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01
GENERAL
Specification dimension drawings ............... Specifications.. ................................................ Weight table .................................................. Fuel, coolant and lubricants ........................
01-2 01-4 01-7 01-8
01-l 0
SPECIFICATION
GENERAL
SPECIFICATION
DIMENSION
DIMENSION
DRAWINGS
DRAWINGS Unit: mm
Serial No.: 11001 - 12050
-
-I
c
0
c c
0 -
SWG00332
01-2 0
GENERAL
SPECIFICATION
DIMENSION
DRAWINGS
Serial No.: 12051 and up
Unit: mm
c
0
c c
a P
01-3 0
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine Serial Overall
model
G D825A-2
No.
f
weight
11001 - 12000
12001-
12050
12051 and up 29,680
kg
29,680
29,680
Load on front wheel
kN {kg1
78.9 {8,040)
78.9 (8,040)
78.9 (8,040)
Load on rear wheel
kN (kg1
212.2 121,640)
212.2 (21,640)
212.2 (21,640)
Overall
length
mm
11,470
11,470
11,470
Overall
width
mm
3,310
3,310
3,310
Overall
height (to top of cab)
mm
3,550
3,550
3,550
Overall
height (to tip of muffler)
mm
2,605
2,605
2,605
mm
7,100
7,100
7,100
mm
1,840
1,840
1,840
(front)
mm
2,620
2,620
2,620
(rear)
mm
2,620
2,620
2,620
mm
440
440
440
1st
km/h
4.0
4.0
4.0
2nd
km/h
5.4
5.4
5.4
Wheelbase Distance
between
tandem Tread
Ground
clearance
Forward
Reverse t
Drawbar
pull
Gradeability Min. turning Static stability
01-4 0
centers of
wheels
radius
3rd
km/h
8.0
8.0
8.0
4th
km/h
11.5
11.5
11.5
5th
km/h
15.8
15.8
15.8
6th
km/h
21.4
21.4
21.4
7th
km/h
31.3
31.3
31.3
8th
km/h
44.9
44.9
44.9
1st
km/h
4.3
4.3
4.3
2nd
km/h
5.8
5.8
5.8
3rd
km/h
8.5
8.5
8.5
4th
km/h
12.2
12.2
12.2
5th
km/h
16.9
16.9
16.9
6th
km/h
22.8
22.8
22.8
7th
km/h
33.4
33.4
33.4
8th
km/h
47.9
47.9
47.9
tN {kg)
169.85 {17,320)
169.85 {17,320}
169.85 (17,320)
deg
24
24
24
m
7.9
7.9
7.9
deg
35
35
35
GENERAL
SPECIFICATIONS
Machine Serial
1
model No.
Model
G D825A-2
3
4-cycle, water-cooled,
Type
vertical,
in-line,
direct injection
type,
ith turbocharger No. of cylinders
- Bore x stroke
mm
6-140x165
6-140x165
6-140x
15.24 {I 5,240I
15.24 {I 5,240)
15.24 {I 5,240)
165
Piston displacement
.Q{cc1
Flywheel
:W/rprr
209/2,100
209/2,100
209/2,100
-iP/rpm
{280/2,100)
~280/2,1001
{280/2,100)
lm/rpn
1,255/l ,400
1,255/l ,400
1,255/l ,400
:gm/rprr
{128/1,4001
{I 28/l ,400)
{128/l ,400}
horsepower
Max. torque
Low idling
rpm
2,350
2,350
2,350
High idling
rpm
650
650
650
g/kWh
201
208
208
g/HPhl
{I501
11551
{I 551
Min. fuel consumption
Starting
ratio
24V, 11 kW
motor
24V, 50A
Alternator
12V, 160Ahx2
Battery
Planetary
gear type, power
multiple Transmission
disc clutch,
actuated, force
lubrication
feed,
deduction
gear
Spiral bevel
Tandem U 3 _ z 5 2 q
5
ij t z
Fullv device
Leaning Max.
Elliott
Hydraulic
leaning
angle
deg
14.5
Type
I Fully hydraulic
Steering
tandem
transmission
Reverse
Type
and planetary
angle
gear
reduction
floating,
Chain
pump
8 speeds,
8 speeds
gear
2-stage 3ear axle
gear
forward
reverse
shift type,
hydraulically
14.5
type
tvoe type angle
type
I
14.5
type (Orbit-roll)
deg
50
50
50
deg
25
25
25
q
ii
Y
Max.
articulating
angle
01-5 0
GENERAL
SPECIFICATIONS
Machine
model
Serial
No.
Size
Inflation
G D825A-2
pressure
11001 - 12000
12001-
(front)
18.00-25-12PR
23.5-25-l
2PR
23.5-25-l
2PR
(rear)
18.00-25-i
23.5-25-l
2PR
23.5-25-l
2PR
(front,
rear
2PR
12050
12051 and up
kPa
240
240
240
:kg/cm?
(2.45)
(2.45)
{2.45}
Rear 4-wheel Main brake
braking
Wet type, multiple
disc
Air actuated Transmission Parking
brake
Dry-type,
output
released Dimensions
(length
(arc height) Dimensions
x height
mm
x thickness) of cutting
4,928
x
800
4,928
(695) x 25
edge
mm
shaft braking
disc type, spring actuated, bv air x
800
4,877
(695) x 25
x
a60
(750) x 25
2,438 x 203 x 19 i 1,438 x 203 x 19 i !,438 x 254 x 25 - 2 pieces
- 2 pieces
- 2 pieces
mm
490
420
450
mm
680
680
950
(left)
mm
1,920
1,920
1,920
Max. side shift distance (right
mm
2,070
2,070
2,070
Turning
angle
deg
360
360
360
Digging
angle
(max.)
deg
a4
a4
115
(min.)
deg
25
25
63
Max. lifting height (from ground) Max. lowering
depth
(from ground) Max. side shift distance
Parallelogram
Type Shank
Standard
to install 7)
149 {15,2001
149 {15,200)
Ripping width
mm
2,978
2,978
2,978
Max. lifting height
mm
675
615
615
mm
480
deg
42.3
of ripper
149 {15,2001
/
kN {kg1
Weight
1
3 (possible
type
(from ground) Max.
lowering
depth
I
480
(from ground)
-
Ripping
01-6 0
angle
52
52
WEIGHT TABLE
GENERAL
WEIGHT TABLE a
Thus . weight
table
is for use when
handling
components
or when
transporting
the machine. Unit:
Machine
Engine
assembly
Radiator
Final drive Tandem Front
(dry)
assembly
(dry)
assembly
drive
axle
(except
11001 - 12000
(dry)
assembly
Transmission
No.
(dry)
assembly
Fuel tank
GD825A-2
model
Serial
assembly
(each)
assembly leaning
Front frame Rear frame
cylinder
and steering
assembly assembly
Operator’s
compartment
assembly
kg
12001-12050
12051 and up
1,360
1,360
1,360
183
183
183
298
298
298
1,147
1,147
1,147
1,802
1,802
1,802
1,242
1,242
1,242
1,024
1,024
1,085
2,982
2,982
2,982
2,093
2,093
2,093
300
300
300
1,000
1,040
1,040
1,125
1,090
1,090
1,160
1,160
1,320
1,540
1,540
1,600
278
278
300
530
530
530
83
83
83
26
26
26
cylinder)
(incl. control) ROPS cab assembly (OPT, High ROPS cab assembly) Drawbar
assembly
Blade assembly Circle rotation
assembly
Wheel assembly Power tilt cylinder Leaning
cylinder
assembly assembly
Blade lift cylinder Drawbar
assembly
shift cylinder
Blade shift cylinder Steering Articulate
cylinder (dry)
Hydraulic
tank (dry)
Hydraulic
pump
Transmission
pump
Circle rotation Ripper assembly
assembly
motor
158 x 2
160 x2
72
72
74
106
106
105
15 x2
cylinder
Ripper cylinder
assembly
158x2
15 x 2
15 x2
72
72
72
130
130
130
53
53
53
106
106
106
12
12
12
55
55
15
2,025
2,025
2,025
01-7 0
GENERAL
FUEL, COOLANT
FUEL, COOLANT
AND
LUBRICANTS
AND LUBRICANTS
Serial No.: 11001 - 12050
UND OF FLUID
RESERVOIR
AMBIENT -22 .30
-4 -20
14 -10
32 0
TEMPERATURE 50 10
68 20
CAPACITY 104 40
86 30
122°F 50°C
Specified
(J?)
Refill
34 (36)
Engine oil pan
+ Transmission
case
25 Engine oil
Final drive case
63
Tandem case (each)
57 95
Front axle housing Hydraulic
t
system
80
Circle rotation (Brake case)
gear case
Circle rotation (Gear case)
gear case
Fuel tank
Cooling
system
0.18 Gear oil
16
Diesel fuel
500
Coolant
Add antifreeze z ASTM
NOTE: (I) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur
content
Change interval of oil in engine oil pan
0.5 to 1.0%
l/2 of regular
interval
Above
l/4 of regular
interval
ASTM: SAE: API:
1.0%
j8 (78.5)
D975 No.1
-
1: Serial No. 12001 - 12050
(2) When starting the engine in an atmospheric temperature of lower than O‘C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal
01-8 0
(
-
and oil in piping. inspection and maintenance.
GENERAL
Serial
FUEL, COOLANT
AND
No.: 12051 and up
arness between CNT03 and transmission solenoid valve.
Repair
Iefective transmission ow solenoid valve.
Replace
shifts to 5th to 8th (F and R) but not to 1st to
4th (F and R).
SerialNo.:11001-12012,12016-
12018 2 YES
YES _ 1 Is voltage between CNT03 (I) and (3) 20 3OV? I
. Turn starting switch ON. - Place shift lever between 1st and 4th. * Connect Tadapter (or socket) to CNT03 (male).
Is voltage between CNT03 I3)-CNTOl (II)ground connection 20 3OV?
_
NO
Defective contact, or disconnection in wiring harness. Defective print board circuit. Iefective contact, or iisconnection in wiring iarness between CNT03 Ind transmission solenoid valve.
Repair or replace.
Reoair
20-113 0
E-6, E-7, E-8
TROUBLESHOOTING
E-6 Transmission
does not shift to 1st (F and R).
Serial No.: 11001 - 12012,
12016 - 12018
Cause
2 YES 1 Is voltage between CNTOZ 14) and CNTOl 13). CNT02 (6) and CNTOI (3) 20 - 3OV?
Is voltage between CNTO~ (3) and (11) 203OV?
YES
No
’ Turn Starti”g switch ON. * Place shift lever at 1st.
E-7 Transmission
E-8 Transmission
2 YES
CNTOI (~),CNTOP (8) and CNTOl (5)
20 - 3OV? . Turn starting switch ON. - Place shift lever at 3rd.
20-114 0
-
between CNTOI (5) and (11) 20 3OV? - Turn
stafiiw
switch ON. * Place shift lever 3rd.
1 NO
Repair
Defective switch.
Repair or replace.
inside rotary
Defective contact, or disconnection in siring harness of rotary switch.
Repair
* Defective p;int board circuit. - Defective contact, or* disconnection in wiring harness between print board and connector.
Replace
IIefective switch.
Repair or replace.
Reoair
12016 - 12018
Is voltage
Is voltage between CNTOZ (4) and
Replace
* Defective print board circuit. - Defective contact, or disconnection in wiring harness between print board and connector.
does not shift to 3rd (F and R).
Serial No.: 11001 - 12012,
YES
Defective contact, or disconnection in siring harness of rotary switch.
12016 - 12018
1 NO
1 -
Repair or reolace.
does not shift to 2nd (F and R).
Serial No.: 11001 - 12012,
. Turn starting switch ON. * Place shift lever atr 2nd.
inside rotary
-
1 NO
* Turn starting switch ON. * Place shift lever at 1st.
Defective switch.
Remedy
inside rotary
-
No
Iefective contact, or zlisconnection in siring larness of rotary switch.
. Defective print board circuit. * Defective contact, or disconnection in wiring harness between print board and connector.
Replace Repair
E-S, E-10, El1
TROUBLESHOOTING
E-9 Transmission Serial
does not shift to 4th (F and R).
No.: 11001 - 12012,
12016 - 12018
2 YES Is voltage YES between CNTOI 1 - (6)and (11) ZO3OV?
Is voltage between CNTOZ (4) and CNTOI (6), _ CNT02 19) and CNTOl (6) 20 3OV?
~
1
. Turn starting switch ON. - Place shift lever at 4th.
NO
switch ON. Place shift levr at 4th.
- Defective
-
E-lOTransmission
does not shift to 5th (F and R).
Serial No.: 11001 - 12012,
YES Is voltage between CNT02 (5) and CNTOI (7), CNTOZ 16) and CNT02 (7) 20 3OV? . Turn starting switch ON. * Place shift lever at 5th.
Is voltage between CNTOI (7) and (11) 20 3OV?
* Turn
starting switch ON. * Place shift lever at 5th.
Serial
1 boardandconnector’
Defective switch.
inside rotary
-
NO
1
Defective contact, or disconnection in wiring harness of rotary switch.
- Defective
print board circuit. . Defective contact, or disconnection in wiring harness between print board and connector.
NO
E-l 1 Transmission
print board circuit. Defective contact, or disconnection in wiring harness between print
12016 - 12018 2 YES
~
Defective contact, or disconnection in wiring harness of rotary switch.
NO
1 -
inside rotary
-
* Turn starting
-
Defective switch.
does not shift to 6th (F and R).
No.: 11001 - 12012,
12016 - 12018
20-115 0
TROUBLESHOOTING
E-12, E-13
E-12Transmission Serial
does not shift to 7th (F and R).
No.: 11001 - 12012,
12016 - 12018 Cause
,EiZ ES
between
i-------NO
CNTOl (9), CNTOS (8)and CNTOl (9)
swtich ON. * Place shift lever
* Turn starting switch ON. * Place shift lever at 7th.
does not shift to 8th (F and R).
19)and CNTOI 20-3OV?
(IO)
* Turn starting switch ON. - Place shift lever at 8th.
20-l16 0
-
Is voltage between CNTOI (IO) and (11) 203OV? ' Turn
starting
switch ON. * Place shift lever at 8th.
1 NO
Repair or replace.
or disconnection in wiring harness between print board and connector.
Replace Repair
12016 - 12018
2
Is voltage between CNTOZ(5) and CNTOl(lO), CNTOP
print board
-Defectivecontact,
No.: 11001 - 12012,
mz 1
inside rotary
Defective contact, or disconnection in wiring harness of rotary switch.
*Defective circuit.
-
E-13Transmission Serial
Defective switch.
CNTOl
YES Iefective switch.
inside rotary
Repair or replace.
-
No
Iefective contact, or disconnection in wiring larnss of rotary switch.
Repair
* Defective print board circuit. * Defective contact, or disconnection in wiring harness between print board and connector.
Replace Repair
TROUBLESHOOTING
LED DISPLAY
LED DISPLAY FOR TRANSMISSION Serial No. 12013 - 12015, 1)
CONTROLLER
CONTROLLER
12019 and up
Self-diagnostic display The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning lamp and alarm buzzer are actuated. Method of displaying error codes and abnormal operation codes again Turn the starting switch OFF + ON and the error code and abnormal operation code will be displayed in the following order: [CHECK.SUMl + [Past failures] + [Existing failures] + [Abnormal operation] When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
2)
I I Error code
Abnormal
system
1 Short
circuit
in 1st clutch
A2
Short
circuit
in 2nd clutch
solenoid
output
system
0
A3
Short
circuit
in 3rd clutch
solenoid
output
system
0
A4
1 Short
circuit
in 4th clutch
solenoid
output
system
A5
Short
circuit
in High/Low
A7
Short circuit in FORWARD/REVERSEclutch solenoid output system
0
bl
Disconnection
in 1st clutch
0
b2
Disconnection
in 2nd clutch
solenoid
output
system
0
0
ET-8
:
b3
Disconnection
in 3rd clutch
solenoid
output
system
0
0
ET-9
g
b4
Disconnection
in 4th clutch
solenoid
output
system
0
0
ET-l 0
b5
( Disconnection
b6
Disconnection
b7
Disconnection
in FORWARD clutch solenoid
output
system
b8
1 Disconnection
in REVERSE clutch solenoid
output
system
cl
Disconnection
c2
Abnormality
in voltage
of shift
potentiometer
(I) signal
c3
/ Abnormality
in voltage
of shift potentiometer
(2) signal
Al
(
1
(
and content solenoid
clutch
of abnormality output
solenoid
solenoid
in Low clutch
solenoid
in High clutch
solenoid
in inching
c4
Discrepancy
in shift
potentiometers
c5
Abnormality
in both
shift
(
ET-3
/ ET-4
0
ET-5
0
ET-6
0
ET-7
0
1
I ET-II
(
0
0
ET-1 2
0
0
ET-13
0
1 ET-14
0
(
o-
-
ET-l 5
0
-
ET-l 6
0
1
-
( ET-17
0
(ET-16.17)
speed
sensor
I Disconnection
in speed
sensor
system
20-152 0
(
(
0 0
0
in engine
when
1
ET-2
signal
systems
are ON
Shift lever is not at P position
0
1
(ET-16.17)
I Disconnection
d7
system
0
1 ET-l
-
potentiometer
oil temperature
(
0
0
d4
in transmission
0
j
(I), (2) signals
1
1 Failure
system
0
0
system
system
) Both F and R switches
d6
/
system
output
dl
rd5
output
output
potentiometer
/
system
output
)
)
FOR TRANSMISSION
system
sensor
starting
switch
is ON
(
(
/
0
)
0
) ET-18
)
1
0
/
-
1 ET-19
1
I
0
I
-
1
-
)
-
) ET-21
0
1
0
xoml -
)
TROUBLESHOOTING
LED DISPLAY
Abnormal
system
and content
FOR TRANSMISSION
CONTROLLER
of abnormality
2
z 2
16
Engine
17
Acceleration
18
Transmission lubricating continued for more than
19
With transmission at neutral, travel speed above 4 km/h and engine speed above 1400 rpm continued for more than 10 seconds
IA
With transmission in F or R and inching pedal depressed, travel speed above 4 km/h and engine speed above 1400 rpm continued for more than 10 seconds
Error code
speed
Gearshifting
above
2350 rpm
to dangerous speed with inching pedal depressed
pattern
oil temperature 30 seconds
when
there
above
is abnormal
120°C
0
0
-
0
0
-
0
0
-
-
-
-
-
-
operation
-
i F
Shifts
N +
F when
travel
speed
is above
-
i A F i A
Shifts
N +
R when
travel
speed
is above
9 km/h
Shifts
F +
R when
travel
speed
is above
9 km/h
A i F
Shifts
R +
F when
travel
speed
is above
9 km/h
F i -
Shifts to F4 or above
when
travel
speed is below
2 km/h
A : -
Shifts to R4 or above
when
travel
speed
2 km/h
F i 0
Inching
used for long time
in F (FORWARD)
A i 0
Inching
used for long time
in R (REVERSE)
9 km/h
is below
t
I-----0 1 2 3 4
: Clutch Clutch Clutch Clutch Clutch
: : : :
temperature temperature temperature temperature temoerature
below 200°C 200 - 230°C 230 - 260°C 260 - 290°C above 290°C
20-153 0
LED DISPLAY
TROUBLESHOOTING
3)
Saving error codes, abnormal operation The transmission controller saves any ated, and keeps these in memory even As a result, when the starting switch is ON, it is possible to check the content Display
item
(order
Transmission
controller
power
2)
All segments
of LED light
3)
(No comment)
4)
CHECK.SUM
5)
Trouble
6)
Error codes d4: Abnormality
Z L =I Z 2
Starting
ON
up
.-P Z ‘X LLI
g
0 ‘E
B x 0
Z E Z 5 m .-? 2 ul
Z 5 Z 2 ? ‘E 2 i2
switch
OFF +
I-! -.-. I-!
ON
5
.Y
0.5
.Y
0.5
display
data
in engine
speed
sensor $
7)
If there are any other failures Steps 5) and 6) are repeated.
8)
Existing failures * If there are no existing failures, displayed for 3 seconds.
9)
Display time (se4
LED display
-
Z 5 Z 2 Y-J I?
CONTROLLER
codes error codes and abnormal operation codes that are generafter the starting switch is turned OFF. turned ON and the transmission controller power is turned of all the abnormalities that have occurred so far.
of display)
1)
FOR TRANSMISSION
t3.E
is
Error codes F4: Disconnection in backup buzzer system, short circuit in power source
IO) If there are any other 9) are repeated.
failures,
11) Abnormal
record
operations
12) Abnormal operation codes 14: Inching used continuously 10 seconds
Steps
f-u
F
3
0.5
1-i
3
8) and
u
for more
13) Gearshift pattern code when there is abnormal operation FO: FORWARD, clutch temperature below 14) Number of times of operation abnormal operation 02: 2 times
c(
in memory,
than
0.5
P+
3
FE
3
r:-- ,I
3
200°C
of this
15) If there are any other abnormal operations in memory, Steps 11) to 14) are repeated.
When the display of abnormal operations in memory is completed, display returns again to existing failures. * If there are no existing failures, fi.3 is displayed.
20-154 0
-
-
TROUBLESHOOTING
.
LED DISPLAY FOR TRANSMISSION
CONTROLLER
Method of deleting error codes from memory After carrying out troubleshooting and completing repairs of the failure, the self-diagnostic display returns to the normal display. Always do as follows to delete the transmission controller error codes from memory. + The abnormal operation items cannot be deleted from memory.
(1) Turn the starting
switch to the ON position, and after completing the display for all the past failures in memory, check that the display returns to 17 17 . to connector number [FRI inside the (2) Take the connector (color of wiring harness: green) cor%zed right console box, and ground it to the chassis. (When doing this, make sure that the starting switch is at the ON position.) . After grounding the connector, install the blind connector to the FR connector in the original way. (3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been deleted from memory. . If the past error codes have been deleted from memory, CHECK.SUM is displayed, then E.!l is displayed immediately. (If there are any abnormal operation items saved in memory, the display will start to show the abnormal items.)
20-155 0
ET-1
TROUBLESHOOTING
ET-1 *
* *
[Al]
(Short circuit in 1st solenoid)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3
1Is voltage
YES
GotoA
H 11[ZFn y$ijiij!;;;g. When
II
(female) (2) and chassis normal?
1st is
YES
betwee”,st Is resistance (male) (1) and (2) normal? -5-20R -Turn starting switch OFF. * Disconnect 1st.
NO
-
switch OFF. * Disconnect 1st and E2. NO
4 YES
Aj$!jnL’JHP
electrical
Short circuit with power source in wiring harness between 1st (female) (2) and E2 (female) (17)
Repair or replace
Short circuit in wiring harness between E2 (7) and 1st (I) and wiring harness between E2 (17) and 1st (2)
Repair or replace
Defective
1st solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 1st (female) (1) and E2 (female) (7)
* Max. 0.1 V NO * Turn starting switch OFF. * Disconnect 1st and E2. * Turn starting switch ON.
ET-1 Related
Remedy
Repair or
circuit diagram
Transmission
controller
I
1st
solenoid
(+I
1st
solenoid
(-1
E2
1st
1st
solenoid
TWG00317
20-156 0
ET-2
TROUBLESHOOTING
ET-2 Ir
* t
[A21 (Short circuit in 2nd solenoid)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
YES
3
GotoA
Is voltage YES 2 is disconnected, is resistance between E2 (female) (81 and (18) normal? * Min. 1 MR *Turn startina switch OFF.. Disconnect 2nd and E2.
between 2nd (female) (2) and chassis normal?
When 2nd
YE 1
(male) (1) and (2) -5-20Q -Turn starting switch OFF. - Disconnect 2nd.
* Max. 0.1 V NO -Turn starting switch OFF. * Disconnect 2nd and E2. - Turn starting switch ON.
-
hln ‘*”
0
4 YES
AjZHP I
I
NO Max. 0.1 V *Turn starting switch OFF. * Disconnect 2nd and E2. *Turn starting switch ON.
electrical
Transmission
I
Repair or replace
Short circuit in wiring harness between E2 (female) (8) and 2nd (female) (1) and wiring harness between E2 (female) (18) and 2nd (female) (2)
Repair or replace
Defective
2nd solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 2nd (female) (1) and E2 (female) (8)
I
-
ET-2 Related
Short circuit with power source in wiring harness between 2nd (female) (2) and E2 (female) (18)
Repair or replace
circuit diagram
controller
I
E2
2nd
2nd
solenoid
20-157 0
ET-3
TROUBLESHOOTING
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3 Is voltage between 3rd (female) (2) and chassis normal?
YES 2 YE 1
(male) (1) and (2) *5-20R . Turn starting switch OFF. s Disconnect 3rd.
When 3rd is disconnected,
is
- resistance between E2 (female) (9) and 119) normal?
* Max.
-
* Min. 1 MC2 * Turn starting switch OFF. * Disconnect 3rd and E2.
0.1 V
YES
GotoA
-
NO
*
Turn starting switch OFF. * Disconnect 3rd and E2. *Turn starting switch ON. NO
,h IV”
4 YES
+ZJgJH--
* Max.
0.1 V
NO
Turn starting switch OFF. * Disconnect 3rd and E2. * Turn starting switch ON.
electrical Transmission
Short circuit with power source in wiring harness between 3rd (female) (2) and E2 (female) (19)
Repair or replace
Short circuit in wiring harness between E2 (female) (9) and 3rd (female) (1) and wiring harness between E2 (female) (19) and 3rd (female) (2)
Repair or replace
Defective
3rd solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 3rd (female) (1) and E2 (female) (9)
*
ET-3 Related
Remedy
Repair or replace
circuit diagram controller I
E2
3rd
3rd
solenoid
(+I
3
3rd
solenoid
(-1
3
3rd
solenoid
TWG00319
20-l 58 0
ET-4
TROUBLESHOOTING
ET-4 +
* *
[A41 (Short circuit in 4th solenoid)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
3 YES 2 -
YES
GotoA
Is voltage between 4th (female) (2) and chassis normal?
I When 4th is YES disconnected, is * Max. 0.1 V - resistance between *Turn starting switch E2 (female) (101and 1 * Disconnect 4th and p (201normal? _ Is resistance *Turn starting switch * Min. 1 MCI between 4th - *Turn starting NO (male) (1) and (2) switch OFF. normal? * Disconnect 4th -5-20R and E2. * Turn starting NO switch OFF. * Disconnect 4th.
NO OFF. E2. ON.
4 YES
+GjjiJH-*
electrical
Transmission
Repair or replace
Short circuit in wiring harness between E2 (female) (IO) and 4th (female) (I) and wiring harness between E2 (female) (20) and 4th (female) (2)
Repair or replace
Defective
4th solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 4th (female) (1) and E2 (female) (10)
Max. 0.1 V NO * Turn starting switch OFF. - Disconnect 4th and E2. - Turn starting switch ON.
ET-4 Related
Short circuit with power source in wiring harness between 4th (female) (2) and E2 (female) (20)
Repair or replace
circuit diagram
controller
I
4th
E2
4th
solenoid
3 4th
solenoid
(-1
3
TWC00320
20- 159 0
TROUBLESHOOTING
ET-5
ET-5
[A51 (Short circuit in High/Low
solenoid)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
GotoA
When YES -
1 ~ Is resistance between Lo (male) (1) and (2) normal? *5-20R *Turn starting switch OFF. * Disconnect Lo.
Lo
is
disconnected. is resistance between E2 (female1 (2) and
* Max.
-
NO
0.1 V
Turn starting switch OFF. * Disconnect Lo and E2. *Turn starting switch ON. .
normal? * Min. 1 MR *Turn starting switch OFF. * Disconnect Lo and E2. (13)
NO
6 When YES 5 -
A
~ Is voltage between Lo (female) (1) and chassis normal?
-
disconnected,
-
_
*5-20R -Turn starting switch OFF. * Disconnect Hi.
YES
Hi is is
resistance between E2 (female) 121and (14) normal?
-
*Min. 1 MR NO *Turn starting switch OFF. * Disconnect Hi and E2.
NO
. * Max. 0.1 V * Turn starting NO switch OFF. * Disconnect Lo and E2. -Turn starting switch ON.
a
YES
(female) (2) and chassis normal? B
between Hi (female) (2) and chassis normal? * Max. 0.1 V * Turn starting switch OFF. * Disconnect Hi and E2. . Turn starting switch ON.
20-160 0
Short circuit in wiring harness between E2 (female) (2) and Lo (female) (I) and wiring harness between E2 (female) (13) and Lo (female) (2) Defective
NO
Is resistance YES between Hi (male) (1) and (2) 4 normal?
Short circuit with power source in wiring harness between Lo (female) (2) and E2 (female) (13)
_
* Max. 0.1 V NO -Turn starting switch OFF. - Disconnect Hi and E2. * Turn starting switch ON.
NO
Low solenoid
Repair or replace
Repair or replace
Replace
GotoB Short circuit in wiring harness between E2 (female) (2) and Lo (female) (I) and wiring harness between E2 (female) (13) and Lo (female) (2)
Repair or replace
Defective
Replace
Hi solenoid
Short circuit with power source in wiring harness between Lo (female) (1) and E2 (female) (2)
Repair or replace
Defective controller
Repair or replace
transmission
Short circuit with power source in wiring harness between Hi (female) (1) and E2 (female) (3)
Repair or replace
Short circuit with power source in wiring harness between Hi (female) (2) and E2 (female) (14)
Repair or replace
ET-5
TROUBLESHOOTING
ET-5 Related
electrical
circuit diagram
Lo solenoid ransmission
I
controller
Lo solenoid
(+I
Hi
solenoid
(+I
Lo solenoid
(+I
id
I
TWG00321
20-161 0
ET-6
TROUBLESHOOTING
ET-6 -+
* *
[A71 (Short circuit in FORWARD/REVERSE
solenoid)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
3 YES YESI
1When
FW is
I (female) (2) and chassis normal?
2 s-l
l-l
* Turn starting switch OFF. . Disconnect FW and E2. NO
-5-20R -Turn starting switch OFF. - Disconnect FW.
and E2.
6
YES
jZ+Z&CJH--
YES
A
Is voltage between FW (female) (1) and chassis normal?
4
Is resistance between RE (male) (1) and (2) normal?
* Min. 1 MD NO *Turn starting switch OFF. * Disconnect RE and E2.
*5-20R -
NO
* Turn starbng switch OFF. * Disconnect RE.
- Max. 0.1 V 1 * Turn starting NO switch OFF. * Disconnect FW and E2. -Turn starting switch ON.
a YE 7
B
f Max. 0.1 V -Turn starting switch OFF. * Disconnect RE and E2. * Turn starting switch ON.
20- 162 0
*
Is voltage between RE (female) (2) and chassis normal?
L-t
GotoA Short circuit with power source in wiring harness 2etween FW (female) (2) snd E2 (female) (15) Short circuit in wiring harness between E2 (female) (2) and FW (female) (1) and wiring harness between E2 (female) (15) and FW (female) (2) defective solenoid
NO
I
YES
Max. 0.1 V NO * Turn starting switch OFF. - Disconnect RE and E2. *Turn starting switch ON.
Remedy
FORWARD
Iepair or eplace
Iepair or eplace
3eplace
GotoB Short circuit in wiring narness between E2 :female) (5) and RE :female) (1) and wiring narness between E2 ifemale) (16) and RE :female) (2) 3efective solenoid
3epair or eplace
REVERSE
Short circuit with power source in wiring harness between FW (female) (1) and E2 (female) (4)
Repair or replace
Defective controller
Repair or replace
transmission
Short circuit with power source in wiring harness between RE (female) (I) and E2 (female) (5)
Repair or replace
Short circuit with power source in wiring harness between RE (female) (2) and E2 (female) (16)
Repair or replace
ET-6
TROUBLESHOOTING
ET-6 Related
electrical
circuit diagram
FORWARD solenoid Transmlsslon
controller
FORWARD
solenoldlt)
REVERSE
solenoid(t)
FORWARD
solenold(-1
REVERSE solenoid
TWG00322
20-163 0
ET-7
TROUBLESHOOTING
ET-7 * *
[bll
(Disconnection
in 1st solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
* 4YES1 Is resistance
YES 3 When
When 1st(female) (1) YI ; Is groundedto chassis, - ISresistancebetween -
(male) (I) and (2) *5-20R * Turn starting switch OFF. * Disconnect 1st.
ET-7 Related
1st (female)
(2)
YES isgroundedto chassis, - is resistance between E2 (female)(17)and 2
~
1
~
E2 (female1
E2 (female) (17).1st ifemale) 12)and chassis normal? ~ * Min. 1 MR * Turn starting switch
chassis n~~m.g
* Max. 1 R - Turn starting
(71 and
switch
between
OFF.
. Disconnect NO
OFF.
chassisnormal? - Disconnect 1st and E2. - Max. 1 R * Ground 1st (female) (2) to chassis. -Turn starting NO switch OFF. + Disconnect 1st and E2. * Ground 1st (female) (1) to chassis.
NO
Transmission
transmission
Short circuit with ground in wiring harness between 1st (female) (2) and E2 (female) (17)
Defective contact or disconnection in wiring 1st and E2. 1 harness between 1st (female) (1) and E2 (female) (17) Defective contact or disconnection in wiring harness between 1st (female) (I) and E2 (female) (7) Defective 1st solenoid (internal disconnection)
\I0
electrical
Defective controller
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Reolace
circuit diagram
controller 1
1st
E2 1st
solenoid
C-t)
3
1st
solenoid
(-1
-3
1st
solenoid
TWG00317
20- 164 0
ET-8
TROUBLESHOOTING
ET-8 Ir Sr
[b2] (Disconnection
in 2nd solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I 4YEA resistance between E2 (female) 118). 2nd (female) (2) and chassis normal? Is
YI 1
-5-20R * Turn starting switch OFF. - Disconnect 2nd.
ET-8 Related
YES 3 When 2nd (female) 12) YES is grounded tO chassis, ~* Min. 1 MR NO - is resistance between *Turn starting E2 (female1 (18) and 2 switch OFF. p chassis normal? When 2nd (female) (1) * Disconnect 2nd and E2. f Max. 1 - R is grounded to chassis, . is resistance between - . Turn starting NO E2(female) (8) and switch OFF. chassisnormal? - Disconnect 2nd and E2. * Max. 1 R - Ground 2nd (female) (2) to chassis. - Turn starting NO switch OFF. * Disconnect 2nd and E2. * Ground 2nd (female) (1) to chassis. IO
electrical
Transmission
inserted.
Remedy
Cause
Defective controller
transmission
Short circuit with ground in wiring harness between 2nd (female) (2) and E2 (female) (18) Defective contact or disconnection in wiring harness between 2nd (female) (2) and E2 (female) (18) Defective contact or disconnection in wiring harness between 2nd (female) (I) and E2 (female) (8) Defective 2nd solenoid (internal disconnection)
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
controller I
2nd
E2
2nd
solenoid
g) 3
I
TWG00318
20- 165 0
ET-9
TROUBLESHOOTING
ET-9 * Ir
Before Always
[b31 (Disconnection carrying connect
out troubleshooting, any disconnected
in 3rd solenoid)
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
4YEI
(female)
startina
(male) (I) and (2) *5-20n . Turn starting switch OFF. * Disconnect 3rd.
ET-9 Related
3rd (female)
Repair or replace
Repair or replace
Repair or replace
Defective 3rd solenoid (internal disconnection)
JO
Transmission
Repair or replace
Defective contact or disconnection in wiring harness between 3rd (female) (1) and E2 (female) (9)
(2) to chassis.
NO switch OFF. * Disconnect 3rd and E2. * Ground 3rd (female) (1) to chassis.
electrical
transmission
Defective contact or disconnection in wiring harness between 3rd (female) (2) and E2 (female) (19)
YE
* Ground
Remedy
Short circuit with ground in wiring harness between 3rd (female) (2) and E2 (female) (19)
(2) and
chassis normal?
*Turn
Defective controller
inserted.
Replace
circuit diagram
controller
I
E2
3rd
3rd
solenoid
(+)
3
3rd
solenoid
(-)
3
3rd
solenoid
TWG00319
20-166 0
ET-10
TROUBLESHOOTING
ET-10 + +
[b41 (Disconnection
in 4th solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
Defective controller
1 When
4th (female)
(2)
is resistance between E2 (female) (20) and
Is 1
1chassis - Min. -Turn
1 /_
normal?
1 MR starting
NI
1
resistance between 4th (male) (I) and (2) normal? 5-20R * Turn starting switch OFF. * Disconnect 4th.
ET-10 Related
chassis normal? * Disconnect 4th and E2. * Max. 1 R * Ground 4th (female) (2) to chassis. * Turn starting NO switch OFF. * Disconnect 4th and E2. . Ground 4th (female) (1) to chassis.
Transmission
Repair or replace
Short circuit with ground in wiring harness between 4th (female) (2) and E2 (female) (20)
Repair or replace
Repair or replace
Defective contact or disconnection in wiring harness between 4th (female) (I) and E2 (female) (IO)
Repair or replace
Defective 4th solenoid (internal disconnection)
0
electrical
transmission
Defective contact or disconnection in wiring harness between 4th (female) (2) and E2 (female) (20)
YE
inserted.
Replace
circuit diagram
controller
E2
I
4th
4th
solenoid
TWG00320
20-167 0
ET-l 1
TROUBLESHOOTING
ET-11 Ir *
[b51 (Disconnection
in Low solenoid)
is displayed
Before carrying out troubleshooting, check that ail the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
Cause
4YES Is resistance between E2 (female) (131, Lo Ifemale) (2) and
YES 3 -
When Lo (female) YES
2
grounded to chassis, is resistance between E2 (female)113) and
~
YE 1
between Lo (male)
-5-20R * Turn starting switch OFF. - Disconnect Lo.
ET-11 Related
(21 is
chassis
normal?
1 *
-
Min. 1 MR NO * Turn starting switch OFF. * Disconnect Lo and E2.
chassisnormal? ~ When Lo (femaleI (1) * Max. 1 R is groundedto chassis, is resistance between * Turn starting NO E2 (female)(2) and switch OFF. chassisnormal? . * Disconnect Lo and E2. * Max. 1 R * Ground Lo (female) (2) to chassis. * Turn starting NO switch OFF. * Disconnect Lo and E2. * Ground Lo (female) (1)
Defective controller
transmission
Repair or replace
Defective contact or disconnection in wiring harness between Lo (female) (2) and E2 (female) (13)
Repair or replace
Defective Low solenoid (internal disconnection)
electrical
Repair or replace
Short circuit with ground in wiring harness between Lo (female) (2) and E2 (female) (13)
Defective contact or disconnection in wiring harness between Lo (female) (I) and E2 (female) (2)
NO
Remedy
Repair or replace
Replace
circuit diagram
Transmission
controller
I
Lo
E2 Lo
solenoid
(+I
3
Lo
solenoid
(-1
3
Lo
solenoid
TWG00323
20-168 0
TROUBLESHOOTING
ET-12 + *
ET-12
[b6] (Disconnection
in High solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I
1When YES
-
2
Hi ifemalel12)
grounded
is 1
to chassis, is
resistancebetweenE2 (femalei 114) and
’- Min.
1 MR NO * Turn starting switch OFF. * Disconnect Hi and E2.
~ chassisnormal? When Hi (female)(1) + Max. 1 R YES is groundedto chassis, - is resistance between - * Turn starting NO E2 (female)13)and switch OFF. 1 ~ chassis normal? ~ * Disconnect Hi and E2. Is resistance * Max. 1 Cl * Ground Hi (female) (2) to chassis. between Hi (male) _ * Turn starting NO (1) and (2) switch OFF. normal? * Disconnect Hi and E2. * Ground Hi (female) (I) to .5-20R 1 chassis. * Turn starting switch OFF. * Disconnect Hi.
ET-12 Related
electrical
Transmission
transmission
Short circuit with ground in wiring harness between Hi (female) (2) and E2 (female) (14) Defective contact or disconnection in wiring harness between Hi (female) (2) and E2 (female) (14) Defective contact or disconnection in wiring harness between Hi (female) (1) and E2 (female) (3) Defective High solenoid (internal disconnection)
NO
Remedy
Cause
Defective controller (female) (2) and chassis normal’
inserted.
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
controller
I Hi
solenoid
(+I
Hi
solenoid
(-1
E2
Hi
Hi
solenoid
@
TWG00324
20-169 0
TROUBLESHOOTING
ET-13 * *
Before Always
ET-13
[b7] (Disconnection carrying connect
out troubleshooting, any disconnected
in FORWARD
solenoid)
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
4YES YES 3 -
Is resistance between E2 (female) (15). FW (female) (21and
When FW(femiii chassis normai? YES isgroundedtochassis. L * Min. 1 MS2 NO - is resistancebetween * Turn starting E2(female)115)and 2 switch OFF. ~ chassisnormal? When Hi (female)(1) * Disconnect FW and E2. - Max. 1 R YES Is grqundedto chassis, - ISreelstancebetween - * Turn starting NO E2(female)(4) and switch OFF. 1 ~ ~chassisnormal? * Disconnect FW and E2. Is resistance * Max. 1 f2 * Ground FW (female) (2) to chassis. between FW * Turn starting (male) (1) and (2) NO switch OFF. normal? * Disconnect FW and E2. * Ground FW (female) (I) -5-200 to chassis. *Turn starting switch OFF. NO - Disconnect FW.
ET-13 Related
electrical
Transmission
Defective controller
transmission
Short circuit with ground in wiring harness between FW (female) (2) and E2 (female) (15) Defective contact or disconnection in wiring harness between FW (female) (2) and E2 (female) (15) Defective contact or disconnection in wiring harness between FW (female) (1) and E2 (female) (4) Defective FORWARD solenoid (internal disconnection)
inserted.
Remedy
Repair or replace
Repair or replace
Repair or replace
Repair or reolace
Replace
circuit diagram
controller
FW
YE2
FORWARD solenoid
FORWARD solenoid(-)
I
20- 170 0
I
TWG00325
ET-14
TROUBLESHOOTING
ET-14 * -)r
Before Always
[b8] (Disconnection carrying connect
in REVERSE solenoid)
out troubleshooting, any disconnected
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
4YES .1 Is resistance
YES 3 YES JZ
grounded to chassis, is
-
between
E2 (female) (16), RE (female1 12) and chassis normal? * Min.
1 MR
Defective controller
transmission
Short circuit with ground in wiring harness between RE (female) (2) and E2 (female) (16) Defective contact or disconnection in wiring harness between RE (female) (2) and E2 1 (female) (16)
-
normal?
Ground
RE (female)
* Disconnect RE and E2. . Ground RE (female) (1) 1 to chassis.
*5-20R * Turn starting switch OFF. * Disconnect RE.
electrical
circuit diagram
Transmission
controller
E2
it
Defective contact or disconnection in wiring harness between RE (female) (1) and E2 (female) (5) Defective REVERSE solenoid (internal disconnection)
NO
ET-14 Related
(2) to chassis.
REVERSE
solenoid(t)
5
REVERSE
solenold(-)
16
I
inserted.
Remedy
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
REVERSE solenoid
TWG00326
20-171 0
TROUBLESHOOTING
ET-15 +
* * *
ET-15
[cl] (Disconnection
in inching potentiometer)
is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code for [Existing failure] is no longer displayed on the LED display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the inching potentiometer mount is normal.
Remedy
Cause
3 YES [When TM11 (female) 12) 1 7
GotoA Defective contact or disconnection in wiring harness between TM11 (female) (2) and E3 (female) (4)
YES 1
r
Short circuit with ground in wiring harness between TM1 1 (female) (3) and E3 (female) (7)
f Ground TM1 1 (female) (2) to chassis.
is grounded f~ chassis, is resistance between E3 Ifemale) (7) and - Max. 1 Q -Turn starting switch OFF. * Disconnect TM1 1 and E3. * Ground TM11 (female) (3) to chassis.
* Disconnect
Disconnection in wiring harness between TM1 1 (female) (3) and E3 (female) (7)
NO
6 YES YES 5
Is voltage between TM I I (3) and (2) normal?
* Min. 1 MR * Turn starting switch OFF. * Disconnect TM1 1 and E3.
electrical
Transmission
Repair or replace
TM1 1
When E3 is YEIS disconnetied, is * 0.45 - 0.61 v NO resistance between + Insert T-adapter into TM1 1. TM11 (female) (1) * Turn starting switch ON. and (21 normal? * Do not depress inching pedal. * Min. 1 Ma * Turn starting NO switch OFF. * Disconnect TM1 1 and E3. L
ET-15 Related
Repair or replace
Repair or replace
Defective transmission controller
Repair or replace
Defective inching potentiometer (internal disconnection)
Replace
Defective contact in wiring harness between TM1 1 (female) (2) and E3 (female) (4) and wiring harness between TM11 (1) and E3 (16)
Repair or replace
Short circuit with ground in wiring harness between TM1 1 (female) (2) and E3 (female) (4)
Repair or replace
circuit diagram controller
Inching
I
I
PO
n
E3
i ome
en
er
Inching input Power
SUPP
I Y (+5V)
GND I
1
\
I
\
/
I TWG00327
ZO-172 0
TROUBLESHOOTING
STANDARDS TABLE
FOR MEASURING
OF FAILURE
HYDRAULIC H-l
MODES
PRESSURE
Abnormal
H-2
Relief
H-3
Hydraulic
noise
sound
HYDRAULIC
AND
is made
is heard
(from
(when
oil overheats
Work
equipment
does
Work
equipment
is slow,
There Steering
H-8
Turning
H-9
Feeling
(work (work
is excessive wheel
equipment speed when
when
lacks power
at neutral)
POSITIONS..
drift
20-204
............................................
20-206
.............................................................................................
20-208
..................................................................................................
20-208
.............................................................................................. control lever is operated (steering at neutral). ..........................
...........................................................................................................
of work
equipment
.................................................................................
.20-208 20-209 20-210 20-21 1
............................................................................................................................
20-21 1
lacks power
at neutral)
operating
pump)
MOUNTING
.20-202
not turn
is slow,
equipment
FILTER
not operating)
not move
hydraulic
does
AND
around
SYSTEM
PRESSURE, AND JUDGEMENT VALUES ................................. ............................................................................................................
not operating)
(when
H-4 H-6
CAUSES
MEASUREMENT
H-5 H-7
CHART FOR HYDRAULIC (H MODE)
............................................................................................................................ wheel is strange.. .....................................................................................
steering
20-212 20-212
20-201 0
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES
TROUBLESHOOTING
STANDARDS JUDGEMENT
FOR MEASURING VALUES
HYDRAULIC
PRESSURE, AND Unit:
T No.
Posture
for
machine
Measurement
Judgement this range
conditions
values (any value indicates a failure) PM (main oressure)
Ps (steering pressure)
*a=
l
All work
l
Work
outside
PP (pilot pressure)
*
equipment
at standard
MPa (kg/cm*)
Min.
position.
1.0 (IO), and
equipment
not operated.
Min.
2.0 (201, and Max. 2.0 (20) + 2.5 + 251 Pp+ 1.0 ( + 101
235FO21025
:Hm
l
Steering
cylinder
relief.
16.2 - 18.1 (165 - 185)
Vlax. Ps + 2.5 (25)
%I PSI & 1.0 (IO)
23.0 - 26.0 (235 - 265)
%I PSI + 1.0 (IO)
23.0 - 26.0 (235 - 265)
235FO2107
l
Left blade
lift cylinder
relief. 235FO2108
n l
Right
blade
lift cylinder
relief. 235FO2109 l
Front
wheels
raised
off
ground. l
Steering
l
Operating 1 turn/2
235FO2110
1.
The oil temperature
2.
Measure within
3.
With
with
shall
Max.
5.9 (60)
Vlax. 6.4 (65)
PQ5
t-205
1
speed: sec.
be 45 - 55°C.
engine
speed
at both
low
idling
and
high
idling,
and check
that
both
measurements
are
the standard. the CLSS, the hydraulic
reason,
pressures
put the measurement
are within El
the
operated.
the specified
“PSI” is the measured
at different
data into a formula
points
are mutually
for calculating
related
the judgement
and change standard,
together.
For this
and check that they
range. data
marked*.
To hydraulic
control
valve
PS \
To steer
ir
valve
I
20-202 0
I
235COO2220
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Parts causing
Failure
Does
z
20-204 0
Pump
Surge pressure absorb-
Priority divider
flow valve
mode
not move
Slow,
P ‘E 8
failure
Turning
lacks power
speed
is slow,
lacks power
Changes Feeling when operating steering wheel is strange
between
There
is kickback
There
is a grating
00 being
feeling
heavy
and light
0
0
I io I do I 4 I Q
0 0
0 0
I in
0
0
I A
z
023502
2
z
equipment
control
link
Troubleshooting
code
Shuttle valve for circle rotation
Slip clutch
Wrk o
gear (%I)
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS
TROUBLESHOOTING
PRESSURE MEASUREMENT
HYDRAULIC POSITIONS.
AND FILTER MOUNTING
Fia 1 0
Measuring
port for work
main
equipment
oil pressure
Priority divler
(PM). l
Measuring
port for steering
oil pressure
(Ps).
flow valve \
PM
Ps
\
/
( _______~______t___i_-______
235CD02221
Fia 2 pressure
l
Pilot
l
LS line
filter
measuring
port
(PP).
Surge Dressure valve absorbing
(3).
1
235COO2222
b@-+@A
Fig 3 .
Pump
filters
0
Filters
(41, (5),
(I),
(2).
I
Fig 4 (6) on top of surge
pressure
absorbing
valve.
absorbing
20-206 0
valve
235CDO2044
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS
TROUBLESHOOTING
Fig 5 0
Control
valve
filters
(71, (8).
I
Control
Valve
R.H.
COntrOl
Valve
L.H
235C00204E
Fia 6 l
Steering
valve
LS line filter
(9).
Fig 7 Measuring (Serial
No.:
port for
brake
piston
(circle)
pressure.
11001 - 12050)
20-207 0
H-l,
TROUBLESHOOTING
H-l
Abnormal
noise is made (from around pump). Remedy
Cause
YES
Is strainer clogged?
YES
3 -
I;“‘”
H-2, H-3
raulic tank el normal?
Is problem corrected when - piping between NO tank and pump is tightened? ~
Y
NO
4YE
Zlogged strainer.
Clean
_ooseness of piping :lamp.
Tighten
Iefective
Replace
pump.
Are metal particles found w,hen hydraulic 011 IS drained? N(
Natch for a short time to ;ee if there is any change n the condition.
Inspect again [according to change in condition).
_ack of oil.
Add hydraulic oil.
Zlogged orifice.
Clean
Zlogged steering LS line ‘ilter (9) (See Fig. 6).
Clean
H-2 Relief sound is heard (when not operating). 1)
From priority
Is LS port orifice clogged?
flow
divider
valve.
H NO
2)
From surge
pressure
absorbing
valve.
Clogged spool orifice of priority flow divider valve.
H-3 Hydraulic 1 YES
oil overheats
(when not operating). Clogged steering LS line filter (9) (See Fig. 6).
Clean
Defective operation servo valve.
Repair or replace.
Is pilot line oil pressure high?
. Priority flow divider valve is being relieved. * Steering oil pressure is high. [I72 MPa (175kg/cm?l
20-208 0
NO
of
H-A
TROUBLESHOOTING
H-4
Work equipment at neutral).
does not move when control lever is operated
Cause I)
No work
equipment
(steering
Remedy
moves.
YES
-
Go to Item 2).
1 Is hydraulic pump main preSsure normal?
-
YES
_
2
24.5 + 1.5 MPa (250+15 NO kg/cm’)
Is pilot oil pressure normal?
YES 3
p
-
$5, MPa
Is surge pressure absorbing valve LS line filter clogged?
(_$ kg/cm*)
-
Main oil pressure
NO
4 YE
Does condition Check filter (3). _ become normal NO when servo valve (See Fig 2) is replaced? - Check operation spool.
2)
Work
equipment
for control
Pump filter (1) or (2) is clogged. (See Fig. 3)
Clean
Clogged filter (3). (See Fig. 2)
Clean
Defective operation servo valve.
Repair or replace.
of
Repair or replace.
N( of
valve on one
side only does not move.
Is surge pressure absorbing valve filter clogged? * Check filter (4) N or (6). (See Fig 4)
2 YES
Work
equipment
NO
Clogged filter.
Iean
Defective operation control valve.
of
lepair or eplace.
Defective operation control valve.
of
Repair or replace.
for one line only does not move. 2 YES
NO Is work equipment control link normal? - Check operation linkage?
Xean
Is control valve filter clogged? * Check filter (7) or (8). (See Fig 5)
3)
Clogged filter
Defective
cylinder.
Repair or replace.
Defective
motor.
Repair or, replace.
Defective clutch.
adjustment
of Circle rotation ge assembly ‘ES
of
4djust
normal?
-
Engine low idling
become normal
Defective operation shuttle valve.
of
qeplace
Defective operation :ontrol valve.
of
qepair or replace.
lefective inkafge.
of
qepair or .eplace.
5.gMPat6’
kg/cm? - Engine high idling : 8.8MPa (90 kg/cm*) - Blade raised.
NC
operation
20-209 0
H-5
TROUBLESHOOTING
is slow, lacks power.
H-5 Work equipment
Remedy
Cause I)
All work
equipment.
io to H-4.
2)
Work
equipment
valve on one side only. jefective
Does condition become normal when relief valve of control valve is adjusted?
idjust
relief valve.
;o to H-4.
. Relief pressure :24.5 t 1.5 MPa (250 2 15 kg/cm’)
3)
for control
NO
Work
equipment
for one line only. hen slow 2 YES Doescondition 1 Ibecome normal when blade float valve is
Blade lift
3epair or eplace.
defective blade float alve.
GotoA
1
* Engine: Rated
Is work equipment control linkage normal? . Check operation linkage.
)
([i%$Thift
1
Whenthereisnopower~
of
sot0
From IA
Is there defect inside cylinder?
4 YES
i!ic$q1damage,
dirt.
sd? * Check for oil leakage. * Defective relief pressure setting (only for machines with relief valve).
20-210 0
11 NO
H-4.
of
3epair or .eplace.
Iefective inkage.
operation
Defective
cylinder.
Repair or replace.
Defective valve.
pilot check
Repair or replace.
Defective
control
Repair or replace.
valve.
TROUBLESHOOTING
H-6
H-6, H-7
There is excessive work equipment.
hydraulic
drift of Remedy
Cause
1 YES Are cylinder, piston, seal damaged?
-
Check for oil leakage, damage.
H-7
NO
Damaged cylinder, piston, seal.
Replace
Defective valve.
pilot check
Repair or reolace.
Defective
steering
?epair or .eplace.
Defective cvlinder.
steering
Steering wheel does not turn (work equipment at neutral). 2 YES YE
L Does
cylinder move normally?
NO
- Is there any internal defect?
YES
‘) - 17.2 + 1.0 MPa (175 + 10 kg/cm’).
valve.
Clogged pump filters (2). (See Fig.3)
I
I
Is pilot pressure , normal?
