after replacing valve and
receiver.
Pressure on low- Abnormally low ambient temperature
pressure side is too Lack of refrigerant Go to B
low (pressure is Clogged in refrigeration cycle Go to C
approx. 0.05 MPa
Faulty expansion valve Go to D
(7.25 PSI) or less)
Frosted evaporator Go to A
Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing)
both sides of high- Overcharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper
pressure and low- conditioner with refrigerant level after purging.
pressure
Pressure is low on Lack of refrigerant
both sides of high-
pressure and low-
pressure

TTNEM50-EN-01(20181109) T5-7-18
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice.
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wiring of frost Short circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator range mm or less)
(faulty sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.

B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.

C: Clogged in refrigeration cycle

Clogged in refrigeration cycle Clogged receiver dryer Replace
Clogged foreign matter in piping Replace

D: Faulty expansion valve

Faulty expansion valve Clogged valve (foreign matter) Replace the valve.
Temporary clogged due to freezing valve Thoroughly perform purging after
(water intrusion) replacing valve and receiver.

TTNEM50-EN-01(20181109) T5-7-19
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty cooling (4)

Condition:
 Fault Code: Un-displayed
 Airflow volume: Normal
 Compressor: Compressor does not rotate normally
Broken V belt or slipping Replace V belt.
Faulty compressor (locked) Replace
Faulty magnet Repair or Open circuit in stator coil Replace
clutch replace Air gap between rotor and stator is too large Repair or
Replacement
Clutch slipping Slip caused by key breakage or inserting no key Replace the key.
Greasy clutch surface Remove oil.
Layer short of coil Replace
Battery voltage drop Charge
Caught foreign matter between rotor and stator Overhaul
Clutch does Check Faulty controller Replace the
not operate wiring controller.
due to faulty Faulty compressor clutch relay Replace
electrical Faulty frost sensor Replace
system
Faulty high/low refrigerant pressure switch Replace
Abnormal high Too high Abnormally high ambient temperature
pressure (2.54 MPa Lack of Clogged fin with Cleaning of fin
(368 PSI)or condenser dirt or mud (washing)
more) cooling
Overcharge air Discharge refrigerant thoroughly and
conditioner with recharge refrigerant to proper level
refrigerant after purging.
Air incorporation Discharge refrigerant thoroughly and
in refrigeration recharge refrigerant to proper level
cycle after purging.
Too low Abnormally low ambient temperature
(0.98 MPa Lack of refrigerant Go to B
(142 PSI) or Clogged during refrigeration cycle Go to C
less)
Faulty expansion valve Go to D
Frosted evaporator Go to A

TTNEM50-EN-01(20181109) T5-7-20
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice.
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wiring of frost Short circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator range mm or less).
(faulty sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.

B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.

C: Clogged in refrigeration cycle

Clogged in refrigeration cycle Clogged receiver dryer Replace
Clogged foreign matter in piping Replace

D: Faulty expansion valve

Faulty expansion valve Clogged valve (foreign matter) Replace the valve.
Temporary clogged due to freezing valve Thoroughly perform purging after
(water intrusion) replacing valve and receiver.

TTNEM50-EN-01(20181109) T5-7-21
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty cooling (5)

Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Faulty wiring, open Wirings inspection
circuit, disconnection of
connector
Faulty servo motor Replace
Caught foreign matter Remove foreign matter.

Condition:
 Fault Code: 51 (Abnormal high/low refrigerant pressure)
High pressure cut is Abnormally high ambient temperature
operated Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing)
cooling
Overcharge air Discharge refrigerant thoroughly and recharge refrigerant to
conditioner with proper level after purging
refrigerant
Air incorporation in Discharge refrigerant thoroughly and recharge refrigerant to
refrigeration cycle proper level after purging
Low pressure cut is Abnormally low ambient temperature
operated Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper
level.
Gas leak Check leak and charge with
refrigerant after repairing faulty.
Faulty compressor Swash plate shoe is locked Replace the compressor.
Piston is locked Replace the compressor.
Faulty suction discharge valve Replace the compressor.
Faulty expansion valve Clogged valve (foreign matter) Replace the valve.
Temporary clogged due to Thoroughly perform purging
freezing valve (water intrusion) after replacing valve and
receiver.

TTNEM50-EN-01(20181109) T5-7-22
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

(Blank)

TTNEM50-EN-01(20181109) T5-7-23
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty heating (1)

Condition:
 Fault code: Un-displayed
Faulty air flow Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
volume rotates. Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles.
Deformation or breakage of blower Replacement of blower
Frosted evaporator Go to A
Adhered dirt on evaporator surface Evaporator surface
cleaning
Slow speed Power source decreases. Check battery charging
system.
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Blowout of fuse Replace with the Blower motor is Replace the blower
does not rotate. same capacity fuse, locked, motor.
Faulty wiring Refer to wiring diagram
and check.
Short circuit Check the wire harness.
Faulty blower motor relay Replace
Faulty blower motor Replace
Faulty power transistor Replace
Blower interferes with case Repair
Faulty controller Replace the controller.
Faulty ground in body Make sure to ground.
Faulty wire harness, disconnection of connector Check the wire harness.
Blowout of power transistor thermal fuse due to locked Replace the motor.
motor
Air flow volume Coolant temperature is low.
is normal Coolant Disconnection of air mix damper link Set the link again.
temperature is Air incorporation in hot-water circuit Bleed air from the circuit.
normal. Clogging, breakage, and bending of piping Repair or replace
Extremely low ambient temperature
Lack of engine coolant level Charge engine coolant
to proper level.
Broken heater core Replace the heater core.

TTNEM50-EN-01(20181109) T5-7-24
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch
magnet clutch circuit relay.
Faulty wiring of frost Short circuit check Repair
sensor
Faulty the frost sensor Characteristic check Replace the frost
characteristics sensor.
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator range mm or less)
(faulty sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.

TTNEM50-EN-01(20181109) T5-7-25
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Faulty heating (2)

Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Caught foreign matter Remove foreign
matter.
Faulty wire harness, open circuit, Check the wire
disconnection of connector harness.
Faulty damper Replace

TTNEM50-EN-01(20181109) T5-7-26
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Others

 Faulty air vent switch

Fault code is un-displayed. Disconnection of link Set the link again.
Fault code 43 (Abnormal air vent damper Faulty wire harness, open circuit, Check the wire harness.
servo motor) disconnection of connector
Faulty servo motor Replace
Caught foreign matter Remove foreign matter.

 Faulty fresh / re-circulated air selection

Fault code is un-displayed. Disconnection of link Set the link again.
Faulty wire harness, open circuit, Check the wire harness.
disconnection of connector
Faulty servo motor Replace
Caught foreign matter Remove foreign matter.

 Ambient temperature is higher or lower than set-temperature

Fault code 11 (Open circuit in re- Open circuit in wire harness, Check the wire harness.
circulated air temperature sensor) disconnection of connector
Open circuit in air circulation sensor Replace
Fault code 12 (Short circuit in re- Short circuit in wire harness Check the wire harness.
circulated air temperature sensor) Short circuit in air circulation sensor Replace
Fault code is un-displayed. (Normal re- Faulty cooling, faulty heating Check by referring to the items of
circulated air temperature sensor) faulty cooling and faulty heating.

TTNEM50-EN-01(20181109) T5-7-27
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

 Noise
Case connection Louver resonance Repair or replace.
Blower fan motor connection Fan contacts case, Foreign matter Remove foreign matter. Readjust fan
enters case motor location.
Brush friction noise, metal and/or Slight noise is unavoidable. Replace if
thrust washer contact loud.
Gas blowing sound (roaring) Gas vibration noise (compressor No functional problem exists.
discharge and/or suction gas noise)
Expansion valve connection, Whistle Abnormal noise from expansion Replace expansion valve if whistle
sound, Gas blowing sound. valve, Expansion valve is normally sound is heard. Gas flow noise can be
functioning slightly heard.
Clutch disengaging sound Faulty clutch bearing, and/or idle Replace
pulley bearing
Contact of clutch amature due to Repair or replace the clutch. Re-tighten
resonance. Loose belt, Loose screws screws.
Compressor rotating sound Noisy compressor Repair or replace
Vibration due to V belt looseness, Re-adjust the belt. Re-tighten screws.
Loose screws

 Others
Water leak, Water splash Broken heater core, Broken hose Replace
Clogged case drain port and/or drain Clean
hose
Abnormal smell Absorbed cigarette and dust smell on Clean the evaporator. When humidity
evaporator fins is high, open door. While rotating fan
at approx. 1500 min-1 in L mode for
more than 10 minutes, flush smell out
by condensed water.

TTNEM50-EN-01(20181109) T5-7-28
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

(Blank)

TTNEM50-EN-01(20181109) T5-7-29
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Blower motor does not operate.

Preparation
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Blower motor is YES: Faulty blower motor
blower motor relay. Blower Switch: ON kept stopped. relay
NO: Go to Procedure No. 2
2 Measure voltage between Key Switch: ON 0V YES: Open circuit in wire
terminal #41B of blower motor harness between fuse #3
relay harness end and the body. and blower motor relay
NO: Go to Procedure No. 3
3 Measure voltage between Key Switch: ON 0V YES: Open circuit in wire
terminal #43A of blower motor Blower Switch: ON harness between blower
harness end and the body. motor relay and blower
motor
NO: Go to Procedure No. 4
4 Check continuity between - 0Ω YES: Faulty blower motor
terminals #43B and #44A of NO: Go to Procedure No. 5
blower motor harness end.
5 Measure voltage between Key Switch: ON 0V YES: Open circuit in
terminal #44B of power transistor Blower Switch: ON wire harness between
harness end and the body. blower motor and power
transistor
NO: Go to Procedure No. 6
6 Measure voltage between Key Switch: ON 0V YES: Faulty air conditioner
terminal #9B of power transistor Blower Switch: ON controller
harness end and the body. NO: Faulty power
transistor
Connector (Wire harness end)
 Blower Motor Relay  Blower Motor

TDC1-05-07-014 TDAB-05-07-027

 Power Transistor

TDAB-05-07-028

TTNEM50-EN-01(20181109) T5-7-30
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Compressor clutch does not operate.

Preparation
 Check that outdoor air temperature is 0˚C (32˚F) or
more first. When outdoor air temperature is less
than 0˚C (32˚F), the air conditioner controller turns
the compressor clutch OFF in order to protect the
compressor.
 Check that fault code 21 or 22 (abnormal frost
sensor) is not displayed. When the frost sensor is
abnormal, the compressor clutch does not operate.
 Check the wiring connections first.

Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Compressor is YES: Faulty compressor
blower motor relay. Blower Switch: ON kept stopped. relay
NO: Go to Procedure No. 2
2 Measure voltage between Key Switch: ON 0V YES: Open circuit in wire
terminal #48A of compressor relay harness between fuse #3
harness end and the body. and compressor relay
NO: Go to Procedure No. 3
3 Measure voltage between Key Switch: ON 0V YES: Open circuit in
terminal #42B of compressor Blower Switch: ON wire harness between
clutch harness end and the body. compressor relay and
compressor clutch
NO: Faulty compressor
clutch

Connector (Wire harness end)  Compressor Clutch

 Compressor Relay

TDAB-05-07-019 TDAB-05-07-024

TTNEM50-EN-01(20181109) T5-7-31
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Cooling circuit check by using manifold gauge

Condition:
 Engine Speed: 1500 min-1
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
 Fresh/re-circulated air selection: Re-circulated Air
 Air conditioner inlet temperature: 30 ~ 35°C (86 ~
95°F)

1. In normal
 Low-pressure side pressure: 0.15 ~ 0.25 MPa (21.8 ~
36.3 PSI)
 High-pressure side pressure: 1.37 ~ 1.57 MPa (198.7 ~
227.7 PSI)
f NOTE: The reading of manifold gauge may depend on
conditions.
TDAA-05-07-018

2. Lack of refrigerant quantity

TroublePressure is low on both sides of high-pressure

and low-pressure. Cooling performance is
low.
Cause Refrigerant quantity is low. Gas leak.
Remedy Check and repair of gas leak. Charge air
conditioner with refrigerant.
TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling

TroublePressure is high on both sides of high-

pressure and low-pressure. Cooling
performance is low.
Cause Overcharge air conditioner with refrigerant.
Faulty condenser cooling.
Remedy Adjust refrigerant quantity. Clean condenser. TDAA-05-07-020
Check for machine cooling system.

4. Water incorporation in circuit.

TroubleAfter using a certain period of time, low-

pressure side gradually indicates negative
pressure.
Cause Water is mixed in circuit.
Remedy Replace receiver tank. Thoroughly perform
purging before charging refrigerant to
remove water. TDAA-05-07-021

TTNEM50-EN-01(20181109) T5-7-32
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

5. Faulty compression of compressor

TroubleLow-pressure side is high and high-pressure

side is low. High-pressure becomes equal to
low-pressure immediately after stopping the
air conditioner.
Cause Faulty compressor.
Remedy Check and repair of compressor.
TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit)

TroubleWhen absolutely clogging, low-pressure side

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

7. Air incorporation in circuit

TroublePressure is high on both sides of high-

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

8. Excessive open of expansion valve

TroublePressure is high on both sides of high-

pressure and low-pressure. Frost (dew)
adheres to low-pressure piping.
Cause Faulty expansion valve.
Remedy Check for installation of thermal cylinder. TDAA-05-07-025

TTNEM50-EN-01(20181109) T5-7-33
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Work after Replacing Components

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

1. Refill Compressor Oil

2. Charge Air Conditioner with Refrigerant

 Purging
 Charge air conditioner with refrigerant
 Warm-up operation
 Inspection

TTNEM50-EN-01(20181109) T5-7-34
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Refill Compressor Oil

When replacing the cooling circuit parts, refill compressor
oil to the specified level.

Replacement Compressor Condenser Evaporator Receiver D hose L hose S hose

parts (between (between (between
compressor condenser and unit and
and condenser) unit) compressor)
Oil- Refer to the 40 cm3 40 cm3 20 cm3 6 to 9 cm3/m 2 to 4 cm3/m 8 to 11 cm3/m
replenishing following. (2.4 in3) (2.4 in3) (1.2 in3) (0.37 to 0.55 (0.12 to 0.24 (0.49 to 0.67
quantity in3/3.3 ft) in3/3.3 ft) in3/3.3 ft)

 When of replacing compressor

New compressor (1) is charged with oil required for  Compressor oil refill container
cooling circuit. When replacing new compressor (1), drain
Oil type Part No Quantity
excess oil from new compressor (1). Adjust oil level so
that oil in new compressor (1) is the same level as oil (B) in ND-OIL8 4422696 40 cm3 (2.4 in3)
compressor (2) to be replaced.

fNOTE: Compressor oil quantity: 160 cm3 (9.8 in3)

1 2

TDAA-05-07-015

1- New Compressor 2- Replacing Compressor

TTNEM50-EN-01(20181109) T5-7-35
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Charge Air Conditioner with Refrigerant

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

1. Pressure rise in the high pressure side

If air remains in the air conditioner circuit, this disturbs
the heat exchange between refrigerant and air in the
condenser. This causes pressure to rise in the high
pressure side (compressor side).
Refrigerant gas is easily liquefied, but air cannot
be liquefied and remains as a gas in the condenser
because the temperature at which air liquefies is
extremely low. Therefore, liquidation of the refrigerant
gas in the condenser decreases by the amount of air in W115-02-10-001
the circuit, and the gas pressure in the high pressure
side increases accordingly.

2. Metal corrosion
If air remains in the air conditioner circuit, a chemical
reaction between refrigerant and moisture in the
air takes place, and as a result, hydrochloric acid is
produced. Hydrochloric aid corrodes metals such as
aluminum, copper and iron.

W115-02-10-002

3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes through
the expansion valve, gas pressure decreases and
temperature drops. Moisture included in high pressure
refrigerant gas in the air conditioner circuit freezes at
the expansion valve orifice, plugging refrigerant flow.
Operation of the air conditioner becomes unstable and
cooling efficiency lowers.

W115-02-10-003

TTNEM50-EN-01(20181109) T5-7-36
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Procedures for charging air conditioner with

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

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve

(7) on manifold gauge (1). Perform purging for 10
minutes or more by operating vacuum pump (4).

TTNEM50-EN-01(20181109) T5-7-37
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

IMPORTANT: If the pointer returns to 0, retighten the 7

line connections and perform purging again.
3. When the low pressure gauge reading falls below
-0.1 MPa (-750 mmHg) (-14.5 PSI), close high
2
pressure valve (2) and low pressure valve (7) and
stop vacuum pump (4).
Wait for approximately five minutes and confirm
that the pointer does not return to 0.

4. With high pressure valve (2) and low pressure valve W115-02-10-005
(7) on manifold gauge (1) closed, connect charge
hose (5) to refrigerant container (8).
7 1

8
5. Open valve (9) of refrigerant container (8).
Push air bleed valve (10) on manifold gauge (1) to
purge air in charge hose (5) with the refrigerant W115-02-10-007
pressure.
When draining refrigerant, immediately release air
bleed valve (10). 10 1

5
9

W115-02-10-007

TTNEM50-EN-01(20181109) T5-7-38
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

IMPORTANT:
 Always stop the engine when charging the air
conditioner with refrigerant.
 Do not position the refrigerant container upside
down during charging operation.
 When changing the refrigerant container during
charging operation, be sure to perform the
procedure in step 10.
 Charge the low-pressure side hose first.
6. Fully tighten charge hose (5) to manifold gauge
(1). Open high pressure valve (2) and valve (9) of
refrigerant container (8). Charge with refrigerant
(R134a). Close high pressure valve (2) and valve
(9) of refrigerant container (8) when high pressure
gauge (11) reading reaches 98 kPa (14.2 PSI). W115-02-10-008

fNOTE: Use warm water of 40˚C (104˚F) or less to warm

refrigerant container (8) to aid in charging operation. 1

11
2

5
9

IMPORTANT: Use the leak tester for R134a.

8
7. After charging, check the line connections for gas
leaks using the leak tester.

W115-02-10-007

TTNEM50-EN-01(20181109) T5-7-39
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

8. Confirm that high pressure valve (2) and low 1

pressure valve (7) on gauge manifold (1) and valve
7
(9) of refrigerant container (8) are closed. Start the
engine and operate the air conditioner.
Operating Conditions of the Air Conditioner 2
 Engine Speed: Low Idle
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
9

W115-02-10-007
IMPORTANT: Do not open high pressure valve (2) on
manifold gauge (1).
9. Open low pressure valve (7) on manifold gauge (1)
1
and valve (9) of refrigerant container (8) to charge
with refrigerant. 7

fNOTE: Required refrigerant quantity: 900±50 g (1.98 ±

0.1 lb) 2

10. If refrigerant container (8) becomes empty during

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

11. After charging, close low pressure valve (7) on

manifold gauge (1) and valve (9) of refrigerant
container (8), and stop the engine.

TTNEM50-EN-01(20181109) T5-7-40
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

IMPORTANT: If the air conditioner is operated with

very low level of refrigerant, it will cause the
damage of the compressor. If the air conditioner
is overcharged with refrigerant, cooling efficiency
will lower and abnormal high pressure will arise in
the air conditioner circuit, causing danger.
12. Start the engine and operate the air conditioner
again. Check that cold air blow out from the vents.
Operating Conditions of the Air Conditioner
 Engine Speed: Low Idle
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool

dCAUTION: When disconnecting the high-

pressure-side charge hose, refrigerant and
compressor oil may spout. Disconnect the high-
pressure side charge hose after the high-pressure
side pressure drops to less than 980 kPa (142 PSI).
13. After checking refrigerant quantity, disconnect the
charge hoses. Disconnect the low-pressure-side
charge hose first. Wait for the high-pressure-side
pressure to drop to less than 980 kPa (142 PSI).
Disconnect the high-pressure-side charge hose.

TTNEM50-EN-01(20181109) T5-7-41
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

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: Low Idle
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool

Inspection
After warm-up operation, carry out gas leak check and
performance check.

dCAUTION: Refrigerant will produce poisonous

material if exposed to heat of 1000°C (1832°F) or
more. Never bring refrigerant close to a fire.
1. Check the air conditioner for gas leaks using a leak
tester.
 Perform checking under well-ventilated conditions.
 Thoroughly wipe off dust from the charge hose
connections of the compressor.
 Pay special attention to check the piping
connections.
 If any gas leaks are found, retighten the piping
connections.

2. Performance Check. Carry out performance check W115-02-10-013

of the air conditioner after checking each air
conditioner component.
 Check each component for abnormalities.
 Carry out ON-OFF check of the compressor clutch.
 Check compressor fan belt tension.
 Check the coolant level in the radiator.
 Operate the air conditioner and check the
performance.

W115-02-10-014

TTNEM50-EN-01(20181109) T5-7-42
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

3. The checklist before the summer season is as

follows:
 Check each air conditioner component for
abnormalities.
 Check the piping connections for oil leaks.
 Check refrigerant quantity.
 Check the engine cooling circuit.
 Check V belt for wear. Replace if necessary.
 Check for clogged condenser.

4. Off-Season Maintenance
 During off-season, operate the idler pulley and
compressor pulley at least once a month for a short
time to check for any abnormal sounds.
 Do not remove the compressor belts during off-
season. Operate the compressor occasionally at
slow speed for 5 to 10 minutes with the belt slightly
loosened in order to lubricate the compressor.

fNOTE: When the machine is in normal and the air

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

Operating Conditions of the Air Conditioner

 Engine Speed: High Idle
 Cab Window: Fully closed
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
 Fresh/re-circulated air selection: Re-circulated Air
 Season: Summer

TTNEM50-EN-01(20181109) T5-7-43
 SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner

Hose and Pipe Tightening Torque A

Use the following tightening torque values when

connecting the pipings.

Joint Location Tube or Bolt Size Tightening Torque

N·m (lbf·ft)
Nut type Pipe with dia. 8 12 to 15 (8.7 to 10.8) TDAA-05-07-016
(Fig. A) Pipe with D1/2 20 to 25
(14.5 to 18.1)
B
Pipe with D5/8 30 to 35
(21.7 to 25.3)
Block joint Receiver M6 Bolt 4.0 to 7.0 (3.0 to 5.0)
(Fig. B) (4T)
M6 Bolt (6T) 8.0 to 12 (5.8 to 8.7)
for other than
Receiver

TDAA-05-07-017

TTNEM50-EN-01(20181109) T5-7-44
MEMO

TTNEM50-EN-01(20181109)
MEMO

TTNEM50-EN-01(20181109)
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com

SERVICE MANUAL REVISION REQUEST FORM

COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
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are requested, use the comment column)
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Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

TTNEM50-EN-01(20181109) (Copy this form for usage)

The Attached Diagram List
The following diagrams are attached to this manual.

01. HYDRAULIC CIRCUIT DIAGRAM (1/2)

02. HYDRAULIC CIRCUIT DIAGRAM (2/2)

03. JOYSTICK STEERING HYDRAULIC CIRCUIT DIAGRAM

04. ELECTRICAL CONNECTION DIAGRAM (1/3)

05. ELECTRICAL CONNECTION DIAGRAM (2/3)

06. ELECTRICAL CONNECTION DIAGRAM (3/3)

07. JOYSTICK STEERING ELECTRICAL CONNECTION DIAGRAM (ELECTRIC TYPE JSS)

08. FRONT FRAME WIRING DIAGRAM

09. REAR FRAME WIRING DIAGRAM (1/3)

10. REAR FRAME WIRING DIAGRAM (2/3)

11. REAR FRAME WIRING DIAGRAM (3/3)

12. FLOOR WIRING DIAGRAM (REAR CONSOLE) (1/4)

13. FLOOR WIRING DIAGRAM (REAR CONSOLE) (2/4)

14. FLOOR WIRING DIAGRAM (REAR CONSOLE) (3/4)

15. FLOOR WIRING DIAGRAM (REAR CONSOLE) (4/4)

16. FLOOR WIRING DIAGRAM (SIDE CONSOLE) (1/2)

17. FLOOR WIRING DIAGRAM (SIDE CONSOLE) (2/2)

18. JOYSTICK STEERING WIRING DIAGRAM (REAR AND SIDE CONSOLE)

19. JOYSTICK STEERING WIRING DIAGRAM (ARMREST HARNESS)

20. FLOOR WIRING DIAGRAM (FRONT CONSOLE)

21. CAB WIRING DIAGRAM

TTNEM50-EN-01(20181109)