GD555-5,GD655-5,GD675-5

SEN0521512-00 40-1

MOTOR GRADER
Shop Manual 40-1

GD555-5
GD655-5
GD675-5

Machine model Serial number

GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

40 Troubleshooting 40-1

GD555-5,GD655-5,GD675-5 40-1
(01)
Table of contents

Table of contents 40-2

40 Troubleshooting
General information on troubleshooting .................................................................................. 40- 7
Points to remember when troubleshooting .......................................................................... 40- 7
Sequence of events in troubleshooting................................................................................ 40- 8
Checks before troubleshooting ............................................................................................ 40- 9
Classification and procedures for troubleshooting ............................................................... 40- 29
Failure codes table............................................................................................................... 40- 30
Failure and troubleshooting numbers .................................................................................. 40- 37
Information in troubleshooting table..................................................................................... 40- 39
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 41
Connector list and layout ..................................................................................................... 40- 43
Connection table for connector pin numbers ....................................................................... 40- 58
T- branch box and T- branch adapter table ......................................................................... 40- 94
Locations of fuses ................................................................................................................ 40- 97
Troubleshooting by failurecode ............................................................................................... 40- 99
Failure code [1500LO] TORQUEFLOW transmission: Double engagement ....................... 40- 99
Failure code [15G0MW] Transmission R clutch: Slip........................................................... 40- 100
Failure code [15H0MW] Transmission FH clutch: Slip......................................................... 40- 101
Failure code [15J0MW] Transmission FL clutch: Slip .......................................................... 40- 101
Failure code [15K0MW] Transmission 1st clutch: Slip......................................................... 40- 102
Failure code [15L0MW] Transmission 2nd clutch: Slip ........................................................ 40- 103
Failure code [15M0MW] Transmission 3rd speed clutch: Slip ............................................. 40- 104
Failure code [15N0MW] Transmission 4th clutch: Slip ........................................................ 40- 105
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF .... 40- 106
Failure code [15SBMA] ECMV R clutch: Malfunction .......................................................... 40- 108
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF .. 40- 110
Failure code [15SCMA] ECMV FH clutch: Malfunction........................................................ 40- 112
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF... 40- 114
Failure code [15SDMA] ECMV FL clutch: Malfunction ........................................................ 40- 116
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF .. 40- 118
Failure code [15SEMA] ECMV 1st clutch: Malfunction ........................................................ 40- 120
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF . 40- 122
Failure code [15SFMA] ECMV 2nd clutch: Malfunction ....................................................... 40- 124
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF . 40- 126
Failure code [15SGMA] ECMV 3rd clutch: Malfunction ....................................................... 40- 128
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF.. 40- 130
Failure code [15SHMA] ECMV 4th clutch: Malfunction........................................................ 40- 132
Failure code [15SJMA] ECMV lockup clutch: Malfunction ................................................... 40- 134
Failure code [15UONT] Inching clutch: Overheating ........................................................... 40- 134
Failure code [2G42ZG] Front accumulater: Oil pressure drop............................................. 40- 135
Failure code [2G43ZG] Rear accumulater: Pressure drop .................................................. 40- 135
Failure code [AA1ANX] Air cleaner: Clogging...................................................................... 40- 136
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.............. 40- 138
Failure code [AB00MA] Alternator: Malfunction ................................................................... 40- 140
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop...................... 40- 142
Failure code: [B@BCNS] Engine coolant overheat ............................................................. 40- 142
Failure code: [B@CENS] Torque converter oil overheat ..................................................... 40- 143
Failure code: [B@CKNS] Differential case: Overheat.......................................................... 40- 144
Failure code: [B@HANS] Hydraulic oil: Overheating ........................................................... 40- 146
Failure code [CA111] Engine controller internal error.......................................................... 40- 148
Failure code [CA115] Engine Ne, Bkup speed sensor error ................................................ 40- 149

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 Table of contents

Failure code [CA122] Charge pressure sensor high error ................................................... 40- 150
Failure code [CA123] Charge pressure sensor low error .................................................... 40- 152
Failure code [CA131] Throttle sensor high error.................................................................. 40- 154
Failure code [CA132] Throttle sensor low error ................................................................... 40- 156
Failure code [CA144] Coolant sensor high error ................................................................. 40- 158
Failure code [CA145] Coolant sensor low error................................................................... 40- 160
Failure code [CA153] Charge temperature sensor high error.............................................. 40- 162
Failure code [CA154] Charge temperature sensor low error ............................................... 40- 164
Failure code [CA155] Speed derating error by high charge temperature ............................ 40- 166
Failure code [CA187] Sensor power supply 2 low error ...................................................... 40- 168
Failure code [CA221] Atmospheric pressure sensor high error........................................... 40- 170
Failure code [CA222] Atmospheric pressure sensor low error ............................................ 40- 172
Failure code [CA227] Sensor power supply 2 high error ..................................................... 40- 174
Failure code [CA234] Engine overspeed ............................................................................. 40- 174
Failure code [CA238] Ne speed sensor power supply error ................................................ 40- 175
Failure code [CA271] IMV/IMA: Short circuit ....................................................................... 40- 176
Failure code [CA272] IMV/IMA open circuit......................................................................... 40- 178
Failure code [CA322] Injector #1 (L#1) open/short.............................................................. 40- 180
Failure code [CA323] Injector #5 (L#5) open/short.............................................................. 40- 182
Failure code [CA324] Injector #3 (L#3) open/short.............................................................. 40- 184
Failure code [CA325] Injector #6 (L#6) open/short.............................................................. 40- 186
Failure code [CA331] Injector #2 (L#2) open/short.............................................................. 40- 188
Failure code [CA332] Injector #4 (L#4) open/short.............................................................. 40- 190
Failure code [CA342] Data compatibility error in engine controller...................................... 40- 192
Failure code [CA351] Injector drive circuit error .................................................................. 40- 193
Failure code [CA352] Sensor power supply 1 low error ...................................................... 40- 194
Failure code [CA386] Sensor power supply 1 high error ..................................................... 40- 195
Failure code [CA428] Water-in-fuel sensor high error ......................................................... 40- 196
Failure code [CA429] Water-in-fuel sensor low error........................................................... 40- 198
Failure code [CA431] Idle validation switch error ................................................................ 40- 200
Failure code [CA432] Idle validation action error................................................................. 40- 204
Failure code [CA435] Engine oil pressure switch error........................................................ 40- 207
Failure code [CA441] Power supply voltage low error......................................................... 40- 208
Failure code [CA442] Power supply voltage high error ....................................................... 40- 210
Failure code [CA449] Common rail pressure high error 2 ................................................... 40- 211
Failure code [CA451] Common rail pressure sensor high error .......................................... 40- 212
Failure code [CA452] Common rail pressure sensor low error ............................................ 40- 214
Failure code [CA488] Torque derating error by high charge temperature ........................... 40- 216
Failure code [CA553] Common rail pressure high error 1 ................................................... 40- 217
Failure code [CA559] Supply pump pressure low error 1 .................................................... 40- 218
Failure code [CA689] Engine Ne speed sensor error .......................................................... 40- 219
Failure code [CA731] Engine Bkup speed sensor phase error............................................ 40- 221
Failure code [CA757] All continuous data lost error ............................................................ 40- 222
Failure code [CA778] Engine Bkup speed sensor error ...................................................... 40- 223
Failure code [CA1633] KOMNET (CAN communication) error ............................................ 40- 226
Failure code [CA2185] Throttle sensor power supply high error ......................................... 40- 228
Failure code [CA2186] Throttle sensor power supply low error........................................... 40- 230
Failure code [CA2249] Supply pump pressure low error 2 .................................................. 40- 232
Failure code [CA2311] Abnormality in IMV (IMA) solenoid.................................................. 40- 233
Failure code [CA2555] Intake heater relay open circuit....................................................... 40- 234
Failure code [CA2556] Intake heater relay short circuit....................................................... 40- 236
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness 40- 238
Failure code [D160KB] Backup lamp relay: Ground fault .................................................... 40- 240
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault............................ 40- 242

GD555-5,GD655-5,GD675-5 40-3
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Table of contents

Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state .... 40- 244
Failure code [DAFRKR] CAN communication failure (monitor panel).................................. 40- 246
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input) ... 40- 248
Failure code [DAQOKT] Transmission controller: Non-volatile memory error ..................... 40- 250
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)
............................................................................................................................................. 40- 252
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement
............................................................................................................................................. 40- 254
Failure code [DAQRKR] Transmission controller CAN communication: Communication error40-256
Failure code [DAQRMA] Transmission controller option setting: Malfunction ..................... 40- 260
Failure code [DB2RKR] Engine controller CAN communication: Communication error ...... 40- 261
Failure code [DD1NLD] Fan reverse switch signal: Short circuit ......................................... 40- 268
Failure code [DD1PKB] RPM set switch power supply short circuit .................................... 40- 270
Failure code [DD1QKB] RPM set mode switch short circuit ................................................ 40- 272
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error ............... 40- 274
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit ............................................ 40- 276
Failure code [DDTJKA] Fill switch for FL clutch: Open circuit.............................................. 40- 276
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit ............................................ 40- 277
Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit............................................ 40- 277
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit ........................................... 40- 278
Failure code [DDTNKA] Fill switch for R clutch: Open circuit .............................................. 40- 279
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit ............................................ 40- 280
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input .......... 40- 281
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error40-285
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range .... 40- 288
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault............................. 40- 290
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range 40- 292
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault ........................... 40- 294
Failure code [DJF1KA] Fuel level sensor: Open circuit ....................................................... 40- 296
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range.................... 40- 298
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range....................... 40- 300
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit..................... 40- 302
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match40-303
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit......... 40- 304
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match
............................................................................................................................................. 40- 305
Failure code [DLM3KA] Fan speed sensor: Open circuit..................................................... 40- 306
Failure code [DLM3LC] Fan speed sensor: Short circuit ..................................................... 40- 307
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit................... 40- 308
Failure code [DV00KB] Buzzer: Short circuit ....................................................................... 40- 310
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit................................... 40- 312
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit ................................... 40- 314
Failure code [DW7BKA] Fan reverse solenoid: Open circuit ............................................... 40- 315
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ............................................... 40- 316
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line............... 40- 318
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit ........................................... 40- 320
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit ........................................... 40- 321
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line .......... 40- 322
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit ............................................ 40- 324
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit ............................................ 40- 325
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line............ 40- 326
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit......................................... 40- 328
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit......................................... 40- 329
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line ........ 40- 330

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 Table of contents

Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit ......................................... 40- 332
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit ......................................... 40- 334
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line ........ 40- 336
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit ........................................ 40- 338
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit......................................... 40- 340
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line ........ 40- 342
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit ....................................... 40- 344
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit ....................................... 40- 346
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line....... 40- 348
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit ........................................ 40- 350
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit ........................................ 40- 352
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line ....... 40- 354
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit........................................... 40- 356
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit........................................... 40- 357
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line .......... 40- 358
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit........................................ 40- 360
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit........................................ 40- 362
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line ....... 40- 364
Troubleshooting of electrical system (E-mode)....................................................................... 40- 366
E-1 Engine does not start (starting motor does not turn)..................................................... 40- 366
E-2 Preheating does not work ............................................................................................. 40- 372
E-3 When starting switch is turned to ON position, machine monitor displays nothing ....... 40- 377
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen
............................................................................................................................................. 40- 380
E-5 When starting switch is turned to ON position, caution monitor flashes or lights up, or machine mon-
itor does not display correct screen ..................................................................................... 40- 380
E-6 Emergency stop monitor lights up while engine is running ........................................... 40- 381
E-7 Speedometer or engine tachometer does not indicate correctly................................... 40- 385
E-8 Engine coolant temperature gauge does not indicate correctly .................................... 40- 386
E-9 Articulation angle indicator does not indicate correctly ................................................. 40- 388
E-10 Torque converter oil temperature gauge does not indicate correctly .......................... 40- 390
E-11 Fuel level gauge does not indicate correctly ............................................................... 40- 392
E-12 Character display does not display correctly............................................................... 40- 394
E-13 Centralized warning lamp does not light up or does not go off ................................... 40- 396
E-14 Alarm buzzer does not sound or does not stop sounding ........................................... 40- 398
E-15 Machine monitor mode selector switch does not work................................................ 40- 400
E-16 Transmission mode does not switch ........................................................................... 40- 404
E-17 Engine mode does not switch ..................................................................................... 40- 406
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock spec-
ification]................................................................................................................................ 40- 408
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]
............................................................................................................................................. 40- 412
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator
specification] ........................................................................................................................ 40- 414
E-21 Horn does not sound or does not stop sounding ........................................................ 40- 418
E-22 Backup alarm does not sound or does not stop sounding .......................................... 40- 420
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off ................... 40- 423
E-24 Working lamp does not light up or does not go off...................................................... 40- 430
E-25 Turn signal lamp and hazard lamp do not flash. ......................................................... 40- 436
E-26 Stop lamp does not light up or does not go off............................................................ 40- 442
E-27 Backup lamp does not light up or does not go off ....................................................... 40- 444
E-28 Windshield wiper does not operate ............................................................................. 40- 446
E-29 Window washer does not operate............................................................................... 40- 454
E-30 KOMTRAX system does not operate correctly ........................................................... 40- 458

GD555-5,GD655-5,GD675-5 40-5
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Table of contents

Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 460

How to read troubleshooting matrix ..................................................................................... 40- 460
H-1 Engine speed lowers significantly or engine stalls. ....................................................... 40- 466
H-2 Machine does not start.................................................................................................. 40- 467
H-3 Gear is not shifted. ........................................................................................................ 40- 468
H-4 Travel lacks speed or power. ........................................................................................ 40- 469
H-5 Torque converter lockup does not work or is not released. .......................................... 40- 474
H-6 A large time lag results at start or in gear shift.............................................................. 40- 475
H-7 Oil temperature of torque converter is high................................................................... 40- 480
H-8 Differential lock-up function does not work or is not released....................................... 40- 485
H-9 Steering lacks speed or power...................................................................................... 40- 486
H-10 Steering wheel does not move.................................................................................... 40- 487
H-11 Wheel brake does not work at all or sufficiently .......................................................... 40- 488
H-12 Wheel brake cannot be released or drags .................................................................. 40- 489
H-13 Parking brake does not work at all or insufficiently ..................................................... 40- 490
H-14 Parking brake (including emergency release system) cannot be released or drags... 40- 491
H-15 All work equipment operation lacks speed or power................................................... 40- 492
H-16 Work equipment does not work at all .......................................................................... 40- 493
H-17 Unusual noise comes out from around hydraulic pump .............................................. 40- 494
H-18 Blade lift operation lacks speed or power ................................................................... 40- 495
H-19 Hydraulic drift of blade lift cylinders is large. ............................................................... 40- 496
H-20 Drawbar side shift operation lacks speed or power .................................................... 40- 497
H-21 Blade side shift operation lacks speed or power......................................................... 40- 498
H-22 Power tilt operation lacks speed or power .................................................................. 40- 499
H-23 Articulate operation lacks speed or power .................................................................. 40- 500
H-24 Leaning operation lacks speed or power .................................................................... 40- 501
H-25 Hydraulic drift of leaning cylinders (leaning) is large................................................... 40- 502
H-26 Blade does not rotate .................................................................................................. 40- 503
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)
............................................................................................................................................. 40- 504
H-28 Blade accumulator function does not work or cannot be released (for machine with blade accumu-
lator float specification) ........................................................................................................ 40- 505
H-29 Blade float function does not work or cannot be released .......................................... 40- 506
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
............................................................................................................................................. 40- 507
Troubleshooting of engine (S-mode) ...................................................................................... 40- 508
Method of using troubleshooting chart................................................................................. 40- 508
S-1 Startability is poor.......................................................................................................... 40- 512
S-2 Engine does not start .................................................................................................... 40- 513
S-3 Engine does not pick up smoothly................................................................................. 40- 516
S-4 Engine stops during operation....................................................................................... 40- 517
S-5 Engine runs rough or is unstable................................................................................... 40- 518
S-6 Engine lacks power ....................................................................................................... 40- 519
S-7 Exhaust smoke is black (incomplete combustion)......................................................... 40- 520
S-8 Oil consumption is excessive (or exhaust smoke is blue) ............................................. 40- 521
S-9 Oil becomes contaminated early ................................................................................... 40- 522
S-10 Fuel consumption is excessive.................................................................................... 40- 523
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) .................................. 40- 524
S-12 Oil pressure drops ....................................................................................................... 40- 525
S-13 Oil level rises (coolant or fuel in oil)............................................................................. 40- 526
S-14 Coolant temperature rises too high (overheating) ....................................................... 40- 527
S-15 Unusual noise is made ................................................................................................ 40- 528
S-16 Vibration is excessive.................................................................................................. 40- 529

40-6 GD555-5,GD655-5,GD675-5
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 General information on troubleshooting
Points to remember when troubleshooting

General information on troubleshooting 40-7

Points to remember when troubleshooting 40-7
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
ventreoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
standthe structure and function. However, a short cut to effective troubleshooting is to ask the operatorvarious
questions to form some idea of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q Parts that have no connection with the failure
or other unnecessary parts will be disassem-
bled.
q It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out trouble-
shooting, it is necessary to carry out thorough
prior investigation and to carry out trouble-
shooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred
before?
4) Check maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to reenact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspec-
tion in Items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or
troubleshooting flowchart to locate the position
of the failure exactly.
a The basic procedures for troubleshooting is
as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or informa-
tion.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.To prevent this, always investigate
why the problem occurred. Then, remove the
root cause.

3. Checks before troubleshooting

1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.

GD555-5,GD655-5,GD675-5 40-7
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General information on troubleshooting
Sequence of events in troubleshooting

Sequence of events in troubleshooting 40-8

(Rev. 2007. 12)

40-8 GD555-5,GD655-5,GD675-5
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 General information on troubleshooting
Checks before troubleshooting

Checks before troubleshooting 40-9

No. Item Criterion Remedy

1 Check for abnormal sounds and smells – Repair

2 Check for dirt around engine – Remove

3 Check for water leakage around engine – Repair

4 Check for oil leakage around engine – Repair

a Engine, lubricating oil and coolant

5 Check for leakage from fuel line – Repair

6 Check of radiator for clogging – Remove

7 Check of level and type of fuel – Refill oil

8 Check for foreign matter in fuel – Clean and drain

9 Check of fuel prefilter – Replace

10 Check of fuel filter – Replace

11 Check of level (in oil pan) and type of engine oil Between H – L Refill oil

12 Check of coolant level (in sub tank) Between H – L Refill coolant

No clogging
13 Check of air cleaner clogging indication on Clean or replace
monitor
1 Check for abnormal sounds and smells – Repair

2 Check for oil leakage – Repair

b Hydraulic and mechanical equipment

3 Check of hydraulic oil Between H – L Refill oil

4 Check of hydraulic oil strainer – Clean and drain

5 Check of hydraulic oil filter – Replace

6 Check of oil level in transmission case Between H – L Refill oil

7 Check of power train pump strainer – Clean and drain

8 Replacement of transmission oil filter – Replace

9 Check of final drive case oil level Between H – L Refill oil

10 Performing air bleeding operation – Air bleeding

GD555-5,GD655-5,GD675-5 40-9
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General information on troubleshooting
Checks before troubleshooting

No. Item Criterion Remedy

Retighten or
1 Check of battery cable terminals for looseness and corrosion –
replace
Retighten or
2 Check of alternator terminals for looseness and corrosion –
replace
Retighten or
3 Check of starting motor terminals for looseness and corrosion –
replace
Charge or
4 Check of battery voltage (with engine stopped) 20–30 V
replace

5 Check of battery electrolyte level Between H - L Add or replace

6 Check of wiring harness for discoloration, burnt areas and cover peeling – Repair or replace

Check for coming off of wiring harness clamp and sagging of wiring har-
7 – Repair
ness
c Electrical equipment

8 Check of grounding – Repair

9 Check for loose connector and damaged lock – Repair or replace

10 Check of connector pin for corrosion, bends and deformation – Repair or replace

Dry, clean or
11 Check for water and foreign matter in connector –
replace

12 Check of open circuit or or short circuit in wiring harness – Repair or replace

13 Check of fuse for blowout and corrosion – Replace

14 Slow-blow fuse – Replace

After several
minutes opera-
15 Check of alternator voltage (when engine speed is medium or higher) Replace
tion: 27.5 - 29.5
V
Check of battery relay operation sound (when starting switch is turned to
16 – Replace
ON or OFF position)
e: Interior parts d: Exterior parts

1 Check of tires – Repair

2 Check of handrails and steps – Repair

3 Check of rear view mirrors – Clean or repair

1 Check of gauges and monitors – Clean or replace

2 Check of seat belt – Repair

40-10 GD555-5,GD655-5,GD675-5
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 General information on troubleshooting
Checks before troubleshooting

Testing procedure before troubleshooting 40-1

Walk-around check 40-1

Before starting the engine, look around and under the machine to check for any loose bolts or nuts, leakage
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.

k Accumulated combustibles around hot engine parts such as the engine muffler, turbocharger, etc.
and leaking fuel and oil may cause a machine fire. Check thoroughly and repair any abnormalities
without fail.

a1., b1. Check for abnormal sounds and smells
Check for abnormal sounds and smells.
Some causes of abnormal sounds and smells
can damage the machine if they are left as they
are. Therefore, stop the machine immediately
when you discover the cause.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around
the engine and any combustibles (dead leaves,
twigs, etc.) on hot engine parts such as the en-
gine muffler, turbocharger, etc.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the battery.
d1. Check of tires for abnormalities, wear, loose
bolts
Repair any abnormalities.

a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any wa-
ter leaks from the cooling system. If any of them
is abnormal, repair it.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and
tubes. If any of them is abnormal, repair it.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the radiator.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning
and testing of radiator fins, oil cooler fins, after-
cooler fins, and air conditioner condenser fins."
d2. Check of handrails and steps for abnormali-
ties and loose bolts
Repair any abnormalities and retighten any
loose bolts.
d3. Check and cleaning of rear view mirrors (if
equipped)
Check and repair any abnormalities and break-
age of the rear view mirrors.
Clean the mirror surfaces and adjust their angles
so that the operator can see the area behind him
from the operator's seat.
e1. Check of gauges and monitors for abnormal-
ities
Check the gauges and monitors inside the oper-
ator cab. If any of them is abnormal, replace it.
Clean up the surfaces.

b2. Check of work equipment, cylinders, linkage e2. Check of seat belt and mounting hardware
and hoses for breakage, wear and clearance Check any damaged hooks, locks and hook fit-
Check the work equipment, cylinders, linkage tings. If any of them is abnormal, repair it.
and hoses for cracks and excessive wear, check
that each clearance is within the normal range,
and then repair any abnormalities.

GD555-5,GD655-5,GD675-5 40-11
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General information on troubleshooting
Checks before troubleshooting
Testing according to testing procedure
a. Engine lubricating oil and coolant
a7. Check of level and type of fuel
k Fuel is flammable and dangerous. Do not
bring any open flame near fuel.
k When adding fuel, take care not to let it over-
flow.
k Wipe off any spilt fuel. If fuel has spilt over
dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (G) in
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
2. If the fuel level is low, open oil filler cap (F) of the
fuel tank and add fuel through the oil filler port to
the necessary level.
q If the filter of breather (1) is clogged, the pres-
sure in the tank decreases and fuel may not
be supplied. To prevent this, clean the filter.
40-12
40-12 a8. Check for foreign material in fuel
40-12 Open drain valve (1) to discharge the sediment and
water in the bottom together with the fuel into a
waste oil container.
a9. Check of fuel pre-filter (water separator)
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel prefilter cartridges use a
special filter with a high filtration efficiency.
When replacing, be sure to use a Komatsu gen-
uine cartridges.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel prefilter cartridge other than
Komatsu genuine one is used, foreign matter
may enter, which can cause a trouble in the in-
jection system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
q Prepare the filter wrench.
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1. Open the left engine side cover.
2. Remove connector (1) and clamp (2).
a Cover the terminals of the removed connec-
tor by using a vinyl bag or a tape to protect
them.
3. Place the fuel container under filter cartridge (3).
4. Disconnect hose (6) connected to drain plug (5).
5. Using the filter wrench, rotate filter cartridge (3)
to the left to remove.
6. Rotate cup (4) of the water separator installed to
the bottom of the removed cartridge to the left to
remove. If there is any damage, replace the cup.
7. Install removed cup (4) to the bottom of the new
fuel prefilter cartridge. At this time, be sure to
replace the seal ring with a new one.
3 Tightening torque of cup (4): 10 Nm
{1.0 kgm}
a When installing the seal ring, apply clean
fuel to its surface.
8. Ensure that drain plug (5) at the bottom of cup
(4) of the fuel prefilter is tightened securely.
3 Tightening torque:
0.2 - 0.45 Nm {0.02 - 0.046 kgm}
9. Clean the filter base.
10. Fill the new filter cartridge with clean fuel through
eight small holes (B) on it.
11. Thinly apply clean oil to the packing surface of
the filter cartridge.
12. Remove filter cartridge cap (A) and install the
filter cartridge to the filter base.
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General information on troubleshooting
Checks before troubleshooting
13. When installing the filter cartridge, tighten it by
3/4 turns after its packing surface has been
securely placed on the sealing surface of the
filter base.
a If the filter cartridge is over tightened, fuel will
leak because of the breakage of the packing.
If the filter cartridge is not tightened suffi-
ciently, fuel will also leak through the clear-
ance of the packing. Therefore, observe the
tightening angle.
14. Connect removed connector (1), clamp (2), and
hose (6).
15. Then, proceed to "a10. Check of fuel filter".
a10. Check of fuel filter
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k High pressure is generated in the engine fuel
piping system while the engine is running.
Wait for at least 30 seconds after stopping
the engine until the internal pressure de-
creases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe-
cial filter with a high filtration efficiency. When re-
placing, be sure to use a Komatsu genuine
cartridges.
a The common rail fuel injection system of this ma-
chine consists of parts that are more precise
compared with the conventional injection pump
and nozzle. If a fuel filter cartridge other than Ko-
matsu genuine one is used, foreign matter may
enter, which can cause a trouble in the injection
system. Never use a substitute.
a When testing and servicing the fuel system, be
extremely careful that no foreign matter enters. If
any dirt sticks, remove it completely by using fu-
el.
q Prepare a container to receive the fuel.
40-13
General information on troubleshooting
Checks before troubleshooting

q Prepare the filter wrench.
1. Open the right engine side cover.
2. Place the fuel container under the filter cartridge.
3. Using the filter wrench, rotate filter cartridge (1)
to the left to remove.
4. Clean the filter base.
a When checking, set the machine in a horizontal
position.
1. Stop the engine.
2. Open the right engine side cover.
3. Remove oil level gauge (G) and wipe oil off with
a cloth.
4. Insert oil level gauge (G) fully and pull it out.

5. Apply oil to the packing surface of the filter 5. If the oil level is between stamps on oil level
cartridge. gauge (G), it is at the correct level.
6. Remove filter cartridge cap (A) and install the If the oil level is below the stamp, add oil through
filter cartridge to the filter base. oil filler port (F).
7. When installing the filter cartridge, tighten it by
3/4 turns after its packing surface has been
securely placed on the sealing surface of the
filter base.
a If the filter cartridge is over tightened, fuel will
leak because of the damage to the packing.
If the filter cartridge is not tightened suffi-
ciently, fuel will also leak through the clear-
ance of the packing. Therefore, observe the
tightening angle.

6. If the oil level is above H

1) Place a waste oil container directly below
drain plug (P) on the rear right side.
A 2) Open drain plug (P) to drain the oil.
3) Tighten drain plug (P).
3 Tightening torque of drain plug:
118 - 162 Nm {12 - 16.5 kgm}

9 J A0 7 6 3 9

a11. Check of level (in oil pan) and type of en-

gine oil
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
7. If the oil is at the correct level, tighten the oil filler
level.
cap securely and close the engine hood.

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a12. Check of coolant level (in sub tank)
k The radiator cap does not need to be opened
for the usual check.. Check the coolant level
on the sub tank side while the engine is cold.
k Immediately after the engine is stopped, the
coolant is hot and pressure is accumulated
in the radiator. If the cap is opened under
these conditions, you may be scalded. When
the radiator cap needs to be removed, wait
until the temperature drops and rotate the
cap slowly to release the pressure. Remove it
fully, exercising care.
1. Check that the coolant level in sub tank (1) is
between FULL and LOW. If the coolant level is
insufficient, open the cover and add Super-
coolant (AF-NAC) through the coolant filler of
sub tank (1) up to between FULL and LOW.
2. After adding the coolant, tighten the cap
securely.
3. If the sub tank has been empty, the coolant may
be leaking. Check and repair immediately if
there is any abnormality. If there are no abnor-
malities, check the coolant level in the radiator
and add Supercoolant (AF-NAC) if necessary.
Then, add Supercoolant (AF-NAC) to the sub
tank.
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General information on troubleshooting
Checks before troubleshooting
a13. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as safety
glasses, cotton gloves, dust mask, etc. to
protect yourself from dirt that will fly out.
k It is dangerous to use excessive force to pull
out the outer element from the air cleaner
body. When working in an elevated or unsta-
ble location, take care that you do not fall due
to the momentum created when you pull out
the outer element.
k If the air cleaner is checked, cleaned, or ser-
viced while the engine is running, dirt will en-
ter the engine and damage the engine. Be
sure to stop the engine before working on the
air cleaner.
Testing
1. Open the right engine side cover.
2. If yellow indicator plate (2) in the transparent
portion of dust indicator (1) has reached red line
(3), clean the air cleaner element.
a Do not clean the element of dust indicator (1).
If the element is cleaned frequently before the
yellow indicator plate of dust indicator (1)
reaches the red line, the true performance of the
air cleaner will not be realized and the cleaning
effect will decrease.
40-15
General information on troubleshooting
Checks before troubleshooting
Cleaning and replacement of outer element
a Do not leave or store the element in direct sun-
light before or after cleaning it.
a Replace the outer element after cleaning it 6
times or after using it for 1 year. When replacing
the outer element, replace the inner element,
too.
a If the yellow indicator plate of the dust indicator
reaches the center of the scale (5 kPa) just after
the outer element is cleaned, replace both outer
and inner elements, even if the outer element
has not been cleaned 6 times.
1. Open the right engine side cover and remove
clip (3) and dust cup (4).
2. Take out outer element (5) and clean the inside
of the air cleaner body and dust cup (4).
a Never remove inner element (6). If it is re-
moved, dirt will enter and can lead to engine
troubles.
a When cleaning the dust cup, do not remove
vacuator valve (7).
40-16
3. Blow dry compressed air (Max. 0.20 MPa {2
kg/cm2}) along the inside pleats of the element.
Next, blow air along the outside pleats, and blow
again along the inside pleats.
4. After cleaning, light up the inside of the element
to check it. If the element has a small hole or a
thin area, replace it.
a When cleaning the element, do not hit it or
strike it against something.
a Do not use the element if its pleats, gasket or
seal is damaged.
a If the element is installed forcibly, it can dam-
age the clip or the air cleaner body. Install it
by pushing it in straight.
a Do not run the engine with the inner element
removed since doing so damages the en-
gine.
5. Set the cleaned outer element, install dust cup
(4), and fix them with clip (3).
k If the inner and outer elements were re-
placed, be sure to replace O-ring (8) with
a new one.
6. Press the button of dust indicator (1) to return the
yellow indicator plate.
7. Close the right engine side cover.
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 General information on troubleshooting
Checks before troubleshooting

b. Hydraulic and mechanical equipment 40-17

b3. Check of hydraulic oil level

k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k If the oil filler cap is removed quickly, the oil
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and remove it.
1. Set the machine in the posture for checking the
oil level according to the following explanation. 5. If the oil level is above the gauge window, drain
q Set the front tires upright in the straight travel the excessive oil through drain plug, and then
direction. check the oil level again.
q Set the front frame and rear frame straight 6. If the oil is at the correct level, tighten the cap of
(articulate angle: 0 degrees) and install the oil filler port (F) securely and remove the hose.
articulate lock pin.
q Set the blade sideway shift mechanism to the b4. Check of hydraulic oil strainer
center of the machine, set the blade at a right k Immediately after the engine is stopped, its
angle to the machine, and then bring it in light parts and oil are still very hot and they may
contact with the ground. burn your hands on contact them. Therefore,
q If the machine is equipped with the blade ac- wait until they have cooled down before
cumulator, turn the blade accumulator switch starting the work.
ON and raise the blade to the maximum to k If the oil filler cap is removed quickly, the oil
discharge the oil from the accumulator. Then, may spurt out. Therefore rotate the oil filler
turn the accumulator switch OFF and lower cap slowly to release the internal pressure
the blade to the ground. and then remove it.
2. Start the engine and run at low idle. 1. Remove bolts (1) to remove cover (2).)
3. Check the oil level by using sight gauge (G). If
the oil level is in the window of gauge (G), it is
proper.
a Do not add oil to above the gauge window. If
too much is added, it may damage the hy-
draulic circuit and spurt out.
a If the oil level is higher than the gauge win-
dow, stop the engine. After the hydraulic oil
has cooled, drain excessive oil through the
drain plug.

2. Loosen oil filler (F) gradually to release all the air

in the hydraulic tank.

4. If the oil level is below the window of gauge (G),

remove bolts (1) (6 pieces) and cover (2), and
add oil through oil filler port (F).

GD555-5,GD655-5,GD675-5 40-17
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General information on troubleshooting
Checks before troubleshooting

b5. Check of hydraulic oil filter

3. After stopping the engine, depress the brake
pedal about 20 times to return the oil in the accu-
mulator to the tank. If the machine is equipped
with the blade accumulator, stop the engine with
the accumulator "ON" and operate the blade lift
lever to release the pressure.
k Immediately after the engine is stopped, its
parts and oil are still very hot and they may
burn your hands on contact them. Therefore,
wait until they have cooled down before
starting the work.
k If the oil filler cap is removed quickly, the oil

4. Place a waste oil container under drain plug (P).
5. Loosen drain plug (P) so that the oil will not spurt
over you, and drain the oil.
a Loosen drain plug (P) slowly so that the oil
will not spout out.
may spurt out. Therefore rotate the oil filler
cap slowly to release the internal pressure
and then remove it.
1. Remove bolts (1) to remove cover (2).
2. Remove bolts (3) to remove cover (4).

6. After draining the oil, remove bolts (3) (6 pieces)

and cover (4).
a When removing bolts (3), keep pressing cov-
er (4) down since it may be flown out by gas
spring (5).
7. Pull up the top of rod (6) and remove spring (5)
and strainer (7).
8. Remove dirt from strainer (7) and clean using
cleaning oil. If strainer (7) is broken, replace it
with a new one.
9. Insert and set strainer (7) in projected portion (8)
of the tank.
10. While pressing down spring (5) with the projec-
tion at the bottom of cover (4), install bolts (3).

11. Tighten drain plug (P).

40-18 GD555-5,GD655-5,GD675-5
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3. Remove the element, clean the removed parts
and the inside of the filter case, and install the
new element.
4. Install cover (4) and bolts (3).
5. Install cover (2) and bolts (1).
GD555-5,GD655-5,GD675-5
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General information on troubleshooting
Checks before troubleshooting
b6. Check oil level in transmission case
k Immediately after the engine is stopped, its
parts and oil are still very hot. Therefore, wait
until they have cooled down before starting
the work.
k Before starting inspection, set the gear shift
lever to the P (PARKING) position so that the
machine does not move, and ensure that all
other levers are in the neutral position.
q Oil remains in each part and the oil level can-
not be checked correctly for 12 hours after
the engine is stopped. Accordingly, wait for at
least 12 hours before checking the oil level.
1. Stop the engine.
2. Remove the cap of oil filler port (F).
3. Pull out oil level gauge (G), wipe the oil from it
with cloth, and the insert it fully in the oil filler pipe
and pull it out.
4. If the oil level is between stamps H and L of oil
level gauge (G), it is at the correct level.
q If the oil level is below L, add oil through oil
filler port (F).
5. If the oil level is above H, remove drain plug (1)
and loosen drain plug (2) gradually to drain the
excessive oil, and then check the oil level again.
40-19
General information on troubleshooting
Checks before troubleshooting

6. If the oil is at the correct level, insert oil level

gauge (G) in the oil filler pipe and install the oil
filler cap.
q Oil level gauge (G) has stamps for checking
(A) while the engine is stopped (ENG STOP)
on one side and (B) while the engine is idling
(ENG IDLING) on the other side. Use the
stamp checking (A) when the engine is
stopped (ENG STOP).

6. Remove dirt from strainer (7) and clean it by

using diesel fuel oil or cleaning oil. If the strainer
is broken, replace it with a new one.
7. After cleaning, install strainer (7), replace O-ring
(6) of cover (5) with a new one, install cover (5),
and tighten bolts (4).

8. Add oil through oil filler port (F) up to the speci-

fied level.
b7. Transmission 9. After adding oil, check the oil level, referring to
1. Place the oil container under the transmission "Check of oil level in transmission case".
case.
2. Remove drain plug (1).
q Loosen drain plug (2) slowly so that the oil
will not spout out.
3. After draining the oil, tighten drain plug (2) and
install drain plug (1).
3 Drain plug (1): 59 - 78.5 Nm {6 - 8 kgm}
3 Drain plug (2): 49 - 78.5 Nm {5 - 8 kgm}
3 Drain plug (3): 9.8 - 12.7 Nm {1.0 - 1.3
kgm}
4. Remove drain plug (3) to drain the oil.
5. Remove bolts (4) to remove cover (5) and
remove and clean strainer (7).

40-20 GD555-5,GD655-5,GD675-5
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 General information on troubleshooting
Checks before troubleshooting

b8. Replacement of transmission oil filter and

cartridge
k Immediately after the engine is stopped, its
parts and oil are still very hot. Therefore, wait
until they have cooled down before starting
the work.
q Prepare the box-end combination wrench.
1. Place the oil container under the filter cartridge.
2. Using the box-end combination wrench, rotate
filter cartridge (1) to the left to remove.
3. Clean the filter base, apply clean engine oil to
the sealing surface of the new filter cartridge,
and install the filter cartridge.
3 Tightening torque: 49 - 59 Nm {5 - 6 4. If the oil level is above H, drain the excessive oil
kgm} through drain plug (P), and then check the oil
level again.
5. If the oil is at the correct level, insert oil level
gauge (G) in the oil filler pipe and install the oil
filler cap.

b9. Check of final drive case oil level

k Since the oil may spurt out due to internal
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.
1. Stop the engine and wait for at least five
minutes.
2. Remove the oil filler cap, pull out oil level gauge
(G) from the oil filler, wipe the oil from it with
b10. Execution of air bleeding operation
q For the procedure for bleeding air from the fuel
system, see Testing and adjusting, "Bleeding air
from fuel circuit".
q For the procedure for bleeding air from the hy-

cloth, and the insert it fully in the oil filler pipe and draulic equipment, see Testing and adjusting,
pull it out. "Bleeding air from work equipment circuit".
3. If the oil level is between stamps H and L of oil
level gauge (G), it is at the correct level.
q If the oil level is below L, add oil through oil
filler port (F).

GD555-5,GD655-5,GD675-5 40-21
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General information on troubleshooting
Checks before troubleshooting
c. Electrical equipment 40-2
c1. Check of battery terminals for looseness and
corrosion
Check the terminals of battery (1) at the left rear of
the cab for looseness and corrosion.
c2. Check of alternator terminals for looseness
and corrosion
Open the engine hood and check alternator termi-
nals B and R for breakage, looseness and corro-
sion.
40-22
c3. Check of starting motor terminals for loose-
ness and corrosion
Open the engine hood and check starting motor ter-
minals B and C for breakage, looseness and corro-
sion.
c4. Testing of battery voltage (with engine
stopped)
Using the battery tester, test the battery voltage
while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery while its electrolyte
level is below LOWER LEVEL. If it is used un-
der that condition, its inside will deteriorate,
its service life will be shortened and it may
lead to an explosion.
k Since the battery produces combustible gas
that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with wa-
ter and contact your doctor.
a Do not add battery electrolyte to above the UP-
PER LEVEL mark. If too much is added, it can
damage the painted surface and corrode the
parts.
a As refined water (example: commercially avail-
able battery fluid) added to the battery may
freeze, add it before starting work for the day so
that it will not freeze.
q When checking the electrolyte level from the
side of the battery
1. Clean around the electrolyte level lines with a
cloth dampened with water and check that the
electrolyte level is between UPPER LEVEL
(U.L.) and LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth since
static electricity may cause an explosion.
GD555-5,GD655-5,GD675-5
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2. If the electrolyte level is below the center
between the U.L. and L.L. lines, remove cap (2)
and add refined water (example: commercially
available battery fluid) to the U.L. line immedi-
ately.
3. After adding the refined water, tighten cap (1)
securely.
a If you have added refined water above the
U.L. line, take some of it out by using a sy-
ringe or similar tool. Neutralize the liquid that
has been taken out with sodium bicarbonate
or other suitable liquid, and wash it out with a
large amount of water.
q When electrolyte level cannot be checked from
the side of the battery
1. Remove cap (1) on the top of the battery.
(described previously)
2. Look into electrolyte level opening (2) to check
the electrolyte level. If the electrolyte level is
below sleeve (3), be sure to add refined water
(example: commercially available battery fluid)
up to the sleeve bottom (U.L. line).
q (A) Correct level: Since the electrolyte level is
higher than the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
q (B) Low: Since the electrolyte level is below
the sleeve bottom, the shape of the electrode
plates will appear straight.
3. After adding the refined water, tighten cap (1).
GD555-5,GD655-5,GD675-5
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General information on troubleshooting
Checks before troubleshooting
a If you have added refined water above the
U.L. line, take some of it out by using a sy-
ringe or similar tool. Neutralize the liquid that
has been taken out with sodium bicarbonate
or other suitable liquid, and wash it out with a
large amount of water.
c6. Check of wiring harness for discoloration,
burnt areas and cover peeling
q Check the wiring harness and cables for discol-
oration and burn.
a Discoloration and burnt areas indicate the possi-
bility of the short circuit or ground fault.
q Check the wiring harnesses and cables for dam-
age and peeling of the covers.
q If any fault are discovered, repair or replace the
wiring harness or cable.
c7. Check for removal of wiring harness clamps
and sagging of the wiring harness
q Check the wiring harnesses for sagging and play
caused by coming off of the clamp.
a In particular, carefully check around the hot and
movable parts.
q If any part is off the clamp, secure it with clamp
again.
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General information on troubleshooting
Checks before troubleshooting

c8. Check of grounding

a Check the ground terminal for looseness and
rusting in particular.
1. Check the connection of ground strap (1) of
engine controller (EC).

5. Open cover (12).

2. Open covers (3) and (4).

3. Remove cover (5).

6. Check ground cables (13) – (15).

4. Check the ground cables (6) – (11).

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 General information on troubleshooting
Checks before troubleshooting

7. Check the ground cable (16).

q Check the connector to see whether it is un-

8. Remove cover (17). locked and check its lock portion and housing for
cracks.
1. Remove covers (1) and (2).

9. Check ground cable (18).

2. Check lock screws (L) of controller (CNT) for

looseness.
a Use a 4-mm (width across flats) hexagonal
wrench.

c9. Check for loose connectors and damaged

locks
q Pull the male and female parts of the connector
by the hand to check the condition of their con-
nection.
q If the connecting condition is abnormal, connect
it securely.

GD555-5,GD655-5,GD675-5 40-25
(01)
General information on troubleshooting
Checks before troubleshooting

c10. Check of connector pin for corrosion, q Remove foreign matter in the connector by using
bends and deformation a cloth or other material, and blow compressed
q Disconnect the connector and check the pins for air against the inside of the connector.
corrosion, bending and retraction. Check that
the female pins have not expanded.
q If any pin is found to be abnormal, repair or re-
place it.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect several times
to shine them. (If the pins do not become shiny,
connect and disconnect the connector 10 times.)

c11. Check for water and foreign matter in the

connector
q Disconnect the connector and check whether
there is water, dirt, sand, etc. in it.

Caution
1. How to disconnect connector R1
Remove the connector straight slowly and check
it for breakage and coming off of the seal and
sticking of foreign matter.
a If the seal is defective, replace it.

a If there is sand or foreign matter in the connec-

tor, check the seal for damage.
q If the seal is defective, repair or replace it.
q Dry the moisture in the connector by using a dri-
er.

2. How to install connector R1

1) Check that the seal is installed to the plug
correctly.
2) Check that the key is fitted to the receptacle
side (It must be in the correct direction).
3) Match the connector on the plug side straight
with the receptacle (since the seal is
projected), and fit the connector a little while
checking that the seal does not roll up.
4) Tighten the hexagonal head bolt at the center
of the connector by 2 - 3 turns.
5) Fit the connector on the plug side fully and
adjust it so that the clearance between it and
receptacle will be even when viewed from
each direction.
6) Tighten the lock bolt to the specified torque.
3 Hexagonal head bolt:
2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}

40-26 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Checks before troubleshooting

a Tightening too strongly can break the lock
bolt. So be careful.
c13. Check of fuse for breakage and corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to the OFF posi-
tion).
q The fuse holder is installed to the right front of
the operator seat.
q If a fuse is corroded and coated with white pow-
der, or there is any play between the fuse and
fuse holder, replace the fuse.
q Replace the fuse with a new one of the same ca-
pacity.

c12. Check of wiring harness for open and short

circuiting
q Check the connections (crimped parts) between
each connector pin and wiring harness.
q If there is any open circuit in wiring harness or
connector as illustrated in (A), repair or replace
them.

q Visually check whether any pins are touching

any adjacent pins due to peeling of the wire cov-
er, defective crimping of the pin, etc.

GD555-5,GD655-5,GD675-5 40-27
(01)
General information on troubleshooting
Checks before troubleshooting
c14. Slow-blow fuse
q The slow-blow fuse breaks the electrical circuit
to protect the electrical equipment and wiring
when an overcurrent flows through it.
q When the starting switch is turned to the ON po-
sition, if the power is not supplied, the slow-blow
fuse may be broken. Check the slow-blow fuse
and replace it if necessary.
(1) 60A: Secondary power supply slow-blow fuse
(2) 30A: Unswitched power supply slow-blow
(3) 120A: Heater relay (intake air heater) slow-blow
fuse
(4) 120A: Alternator slow-blow fuse
40-28
c15. Check of alternator voltage (when engine
speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) line of the tester to alter-
nator terminal (B) and connect the negative (-)
line to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
q If the voltage is abnormal, repair or replace
the alternator.
c16. Check of battery relay operation sound
1. Open the battery cover.
2. Check whether the battery relay operation sound
is heard when starting switch is turned to
ON/OFF position.
q If the operation sound is not heard, check the
related circuits, referring to E-1 in the E
mode.
q If the related circuits are free from abnormal-
ities, replace the battery relay.
GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Classification and procedures for troubleshooting

Classification and procedures for troubleshooting 40-29

Classification of troubleshooting 40-29
Mode Contents
Display of code Troubleshooting by failure code (Display of code)
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine

Procedure for troubleshooting 40-29

If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting
No. according to the following procedure, and then go to the corresponding troubleshooting section.

1. Procedure for troubleshooting when action code is displayed on machine monitor:

If an action code is displayed on the machine monitor, display the failure code by using the abnormality
record display function (electrical system and mechanical system) of the machine monitor (EMMS).
a Since two or more troubles may have occurred simultaneously, press [>] button and record all the fail-
ure codes.
Perform the troubleshooting for the corresponding [Display of code] according to the displayed failure
code.
a Since the failure code "blinks" when a trouble is detected, that trouble may not have been repaired
even if the failure code "lights up" when the starting switch is turned to the ON position (Some codes
detect troubles when the starting switch is turned to the ON position, however).
a If any failure code is recorded, be sure to perform the operation to reproduce that code to see if the
trouble of that code has been or has not been repaired (For the reproduction method, see the trouble-
shooting in "Display of code").

2. Procedure for troubleshooting when failure code is recorded:

If an action code is not displayed on the machine monitor, display the failure code of the electrical system
and mechanical system by using the abnormality record display function of the machine monitor (EMMS).
If a failure code is recorded, perform troubleshooting for the corresponding "Display of code" according to
the failure code.
a Since the failure code "blinks" when a trouble is detected, that trouble may not have been repaired
even if the failure code "lights up" when the starting switch is turned to the ON position (Some codes
detect troubles when the starting switch is turned to the ON position, however).
a If any failure code is recorded, be sure to perform the operation to reproduce that code to see if the
trouble of that code has been or has not been repaired (For the reproduction method, see the trouble-
shooting in "Display of code").

3. Procedure for troubleshooting when action code is not displayed and failure code is not recorded:
If no failure code is found in the machine monitor (EMMS), a trouble that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the list of "Failure and troubleshooting numbers", and then perform troubleshooting
corresponding to that problem in the "E-mode", "H-mode", or "S-mode".

GD555-5,GD655-5,GD675-5 40-29
(01)
General information on troubleshooting
Failure codes table

Failure codes table 40-30

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
TORQFLOW transmission: Double Mechanical
1500L0 TM – Q E03 40-99
engagement system
Electrical
15G0MW Transmission R clutch: Slip TM – Q E03 40-100
system
Electrical
15H0MW Transmission FH clutch: Slip TM – Q E03 40-101
system
Electrical
15J0MW Transmission FL clutch: Slip TM – Q E03 40-101
system
Electrical
15K0MW Transmission 1st clutch: Slip TM – Q E03 40-102
system
Electrical
15L0MW Transmission 2nd clutch: Slip TM – Q E03 40-103
system
Electrical
15M0MW Transmission 3rd clutch: Slip TM – Q E03 40-104
system
Electrical
15N0MW Transmission 4th clutch: Slip TM – Q E03 40-105
system
ECMV R clutch: Fill signal is ON Electrical
15SBL1 TM – – E01 40-106
when command signal is OFF system
Electrical
15SBMA ECMV R clutch: Malfunction TM – Q E03 40-108
system
ECMV FH clutch: Fill signal is ON Electrical
15SCL1 TM – – E01 40-110
when command signal is OFF system
Electrical
15SCMA ECMV FH clutch: Malfunction TM – Q E03 40-112
system
ECMV FL clutch: Fill signal is ON Electrical
15SDL1 TM – – E01 40-114
when command signal is OFF system
Electrical
15SDMA ECMV FL clutch: Malfunction TM – Q E03 40-116
system
ECMV 1st clutch: Fill signal is ON Electrical
15SEL1 TM – – E01 40-118
when command signal is OFF system
Electrical
15SEMA ECMV 1st clutch: Malfunction TM – Q E03 40-120
system
ECMV 2nd clutch: Fill signal is ON Electrical
15SFL1 TM – – E01 40-122
when command signal is OFF system
Electrical
15SFMA ECMV 2nd clutch: Malfunction TM – Q E03 40-124
system
ECMV 3rd clutch: Fill signal is ON Electrical
15SGL1 TM – – E01 40-126
when command signal is OFF system
Electrical
15SGMA ECMV 3rd clutch: Malfunction TM – Q E03 40-128
system
ECMV 4th clutch: Fill signal is ON Electrical
15SHL1 TM – – E01 40-130
when command signal is OFF system
Electrical
15SHMA ECMV 4th clutch: Malfunction TM – Q E03 40-132
system
Electrical
15SJMA ECMV lockup clutch: Malfunction TM – Q E03 40-134
system
Mechanical
15U0NT Inching clutch: Overheat TM – Q E02 40-134
system
Mechanical
2G42ZG Front accumulator: Pressure drop MON Q*2 Q E03 40-135
system
Mechanical
2G43ZG Rear accumulator: Pressure drop MON Q*2 Q E03 40-135
system
Mechanical
AA1ANX Air cleaner clogging MON Q*1 – E01 40-136
system

40-30 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Alternator: Engine start and stop Electrical
AB00L6 MON Q Q E03 40-138
signals are not matched system
Mechanical
AB00MA Alternator: Malfunction MON Q Q E03 40-140
system
Derating in speed due to engine oil Mechanical
B@BAZG ENG Q Q E03 40-142
pressure drop system
Mechanical
B@BCNS Engine coolant overheat ENG Q Q E02 40-142
system
Mechanical
B@CENS Torque converter oil overheat MON Q Q E02 40-143
system
Mechanical
B@CKNS Differential case: Overheat MON Q Q E02 40-144
system
Mechanical
B@HANS Hydraulic oil: Overheating MON Q Q E02 40-146
system
Electrical
CA111 Engine controller internal error ENG – Q E03 40-148
system
Electrical
CA115 Engine Ne, Bkup speed sensor error ENG – Q E03 40-149
system
Electrical
CA122 Charge pressure sensor high error ENG – Q E03 40-150
system
Electrical
CA123 Charge pressure sensor low error ENG – Q E03 40-152
system
Electrical
CA131 Throttle sensor high error ENG – Q E03 40-154
system
Electrical
CA132 Throttle sensor low error ENG – Q E03 40-156
system
Electrical
CA144 Coolant sensor high error ENG – – E01 40-158
system
Electrical
CA145 Coolant sensor low error ENG – – E01 40-160
system
Charge temperature sensor high Electrical
CA153 ENG – – E01 40-162
error system
Electrical
CA154 Charge temperature sensor low ENG – – E01 40-164
system
Speed derating error by high charge Electrical
CA155 ENG – Q E03 40-166
temperature system
Electrical
CA187 Sensor power supply 2 low error ENG – Q E03 40-168
system
Atmospheric pressure sensor high Electrical
CA221 ENG – – E01 40-170
error system
Atmospheric pressure sensor low Electrical
CA222 ENG – – E01 40-172
error system
Electrical
CA227 Sensor power supply 2 high error ENG – Q E03 40-174
system
Mechanical
CA234 Engine overspeed ENG – Q E02 40-174
system
Electrical
CA238 Ne speed sensor power supply error ENG – Q E03 40-175
system
Electrical
CA271 IMV/IMA: Short circuit ENG – Q E03 40-176
system
Electrical
CA272 IMV/IMA open circuit ENG – Q E03 40-178
system
Electrical
CA322 Inj #1 (L#1) open/short ENG – Q E03 40-180
system
Electrical
CA323 Inj #5(L#5) open/short ENG – Q E03 40-182
system
Electrical
CA324 Inj #3 (L#3) open/short ENG – Q E03 40-184
system
Electrical
CA325 Inj #6 (L#6) open/short ENG – Q E03 40-186
system

GD555-5,GD655-5,GD675-5 40-31
(01)
General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Electrical
CA331 Inj #2 (L#2) open/short ENG – Q E03 40-188
system
Electrical
CA332 Inj #4 (L#4) open/short ENG – Q E03 40-190
system
Data compatibility error in engine Electrical
CA342 ENG – Q E03 40-192
controller system
Electrical
CA351 Injector drive circuit error ENG – Q E03 40-193
system
Electrical
CA352 Sensor power supply 1 low error ENG – Q E03 40-194
system
Electrical
CA386 Sensor power supply 1 high error ENG – Q E03 40-195
system
Electrical
CA428 Water-in-fuel sensor high error ENG – – E01 40-196
system
Electrical
CA429 Water-in-fuel sensor low error ENG – – E01 40-198
system
Electrical
CA431 Idle validation switch error ENG – – E01 40-200
system
Electrical
CA432 Idle validation action error ENG – Q E03 40-204
system
Electrical
CA435 Engine oil pressure switch error ENG – – E01 40-207
system
Electrical
CA441 Power supply voltage low error ENG – Q E03 40-208
system
Electrical
CA442 Power supply voltage high error ENG – Q E03 40-210
system
Electrical
CA449 Common rail pressure high error 2 ENG – Q E03 40-211
system
Common rail pressure sensor high Electrical
CA451 ENG – Q E03 40-212
error system
Common rail pressure sensor low Electrical
CA452 ENG – Q E03 40-214
error system
Torque derating error by high charge Electrical
CA488 ENG – Q E03 40-216
temperature system
Electrical
CA553 Common rail pressure high error 1 ENG – Q E03 40-217
system
Electrical
CA559 Supply pump pressure low error 1 ENG – Q E03 40-218
system
Electrical
CA689 Engine Ne speed sensor error ENG – Q E03 40-219
system
Engine Bkup speed sensor phase Electrical
CA731 ENG – Q E03 40-221
error system
Electrical
CA757 All continuous data lost error ENG – Q E03 40-222
system
Electrical
CA778 Engine Bkup speed sensor error ENG – Q E03 40-223
system
Electrical
CA1633 KOMNET CAN communication error ENG – Q E03 40-226
system
Throttle sensor power supply high Electrical
CA2185 ENG – Q E03 40-228
error system
Throttle sensor power supply low Electrical
CA2186 ENG – Q E03 40-230
error system
Electrical
CA2249 Supply pump pressure low error 2 ENG – Q E03 40-232
system
Electrical
CA2311 Abnormality in IMV (IMA) solenoid ENG – Q E03 40-233
system
Electrical
CA2555 Intake heater relay open circuit ENG – – E01 40-234
system

40-32 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Electrical
CA2556 Intake heater relay short circuit ENG – – E01 40-236
system
Backup lamp relay: Open circuit, hot Electrical
D160KA TM – – E01 40-238
short ciruit in wiring harness system
Electrical
D160KB Backup lamp relay: Ground fault TM – – E01 40-240
system
Differential lock relay: Open circuit, Electrical
D19KKZ TM – – E01 40-242
ground fault system
C terminal signal: Signal does Electrical
D5ZHL6 MON – – E01 40-244
match to actual engine state system
CAN communication failure (monitor Electrical
DAFRKR TM – Q E03 40-246
panel) system
Transmission controller: Power sup- Electrical
DAQ0KK TM – Q E03 40-248
ply voltage drop (input) system
Transmission controller: Non-vola- Electrical
DAQ0KT TM – – E01 40-250
tile memory error system
Transmission controller load power
Electrical
DAQ2KK line: Power supply voltage drop TM – Q E03 40-252
system
(input)
Transmission controller model
DAQ9KQ selection: Model selection signal MON – Q E03 – 40-254
disagreement

Transmission controller CAN com- Electrical

DAQRKR MON – Q E03 40-256
munication: Communication error system

Transmission controller option set-

DAQRMA MON – Q E03 – 40-260
ting: Malfunction
Engine controller CAN communica- Electrical
DB2RKR MON – Q E03 40-261
tion: Communication error system
Fan reverse switch signal: Short cir- Electrical
DD1NLD TM – – E01 40-268
cuit system
RPM set switch power supply short Electrical
DD1PKB TM – Q E03 40-270
circuit system
Electrical
DD1QKB RPM set mode switch short circuit TM – Q E03 40-272
system
Transmission gearshift lever: Park- Electrical
DDB6L4 TM – Q E03 40-274
ing brake signal error system
Electrical
DDTHKA Fill switch for FH clutch: Open circuit TM – – E01 40-276
system
Electrical
DDTJKA Fill switch for FL clutch: Open circuit TM – – E01 40-276
system
Electrical
DDTKKA Fill switch for 1st clutch: Open circuit TM – – E01 40-277
system
Fill switch for 2nd clutch: Open cir- Electrical
DDTLKA TM – – E01 40-277
cuit system
Fill switch for 3rd clutch: Open cir- Electrical
DDTMKA TM – – E01 40-277
cuit system
Electrical
DDTNKA Fill switch for R clutch: Open circuit TM – – E01 40-278
system
Electrical
DDTPKA Fill switch for 4th clutch: Open circuit TM – – E01 40-279
system
Transmission gearshift lever: No Electrical
DF10KA TM – Q E03 40-281
gear speed signal is input system

GD555-5,GD655-5,GD675-5 40-33
(01)
General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
Transmission gearshift lever: Gear Electrical
DF10L4 TM – Q E03 40-285
speed/travel direction signal error system
Transmission oil temperature sen- Electrical
DGF1KX TM – Q E03 40-288
sor: Input signal out of range system
Hydraulic oil temperature sensor: Electrical
DGH2KB TM – – E01 40-290
Ground fault system
Torque converter oil temperature Electrical
DGT1KX TM – – E01 40-292
sensor: Input signal out of range system
Differential oil temperature sensor: Electrical
DGT7KB TM – – E01 40-294
Ground fault system
Electrical
DJF1KA Fuel level sensor: Open circuit MON – – E01 40-296
system
Inching pedal angle sensor: Input Electrical
DK70KX TM – Q E03 40-298
signal out of range system
Articulation angle sensor: Input sig- Electrical
DKD0KA TM – – E01 40-300
nal out of range system
Transmission input shaft speed sen- Electrical
DLF1KA TM – Q E03 40-302
sor: Open circuit system
Transmission input shaft speed sen- Electrical
DLF1LC TM – Q E03 40-303
sor: Speed signal does not match. system
Transmission intermediate shaft Electrical
DLF2KA TM – Q E03 40-304
speed sensor: Open circuit system
Transmission intermediate shaft
Electrical
DLF2LC speed sensor: Speed signal does TM – Q E03 40-305
system
not match.
Electrical
DLM3KA Fan speed sensor: Open circuit TM – – E01 40-306
system
Electrical
DLM3LC Fan speed sensor: Short circuit TM – – E01 40-307
system
Transmission output shaft speed Electrical
DLT3KA TM – Q E03 40-308
sensor: Open circuit system
Electrical
DV00KB Bazzer: Short circuit MON – – E01 40-310
system
Parking brake solenoid valve: Open Electrical
DW4BKA TM – Q E03 40-312
circuit system
Parking brake solenoid valve: Short Electrical
DW4BKB TM – Q E03 40-314
circuit system
Electrical
DW7BKA Fan reverse solenoid: Open circuit TM – – E01 40-315
system
Electrical
DW7BKB Fan reverse solenoid: Short circuit TM – – E01 40-316
system
Fan reverse solenoid: Short circuit Electrical
DW7BKY TM – – E01 40-318
to power supply line system
Fan motor EPC solenoid: Open cir- Electrical
DX16KA TM – – E01 40-320
cuit system
Fan motor EPC solenoid: Short cir- Electrical
DX16KB TM – – E01 40-321
cuit system
Fan motor EPC solelnoid: Short cir- Electrical
DX16KY TM – – E01 40-322
cuit to power supply line system
Electrical
DXH1KA Lockup solenoid: Open circuit TM – Q E03 40-324
system
Electrical
DXH1KB Lockup solenoid: Short circuit TM – Q E03 40-325
system
Lockup ECMV solenoid: Short cir- Electrical
DXH1KY TM – Q E03 40-326
cuit to power supply line system

40-34 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure codes table

Centralized
Compon Reference
Failure Caution warning Action Category of
Failure ent in document
code lamp lamp/Alarm code record
charge page
buzzer
FH clutch ECMV solenoid: Open cir- Electrical
DXH2KA TM – Q E03 40-328
cuit system
FH clutch ECMV solenoid: Short cir- Electrical
DXH2KB TM – Q E03 40-329
cuit system
FH clutch ECMV solenoid Short cir- Electrical
DXH2KY TM – Q E03 40-330
cuit to power supply line system
FL clutch ECMV solenoid: Open cir- Electrical
DXH3KA TM – Q E03 40-332
cuit system
FL clutch ECMV solenoid: Short cir- Electrical
DXH3KB TM – Q E03 40-334
cuit system
FL clutch ECMV: Short circuit to Electrical
DXH3KY TM – Q E03 40-336
power supply line system
1st clutch ECMV solenoid: Open cir- Electrical
DXH4KA TM – Q E03 40-338
cuit system
1st clutch ECMV solenoid: Short cir- Electrical
DXH4KB TM – Q E03 40-340
cuit system
1st clutch ECMV solenoid: Short cir- Electrical
DXH4KY TM – Q E03 40-342
cuit to power supply line system
2nd clutch ECMV solenoid: Open Electrical
DXH5KA TM – Q E03 40-344
circuit system
2nd clutch ECMV solenoid: Short Electrical
DXH5KB TM – Q E03 40-346
circuit system
2nd clutch ECMV solenoid: Short Electrical
DXH5KY TM – Q E03 40-348
circuit to power supply line system
3rd clutch ECMV solenoid: Open cir- Electrical
DXH6KA TM – Q E03 40-350
cuit system
3rd clutch ECMV solenoid: Short cir- Electrical
DXH6KB TM – Q E03 40-352
cuit system
3rd clutch ECMV solenoid: Short cir- Electrical
DXH6KY TM – Q E03 40-354
cuit to power supply line system
R clutch ECMV solenoid: Open cir- Electrical
DXH7KA TM – Q E03 40-356
cuit system
R clutch ECMV solenoid: Short cir- Electrical
DXH7KB TM – Q E03 40-357
cuit system
R clutch ECMV solenoid: Short cir- Electrical
DXH7KY TM – Q E03 40-358
cuit to power supply line system
4th clutch ECMV solenoid: Open cir- Electrical
DXHHKA TM – Q E03 40-360
cuit system
4th clutch ECMV solenoid: Short cir- Electrical
DXHHKB TM – Q E03 40-362
cuit system
4th clutch ECMV solenoid: Short cir- Electrical
DXHHKY TM – Q E03 40-364
cuit to power supply line system

GD555-5,GD655-5,GD675-5 40-35
(01)
General information on troubleshooting
Failure codes table

*1: If the air cleaner is clogged, the maintenance caution lamp lights up.
*2: If the accumulator oil pressure drops, the brake oil pressure caution lamp lights up.
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
TM: Transmission controller
a The failure codes having no numbers in the action code column are not displayed on the ordinary screen
when abnormality related to them occurs. They are simply recorded in the fault history of the service menu
(electrical equipment system or mechanical equipment system).
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the failure history of service menu.

40-36 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Failure and troubleshooting numbers

Failure and troubleshooting numbers 40-37

Failure and troubleshooting numbers
Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Action code and failure code
The action code and failure code are displayed on the machine moni-
1
tor.
When abnormality record is checked, failure code is shown in
2 Take actions by following the failure code.
mechanical system abnormality record
When abnormality record is checked, failure code is shown in electri-
3
cal system abnormality record

Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Failure related to engine
4 Starting performance is poor S-1 40-512
5 Engine does not start E-1, S-2 40-366, 40-513
6 Engine does not pick up smoothly S-3 40-516
7 Engine stops during operations S-4, H-1 40-517, 40-466
8 Engine does not run smoothly S-5 40-518
9 Engine lacks output (or lacks power) S-6 40-519
10 Exhaust smoke is black (incomplete combustion) S-7 40-520
11 Oil consumption is excessive (or exhaust smoke is blue) S-8 40-521
12 Oil becomes contaminated quickly S-9 40-522
13 Fuel consumption is excessive S-10 40-523
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11 40-524
15 Oil pressure drops S-12 40-525
16 Oil level rises (Entry of coolant/fuel) S-13 40-526
17 Coolant temperature becomes too high (overheating) S-14 40-527
18 Abnormal noise is made S-15 40-528
19 Vibration is excessive S-16 40-529
20 The preheater does not operate E-2 40-372
Failure related to power train
21 Machine does not start. H-2 40-467
22 Gear is not shifted. H-3 40-468
23 Machine travel speed is slow or power is insufficient. H-4 40-469
24 Torque converter lockup does not operate, or can not be released. H-5 40-474
25 Too much time lag at starting of travel or changing gear shift H-6 40-475
26 Oil temperature of torque converter is high. H-7 40-480
27 Differential lock-up function does not operate or can not be released. H-8, E-18 40-485, 40-408
Failure related to steering
28 Steering speed is slow or power is insufficient. H-9 40-486
29 Steering wheel does not move. H-10 40-487
Failure related to brake
30 Wheel brake does not operate or insufficient. H-11 40-488
31 Wheel brake cannot be released or drags. H-12 40-489
32 Parking brake does not operate or insufficient. H-13 40-490
Parking brake (including emergency release system) cannot be
33 H-14 40-491
released or drags.
Failure related to work equipment
34 Speed of all work equipment is slow or power is insufficient. H-15 40-492
35 No work equipment operates. H-16 40-493
36 Abnormal sound comes out from around hydraulic pump H-17 40-494
37 Blade lift speed is too slow or lacks power. H-18 40-495
38 Excessive hydraulic drift of blade lift cylinders H-19 40-496
39 Speed of shifting drawbar in sideways is slow or power is insufficient. H-20 40-497
40 Speed of shifting blade in sideways is slow or power is insufficient. H-21 40-498
41 Power tilt speed is slow or power is insufficient. H-22 40-499
42 Articulate speed is low or power is insufficient. H-23 40-500
43 Leaning speed is slow or power is insufficient. H-24 40-501
44 Excessive hydraulic drift of leaning cylinders. (leaning) H-25 40-502
45 Blade does not rotate. H-26 40-503

GD555-5,GD655-5,GD675-5 40-37
(01)
General information on troubleshooting
Failure and troubleshooting numbers

Troubleshooting
No. Phenomena supposed to show troubles Reference document
Index
page
Lift arm lock pin does not lock, or lock cannot be released.
46 H-27, E-19 40-504, 40-412
[for lift arm specification]
Blade accumulator function does not operate or cannot be released.
47 H-28, E-20 40-505, 40-414
[for blade accumulator and float specification]
Blade float function does not operate or cannot be released.
48 H-29, E-1 40-506, 40-366
[for blade accumulator and float specification]
Failure related to machine monitor
49 When starting switch turned ON, machine monitor displays nothing E-3 40-377
When starting switch is turned to ON position, machine monitor does
50 E-4 40-380
not display normally.
When starting switch is turned to ON position, caution item blinks or
51 E-5 40-380
lights up, or machine monitor does not display normally.
52 Emergency stop item lights up while engine is running E-6 40-381
53 Speedometer and engine tachometer do not display normally. E-7 40-385
54 Engine coolant temperature gauge does not indicate normally E-8 40-386
55 Articulation gauge does not display normally. E-9 40-388
56 Torque converter oil temperature gauge does not display normally. E-10 40-390
57 Fuel level gauge does not indicate normally E-11 40-392
58 Character display does not display normally. E-12 40-394
59 Centralized warning lamp does not light up or go off. E-13 40-396
60 Alarm buzzer does not sound or stop sounding. E-14 40-398
61 Machine monitor mode selector switch does not function. E-15 40-400
62 Transmission mode does not change. E-16 40-404
63 Engine mode does not change. E-17 40-406
Differential lock function does not work or is not reset [for differential
64 E-18 40-408
lock-up specification].
65 Lift arm lock pin is not locked or reset [for lift arm specification]. E-19 40-412
Blade accumulator function does not work or is not reset [for blade
66 E-20 40-414
accumulator specification].
67 Horn does not sound or stop sounding. E-21 40-418
68 Backup alarm does not sound or stop sounding. E-22 40-420
69 Headlamp, clearance lamp, and tail lamp do not light up or go off. E-23 40-423
70 Front working lamp does not light up or go off. E-24 40-430
71 Turn signal lamp and hazard lamp do not blink. E-25 40-436
72 Stop lamp does not light up or go off. E-26 40-442
73 Backup lamp does not light up or go off. E-27 40-444
74 Windshield wiper does not operate. E-28 40-446
75 Window washer does not operate. E-29 40-454
76 KOMTRAX system does not operate normally. E-30 40-458

40-38 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Information in troubleshooting table

Information in troubleshooting table 40-39

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.

User code Failure code

Description of failure that is diaplayed on machine monitor
Display on Failure
Display on machine as abnormality record
machine moni-
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action taken by the controller or machine monitor to protect system or devices when
Action of controller
machine monitor or controller detects failure
Problem that appears on the machine as a result of the action taken by the machine mon-
Problem on machine
itor or controller (shown above)
Related information Information related to the detected failure or troubleshooting

Cause Procedure, measuring location, criteria and remarks

Probable causes
1 Defective xxxx
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3
(Contact with ground circuit)
Hot short
4
(Contact with 24 V circuit)
5 Short circuit in wiring harness
6 Defective controller
<Details of description>
q Procedure
q Measuring location
a "Between A and B" means the measurement of voltage, resistance or
others between terminals A and B.
q Criteria: voltage, resistance, etc.
q Remarks for judgment
<How to use the troubleshooting sheet>
q Perform troubleshoot in the following procedure in numerical order.
q If the test result does not meet the criteria, the probable cause described
on the left column is the actual cause of the failure.
q If the test result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
<Failures in wiring harness>
q Open circuit in wiring
The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
A harness not connected to the power circuit (24 V) contacts the power
circuit.
q Short circuit
An independent wire in the harness abnormally contacts with other wire.
(Poor insulation at connector and others)
<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless other-
wise specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
male connectors.
q When "male" or "female" is indicated with a connector number, discon-
nect the connector, and connect T-adapter only to either male or femae
end.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
q Connect the negative (-) lead to a pin or wire indicated second.

GD555-5,GD655-5,GD675-5 40-39
(01)
General information on troubleshooting
Information in troubleshooting table

Circuit diagram related to - - - - - 40-40

This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed

40-40 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

Troubleshooting method for open circuit in wiring harness of pressure

sensor system 40-41
a Since pressure sensor consists not only of resistors but also electronic circuits such as amplifiers, it may
have the differences among the resistances measured and its own polarities. So troubleshooting must be
performed carefully.

Failure codes applicable to this diagnosis

q CA123: Charge air pressure sensor low error
q CA451: RailPress sensor high error

Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor.
2) Measure resistances R1 and R2 between pins.
a If tester probes polarities to apply are reversed, measured values may change. Therefore, when
measuring resistances, apply the same tester probe polarities to the pressure sensor in steps 1 and
2.
a If measured value is infinite, take measurements with tester probes polarities exchanged each oth-
er and record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements.
Cause of this dispersion appears to be a charge in a sensor. Take several measurement in both
steps 1 and 2. Consider this dispersion when judging whether the wiring harness is disconnected
in step 3.

2. Measure and record resistance with wiring harness between pressure sensor and engine controller
connected.
1) Since 5 V power supply to pressure sensor is supplied to other sensors, disconnect the other sensor
connectors first.(*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on engine controller side, and
connect T-adapter (4) to wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.

3. Judging open circuit

If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is disconnected".
a "Apparent difference" means a difference of 10 or more times.

GD555-5,GD655-5,GD675-5 40-41
(01)
General information on troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure sensor system

List of pressure sensor measuring locations and reference values

Internal resistance of
Measuring location at sensor
Sensor sensor Remarks
pin
(reference value)
Charge pressure R2: Between (2) and (4) Approx. 100 z Sensor is common to engine mod-
sensor R1: Between (1) and (4) Approx. 200 z els 107 and 114
Sensor is common to engine mod-
R2: Between (3) and (1) Approx. 23 kz
Common rail els 107 and 114
pressure sensor If polarities are inverted, resis-
R1: Between (1)(+) and (2)(-) Approx. 10 Mz
tance is infinite.

*: In addition to the above, when measuring R2', disconnect the following: (See circuit diagram related to each
code)
q When measuring R2' of charge pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water sepa-
rator)
q When measuring R2' of common rail pressure sensor (CA451):
Connectors of charge pressure sensor, CAM sensor and water-in-fuel sensor (water separator)

Measurement record (For measuring locations, see circuit diagram related to each code.)
Sensor + Wiring harness
Sensor unit
(Measuring location at wir- Measured
Sensor (Measuring location on sen- Measured value
ing harness on engine value
sor pin side)
controller side)
R2': Between (37) and (47)
Charge pressure R2: Between (2) and (4)
(*)
sensor
R1: Between (1) and (4) R1': Between (44) and (47)
R2': Between (37) and (47)
R2: Between (3) and (1)
Common rail (*)
pressure sensor R1': Between (47)(+) and
R1: Between (1)(+) and – (2)(-)
(25)(-)

40-42 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Connector list and layout 40-43

GD555-5,655-5,675-5
Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
A. PRESS. SEN. 3 Ambient pressure sensor ZY-3
AC1 SWP 12 Intermediate connector U-6
AC3 SWP 14 Intermediate connector AM-4
AC4 SWP 6 Intermediate connector AM-4
AC5 SWP 22 Controller (inside cab) AK-8
AC6 SWP 14 Controller (inside cab) AK-8
B. PRESS. TEMP.
4 Boost pressure and boost temperature sensor AY-3
SEN.
B11 DT2 3 Articulation sensor T-4
B13 DT2 3 Blake lamp switch R-3
B15 KES1 2 Window washer door U-2
B16 YAZAKI 2 Front window washer T-2
B17 YAZAKI 2 Rear window washer T-2
B19 DT2 2 T-6
BZ DT2 2 Backup alarm J-7
C. RAIL PRESS. SEN. 3 Common rail pressure sensor AZ-4
C1 DT2 12 Intermediate connector V-5
C1 DT2 12 Intermediate connector AM-4
C10 KES 6 Rear wiper relay AM-5
C11 M 4 Left door wiper motor AL-4
C12 KES 6 Door wiper relay AM-5
C13 M 4 Right door wiper motor AJ-6
C14 KES 6 Front wiper relay AM-5
C15 X 6 Front wiper motor AK-6
C16 M 4 Rear window wiper motor AM-5
C17 SWP 6 Front wiper switch AM-6
C18 M 2 Rear fan AM-7
C2 DT2 12 Intermediate connector V-5
C2 DT2 12 Intermediate connector AM-4
C20 SWP 6 Revolving warning lamp switch AL-6
C21 SWP 6 Work lamp switch AL-6
C22 KES 6 Work lamp relay AM-5
C23 M 2 work lamp AJ-6
C24 M 2 work lamp AJ-6
C25 M 2 work lamp AJ-6
C26 M 2 work lamp AJ-6
C27 M 3 Right winker AJ-6
C28 M 3 Left winker AJ-6
C29 DT-T 2 Intermediate connector AJ-6
C3 KES 2 Room lamp AK-6
C30 DT-T 2 Rotary lamp AJ-7
C31 KES 6 Revolving warning lamp relay AM-5
C33 YAZAKI 6 Front wiper intermit relay AM-5

GD555-5,GD655-5,GD675-5 40-43
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
C34 YAZAKI 6 Rear wiper intermit relay AM-5
C35 YAZAKI 6 Right door wiper intermit relay AM-5
C36 YAZAKI 6 Left door wiper intermit relay AM-5
C37 SWP 6 Intermit wiper switch AM-6
C38 DT-T 2 Diode AJ-4
C39 X 2 Inter lock door solenoid AJ-4
C40 M 1 Right door switch AJ-6
C41 M 1 Left door switch AK-5
C42 KES 6 Inter lock door solenoid relay AJ-4
C5 YAZAKI 9 Radio AK-7
C6 M 2 Left speaker AL-7
C7 M 2 Left speaker AM-7
C8 SWP 6 Rear wiper switch AM-6
C9 SWP 6 Door wiper switch AM-6
CAN DT2 12 KOMNET service connector S-5
CAN 3 CAN AX-2
CAN1 DT-T 3 CAN terminating resistance AY-2
CHK0A X 1 Intermediate connector T-5
CHK0B X 1 Intermediate connector T-5
CHK1A X 1 Intermediate connector T-2
CHK1B X 1 Intermediate connector T-5
CON DT2 6 12 V converter AF-6
CT41 Terminal 1 Ground AM-4
E01 DT-T 2 Safety relay AW-6
E02 Terminal 1 Alternator AX-7
E07 Terminal 1 Grid heater AY-3
E19 Terminal 1 Safety relay AW-6
E20 Terminal 1 Safety relay AW-6
E21 Terminal 1 Starting motor AW-5
E29 Terminal 1 Alternator AX-7
E30 Terminal 1 Starting motor K-2, AW-5
E31 Terminal 1 Holder 2 AW-6
E32 Terminal 1 Holder 2 AW-6
E33 Terminal 1 Holder 2 AW-6
EC1 DRC 60 Engine controller AY-2
EC2 DRC 50 Engine controller AY-3
EC3 DRC 4 Engine controller AY-2
ENG.PRESS.SW. Terminal 1 Engine oil pressure switch (low pressure) AY-3
ENG.W.TEMP.SW. 2 Engine coolant temperature sensor AX-3
ER1 DT2 12 Intermediate connector I-6, AW-6
ER2 DTP 2 Intermediate connector I-6, AW-6
ER3 DT2 12 Intermediate connector I-6, AW-6
ET103A Terminal 1 Ground AY-3
ET103B Terminal 1 Ground AY-3

40-44 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
ET104 DT-T 2 Intermediate connector AW-6
ET39 DT2 2 Fuel level sensor J-7
ET40A Terminal 1 Breaker K-3
ET40B Terminal 1 Ground K-1
ET41A Terminal 1 Battery K-3
ET41B Terminal 1 Breaker K-3
ET42 Terminal 1 Battery K-3
ET43 Terminal 1 Battery K-3
ET44 Terminal 1 Battery K-3
ET45 Terminal 1 Battery relay B-7
ET46 Terminal 1 Battery relay B-7
ET47 Terminal 1 Fuse holder B-8
ET48 Terminal 1 Fuse holder B-8
ET49 Terminal 1 Battery relay B-7
ET54 Terminal 1 Heater relay AW-6
ET58 Terminal 1 Battery relay B-7
ET59 Terminal 1 Fuse holder B-8
ET60 Terminal 1 Fuse holder B-8
ET75 Terminal 1 Battery relay B-7
ET76 Terminal 1 Battery relay B-7
ET77 Terminal 1 Ground I-6
ET82 Terminal 1 Heater relay AW-6
ET88 DT 2 Chlorofluorocarbon compressor magnetic clutch AY-2
ET89 Terminal 1 Ground I-6
FB1 – 30 Fuse box AC-6
FB2 – 30 Fuse box AD-6
FL1 DT2 3 Right head lamp B-4
FL10 DT 2 Front work lamp L.H. G-5
FL11 DT2 2 Center work lamp R.H. D-5
FL12 DT2 2 Center work lamp L.H. D-5
FL13 DT2 2 Right accumulator solenoid valve E-5
FL14 DT 2 Left accumulator solenoid valve E-5
FL15 DT 2 Diode E-5
FL17 DT2 12 Intermediate connector Q-4
FL17 DT2 12 Intermediate connector G-6
FL18 DT2 6 Intermediate connector C-4
FL2 DT2 3 Left head lamp D-3
FL3 DT 3 Right turn signal B-4
FL4 DT 3 Left turn signal C-3
FL5 DT 2 Right clearance lamp B-4
FL6 DT 2 Left clearance lamp C-3
FL6 DT2 3 Inching pedal R-3
FL7 X 2 Right horn B-3
FL8 X 2 Left horn C-3

GD555-5,GD655-5,GD675-5 40-45
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
FL9 DT 2 Front work lamp R.H. F-5
FLG1 Terminal 1 Ground (frame front end) C-3
FLG2 Terminal 1 Ground (ROPS frame) F-6
FP1 AMP070 20 Monitor panel P-7
FP10 DT2 12 Intermediate connector Q-4
FP11 DT2 12 Intermediate connector Q-4
FP12 DT2 6 Differential lockup switch N-7
FP13 DT2 4 Intermediate connector Q-5
FP14 DT-T 3 Left float engine cancel switch X-7
FP15 DT-T 3 Right float engine cancel switch Q-3
FP2 AMP070 12 Monitor panel P-7
FP3 DT-2 12 Monitor panel P-7
FP4 M 2 Alarm buzzer Q-7
FP5 DT-2 6 Monitor mode switch 2 Q-7
FP6 DT-2 6 Monitor mode switch 1 Q-7
FP7 DT-2 6 Dimmer switch P-7
FP8 DT-2 3 Turn signal switch P-7
FP9 DT-2 2 Horn switch N-7
FT10 Terminal 1 Ground T-3
FT11 Terminal 1 Ground U-3
FT12 Terminal 1 Ground G-5
FT13 Terminal 1 Ground I-6
G SEN. 3 G sensor AX-2
H X 1 Intermediate connector AG-3
H3 DT-T 6 Additional heater switch –
H5 DT-T 3 Additional heater unit –
IMA 2 IMA fuel pump actuator AZ-3
ING. #1,2 4 Injector #1, 2 AX-3
ING. #3,4 4 Injector #3, 4 AY-3
ING. #5,6 4 Injector #5, 6 AY-4
L80 DRC 40 KOMTRAX controller U-6
NE SEN. 3 NE sensor AX-2
R1 DRC 70 Intermediate connector T-3
R1 DRC 70 Intermediate connector G-5
R10 DT 2 Lifter solenoid H-7
R11 DT 2 Park solenoid H-7
R15 DT2 2 Accumulator oil pressure switch J-2
R16 DT2 2 Accumulator oil pressure switch J-2
R17 DT-T 2 Hydraulic oil temperature sensor J-3
R18 DT 2 Diode B-8
R19 DT 2 Diode B-8
R20 DT2 2 Dust indicator K-3,AV-8
R21 DT2 6 Intermediate connector J-3
R28 DT 2 Diode AW-6

40-46 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
R29 DT 2 Diode AW-6
R31 DT-T 2 Diode AW-6
R5 #4 1 Intermediate connector G-5
R5 DTDH 1 Intermediate connector S-3
R6 #8 1 Intermediate connector G-5
R6 DTDH 1 Intermediate connector S-3
R7 DTP 2 Intermediate connector G-5,S-3
R8 DT 2 Differential oil temperature sensor I-6
R9 DT 2 Differential lockup solenoid I-6
RL1 DT2 12 Intermediate connector J-8
RL10 DT 2 License lamp –
RL2 DT 6 Right combination lamp J-8
RL3 DT 6 Left combination lamp J-7
RL4 DT 2 Rear work equipment lamp J-9
RL5 DT 2 Rear work equipment lamp K-8
RL9 DT 2 Intermediate connector J-8
RT6 DT2 2 Fan reverse rotation valve J-8
RT7 DT2 2 Fan motor EPC J-8
RT8 DT2 2 Fan speed sensor J-8
SCT1 YAZAKI 2 12 V power supply AE-8
SP11 KES 6 Dimmer relay AE-7
SP12 KES 6 Small lamp relay AE-7
SP13 KES 6 Head lamp relay AE-7
SP14 KES 6 Front work lamp relay AE-7
SP15 KES 6 Rear work lamp relay AE-7
SP16 KES 6 Stop lamp relay AE-7
SP17 KES 6 Safety relay AE-7
SP18 KES 6 Hazard lamp relay 1 AE-7
SP19 KES 6 Hazard lamp relay 2 AE-7
SP21 SWP 6 Accumulator switch AD-8
SP22 KES 6 Head lamp switch AE-8
SP23 SWP 6 Front work lamp switch AD-8
SP24 SWP 6 Rear work lamp switch AD-8
SP25 SWP 6 Hazard lamp switch AD-8
SP26 KES 4 Turn signal lamp relay AE-2
SP27 KES 6 Horn relay AE-7
SP28 DT2 2 Lifter lock switch AE-7
SP29 YAZAKI 2 24 V cigarette lighter AE-8
SP30 KES 6 Cut out relay 1 AE-7
SP31 KES 6 Accumulator relay AE-7
SP32 KES 6 Dust indicator relay AE-7
SP33 KES 6 S hold relay AE-7
SP34 DT 2 Diode AF-3
SP35 DT 2 Diode AF-3
SP36 DT 2 Diode AE-3

GD555-5,GD655-5,GD675-5 40-47
(01)
General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
SP37 DT 2 Diode AE-3
SP38 KES 6 Float engine cancel relay AG-3
SP39 KES 6 Float lamp relay AG-3
SP40 KES 6 Preheater relay AF-3
ST10 Terminal 1 Starting switch ACC AE-8
ST6 Terminal 1 Starting switch B AE-8
ST7 Terminal 1 Starting switch BR AE-8
ST8 Terminal 1 Starting switch R1 AE-8
ST9 Terminal 1 Starting switch C AE-8
T20 DT2 12 Intermediate connector AS-6
T21 DT2 12 Intermediate connector AS-6
T22 DT2 12 Intermediate connector AS-5
T24 DT2 2 FL solenoid AQ-7
T25 DT2 2 FH solenoid AP-7
T26 DT2 2 R solenoid AP-7
T27 DT2 2 1st clutch solenoid AP-7
T28 DT2 2 2nd clutch solenoid AQ-7
T29 DT2 2 3rd clutch solenoid AQ-7
T30 DT2 2 4th clutch solenoid AQ-7
T31 DT2 2 L/U solenoid AQ-7
T32 DT2 2 Transmission input shaft speed sensor AT-1
T33 DT2 2 Transmission output shaft speed sensor AR-4
T34 DT2 2 Torque converter oil temperature sensor AS-4
T35 DT2 2 Transmission oil temperature sensor AQ-5
T36 DT2 2 FL clutch oil pressure AQ-7
T37 DT2 2 FH clutch oil pressure AP-7
T38 DT2 2 R clutch oil pressure AP-7
T39 DT2 2 1st clutch oil pressure AP-7
T40 DT2 2 2nd clutch oil pressure AP-7
T41 DT2 2 3rd clutch oil pressure AQ-7
T42 DT2 2 4th clutch oil pressure AQ-5
T47 DT2 2 Intermediate shaft speed sensor AQ-5
T9A DT2 6 Accelerator pedal R-4
T9B DT2 2 Accelerator pedal R-4
TEL DT-T 12 Intermediate connector V-6
TG1 Terminal 1 Ground AQ-7
TM30 SWP 6 Transmission mode switch AD-8
TM31 SWP 6 Hydraulic fan reverse rotation switch AE-8
TM35 DT2 3 Intermediate connector AG-3
TM36 DT-T 21 Shifter AG-3
TM37 SWP 6 RPM set/resume switch AD-7
TM38 KES 7 RPM set mode switch AD-8
TM39 DRC 24 Transmission controller U-6
TM40 DRC 40 Transmission controller U-5

40-48 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

Number of Three-dimensio
Connector No. Model Equipment name
pins nal layout
TM41 DRC 40 Transmission controller U-5
TM42 KES 6 Backup lamp relay AE-7
TM43 KES 6 Differential lockup relay AE-7
TM45 SWP 6 Engine mode switch AE-8
W60 KES 6 Engine cut relay U-5
WIF1 DT-T 2 WIF AY-7
WIF2 DT-T 2 Intermediate connector AY-2
– 4 Compressor relay –
– 2 Pressure switch –
– 4 Blower OFF relay –
– 2 Blower motor –
– 3 Blower amplifier –
– 2 Evacuator sensor –
– 6 Motor actuator (air mix) –
Motor actuator (FRESH/RECIRC air change-
– 6 –
over)

GD555-5,GD655-5,GD675-5 40-49
(01)
General information on troubleshooting
Connector list and layout

Layout of connector (1/8)

40-50 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(2/8)

GD555-5,GD655-5,GD675-5 40-51
(01)
General information on troubleshooting
Connector list and layout

(3/8)

40-52 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(4/8)

GD555-5,GD655-5,GD675-5 40-53
(01)
General information on troubleshooting
Connector list and layout

(5/8)

40-54 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(6/8)

GD555-5,GD655-5,GD675-5 40-55
(01)
General information on troubleshooting
Connector list and layout

(7/8)

40-56 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connector list and layout

(8/8)

GD555-5,GD655-5,GD675-5 40-57
(01)
General information on troubleshooting
Connection table for connector pin numbers

Connection table for connector pin numbers 40-58

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

40-58 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-59
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-60 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-61
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-62 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-63
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-64 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-65
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-66 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-67
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-68 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-69
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-70 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-71
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-72 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-73
(01)
General information on troubleshooting
Connection table for connector pin numbers

40-74 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-76 GD555-5,GD655-5,GD675-5
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 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-78 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-79
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General information on troubleshooting
Connection table for connector pin numbers

40-80 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-82 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-83
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General information on troubleshooting
Connection table for connector pin numbers

40-84 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-86 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-88 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-90 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

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General information on troubleshooting
Connection table for connector pin numbers

40-92 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Connection table for connector pin numbers

GD555-5,GD655-5,GD675-5 40-93
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General information on troubleshooting
T- branch box and T- branch adapter table

T- branch box and T- branch adapter table 40-94

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P q
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2760 Adapter for ECONO 3 ECONO3P q q
799-601-2770 Adapter for ECONO 4 ECONO4P q q
799-601-2780 Adapter for ECONO 8 ECONO8P q q
799-601-2790 Adapter for ECONO 12 ECONO12P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2820 Adapter for DLI 12 DLI-12P q q
799-601-2830 Adapter for DLI 16 DLI-16P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7030 Adapter for X 3 X3P q q q q
799-601-7040 Adapter for X 4 X4P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7120 Adapter for M 4 M4P q q q q
799-601-7130 Adapter for M 6 M6P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for M 7 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q

40-94 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7160 Adapter for S (Blue) 12 S12P q q q

799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 ― q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapterfor relay 5 REL-5P q
799-601-7370 Adapterfor relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 ― q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-60 -9040 Adapter for DT 4 DT4 q q q q
799-60 -9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 p q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q

GD555-5,GD655-5,GD675-5 40-95
(01)
General information on troubleshooting
T- branch box and T- branch adapter table

T-adapter kit

Number of pins

799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

Socket for engine (HPI-T2)

795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 ― q
795-799-5470 Cable for engine (HPI-T2) 3 ― q
795-799-5480 Cable for engine (HPI-T2) 3 ― q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
Socket for engine (CRI-T3)
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
Socket for engine (CRI-T3)
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 ― q
799-601-4280* Box for controller (PUMP) 121 ― q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 – 4 and DTM2 3, ― q
4
“*” Shows not T-adapter but socket.

40-96 GD555-5,GD655-5,GD675-5
(01)
 General information on troubleshooting
Locations of fuses

Locations of fuses 40-97

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box (A
switched power supply is the power which is supplied only while the starting switch is in the ON position
and the unswitched power supply is the power which is supplied while the starting switch is in the OFF and
ON positions).
a When performing troubleshooting related to the electrical system, check the fuse boxes to see if the power
is supplied properly.

Fuse box 1 (Fuse box FB1)

Power supply
Fuse No. Fuse capacity Destination of power
type
1 10A Monitor
Unswitched
power supply 2 15 A Key switch
slow-blow fuse 3 10 A Transmission controller unswitched power supply
(30A)
4 10A Hazard lamp
5 15 A Cab-mounted working lamp
6 10 A Turn signal lamp
7 15 A Solenoid
8 10A Cigarette lighter
Switched
power supply 9 15 A Rear working lamp
slow-blow fuse 10 15 A Front working lamp
(60A)
11 10A Transmission controller
12 15 A Headlamp
13 10 A Backup lamp and stop lamp
14 10A Horn
Switched
power supply
15 5A Engine controller
Starting switch
ACC

GD555-5,GD655-5,GD675-5 40-97
(01)
General information on troubleshooting
Locations of fuses

Fuse box 2 (Fuse box FB2)

Power supply
Fuse No. Fuse capacity Destination of power
type
1 20 A Air conditioner blower motor
Unswitched
power supply 2 10 A Cab unswitched power supply
slow-blow fuse 3 10A Room lamp
(30A)
4 30 A Engine controller unswitched power supply
5 10A Optional device (heater)
6 10 A Optional device (12 V inverter)
7 5A Radio
8 5A Air conditioner compressor (clutch)
Switched 9 10A Illumination
power supply
10
slow-blow fuse
(60A) 11 5A Air conditioner controller
12 15 A Cab-mounted working lamp
13 10 A Yellow revolving warning lamp
14 20 A Door glass wiper
15 20 A Front and rear wipers

Location of fuse box and fuse numbers

40-98 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [1500LO] TORQUEFLOW transmission: Double engagement

Troubleshooting by failurecode 40-9

Failure code [1500LO] TORQUEFLOW transmission: Double engage-
ment 40-9
Action code Failure code TORQFLOW transmission: Double engagement
Failure
(Transmission controller system)
E02 1500L0
Detail of failure q Fill signals for two clutches for unusual combination is input.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains gear speed in Neutral.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Machine stops when traveling and it does not start to travel when stopped.
machine
q Input (ON/OFF) from each clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234HL)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (every gear speed).

Cause Procedure, measuring location, criteria and remarks

1 Defective clutch ECMV system If different failure code is displayed, perform troubleshooting for it.

When no other failure code is displayed, controller may be defective. (Since it

2 Defective transmission controller
is an internal defect, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-99
(01)
Troubleshooting by failurecode
Failure code [15G0MW] Transmission R clutch: Slip

Failure code [15G0MW] Transmission R clutch: Slip 40-10

Action code Failure code Transmission R clutch: Slip
Failure
(Transmission controller system)
E03 15G0MW
q When outputting to R clutch ECMV solenoid, the value calculated from engine speed, transmission
Detail of failure input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, transmission
output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to R clutch ECMV solenoid can be checked with
Related infor- monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of R1 to R4).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective reverse clutch oil pres-
1 2. Check that clutch oil pressure is normal by referring to Testing and
sure or mechanical system
adjusting, "Testing power train oil pressure".

Defective reverse clutch ECMV Perform troubleshooting for failure codes [DXH7KA], [DXH7KB] and
2
solenoid system [DXH7KY].

40-100 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15H0MW] Transmission FH clutch: Slip

Failure code [15H0MW] Transmission FH clutch: Slip 40-101

Action code
Failure code Transmission FH clutch: Slip
Failure
(Transmission controller system)
E03 15H0MW
q When outputting to FH clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code:TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F2, F4, F6
and F8)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective FH clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

Defective FH clutch ECMV sole- Perform troubleshooting for failure codes [DXH2KA], [DXH2KB] and
2
noid system [DXH2KY].

Failure code [15J0MW] Transmission FL clutch: Slip 40-101

Action code Failure code Transmission FL clutch: Slip
Failure
(Transmission controller system)
E03 15J0MW
q When outputting to FL clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV H DIR, TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective FL clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

Defective FL clutch ECMV sole- Perform troubleshooting for failure codes [DXH3KA], [DXH3KB] and
2
noid system [DXH3KY].

GD555-5,GD655-5,GD675-5 40-101
(01)
Troubleshooting by failurecode
Failure code [15K0MW] Transmission 1st clutch: Slip

Failure code [15K0MW] Transmission 1st clutch: Slip 40-102

Action code Failure code Transmission 1st clutch: Slip
Failure
(Transmission controller system)
E03 15K0MW
q When outputting to 1st clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 1st clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code:TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 1st clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 1st clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXH4KA], [DXH4KB] and
[DXH4KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-102

40-102 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15L0MW] Transmission 2nd clutch: Slip

Failure code [15L0MW] Transmission 2nd clutch: Slip 40-103

Action code Failure code Transmission 2nd clutch: Slip
Failure
(Transmission controller system)
E03 15L0MW
q When outputting to 2nd clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 2nd clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code:TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F3, F4, and
R2).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 2nd clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 2nd clutch ECMV sole- Perform troubleshooting for failure codes [DXH5KA], [DXH5KB] and
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
[DXH5KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-103

GD555-5,GD655-5,GD675-5 40-103
(01)
Troubleshooting by failurecode
Failure code [15M0MW] Transmission 3rd speed clutch: Slip

Failure code [15M0MW] Transmission 3rd speed clutch: Slip 40-104

Action code Failure code Transmission 3rd clutch: Slip
Failure
(Transmission controller system)
E03 15M0MW
q When outputting to 3rd clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 3rd clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F5, F6 and
R3)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 3rd clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 3rd clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXH6KA], [DXH6KB] and
[DXH6KY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-104

40-104 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15N0MW] Transmission 4th clutch: Slip

Failure code [15N0MW] Transmission 4th clutch: Slip 40-105

Action code Failure code Transmission 4th clutch: Slip
Failure
(Transmission controller system)
E03 15N0MW
q When outputting to 4th clutch ECMV solenoid, the value calculated from engine speed, transmis-
Detail of failure sion input shaft speed sensor signal, transmission intermediate shaft speed sensor signal, trans-
mission output shaft speed signal is incorrect.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Keeps system not reset itself until starting switch is turned to OFF position even if cause of failure
troller
disappears.
Problem on
q None in particular
machine
q Output command current and sensed current to 4th clutch ECMV solenoid can be checked with
monitoring function.
Related infor-
(Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F7, F8 and
R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging etc.

Defective 4th clutch oil pressure
1 2. Check that clutch oil pressure is normal by referring to Testing and
system or mechanical system
adjusting, "Testing power train oil pressure".

Defective 4th clutch ECMV sole-
2
noid system
Ground fault in transmission out-
3 put shaft speed sensor circuit
(Contact with ground circuit)
Hot short in transmission output
4 shaft speed sensor circuit
(Contact with 24 V circuit)
Perform troubleshooting for failure codes [DXHHKA], [DXHHKB] and [DXH-
HKY].
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T33, and connect T-adapter to female
side of either connector.
Between ground and TM40 (female) 30 or T33
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T33 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between T33 (female) (1) and (2) Voltage 3–4V

Circuit diagram related to transmission output shaft speed sensor 40-105

GD555-5,GD655-5,GD675-5 40-105
(01)
Troubleshooting by failurecode
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF

Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command

signal is OFF 40-106
Action code Failure code ECMV R clutch: Fill signal is being sent when command signal is
Failure not being sent
E01 15SBL1 (Transmission controller system)

q Signal from fill switch remains turned ON after output to R clutch ECMV solenoid is turned OFF,
Detail of failure
and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Only reverse travel is available.
machine
q Command current value output to R clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
mation q Input (ON/OFF) from R clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective R clutch oil pressure
1 2. Then, check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective R clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SBL1] recurs, ground fault is present in wiring harness or
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T38 and connect T-adapter to male side.
Between T38 (female) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T38.
power train controller is defective.
(If failure code [15SBL1] does not appear anymore, R clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T38, and connect T-adapter to female
side of one of them.
Between TM40 (female) (27) or T38 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector T38.
a Maintain gear shift lever at N position.
Between TM40 (27) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (27) and ground R1 Voltage Max. 1 V

40-106 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SBL1] ECMV R clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to reverse clutch ECMV40-107

GD555-5,GD655-5,GD675-5 40-107
(01)
Troubleshooting by failurecode
Failure code [15SBMA] ECMV R clutch: Malfunction

Failure code [15SBMA] ECMV R clutch: Malfunction 40-108

Action code Failure code ECMV R clutch: Malfunction
Failure
(Transmission controller system)
E02 15SBMA
q Signal from fill switch remains turned OFF even after power is output to R clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to R clutch ECMV solenoid, clutch slip is detected from engine speed signal,
transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor signal
and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to R clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Only forward travel is available.
machine
q Command current value output to R clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31606-ECMV R DIR, TRANSMISSION1-31616-ECMV R)
mation q Input (ON/OFF) from R clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective R clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T38 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T38 (male) (1) and ground Resistance Min. 1 Mz
Defective R clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T38 (male) (1) and ground R1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T38, and connect T-adapters to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (27) and T38 (female) (1) Resistance Max. 1 z

1. Turn starting switch to OFF position.

2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.

Between TM40 (27) and ground Voltage 7 – 11 V

4 Defective transmission controller
1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (27) and ground R1 Voltage Max. 1 V

40-108 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SBMA] ECMV R clutch: Malfunction

Circuit diagram related to reverse clutch ECMV40-109

GD555-5,GD655-5,GD675-5 40-109
(01)
Troubleshooting by failurecode
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF

Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command

signal is OFF 40-1 0
Action code Failure code ECMV FH clutch: Fill signal is being sent when command signal
Failure is not being sent
E01 15SCL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to FH clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F2, F4, F6, and F8 is available
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FH clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective FH clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SCL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T37 and connect T-adapter to male side.
Between T37 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch is turned OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T37.
ness or transmission controller is defective.
(If failure code [15SCL1] does not appear anymore, FH clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T37, and connect T-adapter to female
side of one of them.
Between TM40 (female) (7) or T37 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (7) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (7) and ground F2 Voltage Max. 1 V

40-110 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SCL1] ECMV FH clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to FH clutch ECMV 40-1 1

GD555-5,GD655-5,GD675-5 40-111
(01)
Troubleshooting by failurecode
Failure code [15SCMA] ECMV FH clutch: Malfunction

Failure code [15SCMA] ECMV FH clutch: Malfunction 40-1 2

Action code Failure code ECMV FH clutch: Malfunction
Failure
(Transmission controller system)
E02 15SBMA
q Signal from fill switch remains turned OFF even after power is output to FH clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to FH clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to FH clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1, F3, F5, F7, R1, R2, R3, and R4 is available.
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
Related infor-
q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F2, F4, F6
and F8)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FH clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T37 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T37 (male) (1) and ground Resistance Min. 1 Mz
Defective FH clutch ECMV fill
2 1 and 2 are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T37 (male) (1) and ground F2 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T37, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (7) and T37 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (7) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (7) and ground F2 Voltage Max. 1 V

40-112 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SCMA] ECMV FH clutch: Malfunction

Circuit diagram related to FH clutch ECMV 40-1 3

GD555-5,GD655-5,GD675-5 40-113
(01)
Troubleshooting by failurecode
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF

Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command

signal is OFF 40-1 4
Action code Failure code ECMV FL clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SDL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after output power to FL clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F1, F3, F5, and F7 is available.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
mation q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective FL clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective FL clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SDL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T36 and connect T-adapter to male side.
Between T36 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T36.
ness or transmission controller is defective.
(If failure code [15SDL1] does not appear any more, FL clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T36, and connect T-adapter to female
side of either connector.
Between TM40 (female) (17) or T36 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (17) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (17) and ground F1 Voltage Max. 1 V

40-114 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SDL1] ECMV FL clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to FL clutch ECMV 40-1 5

GD555-5,GD655-5,GD675-5 40-115
(01)
Troubleshooting by failurecode
Failure code [15SDMA] ECMV FL clutch: Malfunction

Failure code [15SDMA] ECMV FL clutch: Malfunction 40-1 6

Action code Failure code ECMV FL clutch: Malfunction
Failure
E02 15SDMA (Transmission controller system)
q Signal from fill switch remains turned OFF even after power is output to FL clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to FL clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to FL clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F2, F4, F6, F8, R1, R2, R3, and R4 is available.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
Related infor-
q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F3, F5,
and F7)
Cause Procedure, measuring location, criteria and remarks
1. Check transmission oil filter for clogging, etc.
Defective FL clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T36 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Defective FL clutch ECMV fill Between T36 (male) (1) and ground Resistance Min. 1 Mz
2 1 to 2 are same as above.
switch (It does not turn ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T36 (male) (1) and ground F1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness
3 (wire breakage or defective con- 2. Disconnect connectors TM40 and T36, and connect T-adapter to each
tact) female side.
Between TM40 (female) (17) and T36 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
4. Start engine.
4 Defective transmission controller a Maintain gear shift lever at N position.
Between TM40 (17) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (17) and ground F1 Voltage Max. 1 V

40-116 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SDMA] ECMV FL clutch: Malfunction

Circuit diagram related to FL clutch ECMV 40-1 7

GD555-5,GD655-5,GD675-5 40-117
(01)
Troubleshooting by failurecode
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF

Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command
signal is OFF 40-1 8
Action code Failure code ECMV 1st clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SEL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after output power to 1st clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F1, F2, and R1 is available
machine
q Commanded current value output to 1st clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 1st clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 1st clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SEL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T39 and connect T-adapter to male side.
Between T39 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T39.
ness or transmission controller is defective.
(If failure code [15SEL1] is not displayed, 1st clutch fill switch is defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T39, and connect T-adapter to female
side of one of them.
Between TM40 (female) (13) or T39 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (13) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V

40-118 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SEL1] ECMV 1st clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 1st clutch ECMV 40-1 9

GD555-5,GD655-5,GD675-5 40-119
(01)
Troubleshooting by failurecode
Failure code [15SEMA] ECMV 1st clutch: Malfunction

Failure code [15SEMA] ECMV 1st clutch: Malfunction 40-120

Action code Failure code ECMV 1st clutch: Malfunction
Failure
(Transmission controller system)
E02 15SEMA
q Signal from fill switch remains turned OFF even after power is output to 1st clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 1st clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 1st clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F3 - F8 and R2 - R4 is available
machine
q Command current value output to 1st clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
Related infor-
q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 1st clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T39 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T39 (male) (1) and ground Resistance Min. 1 Mz
Defective 1st clutch ECMV fill
2 1 and 2 are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T39 (male) (1) and ground F1/R1 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T39, and connect T-adapter to each
3 (disconnection or defective con- female side.
tact)
Between TM40 (female) (13) and T39 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (13) and ground Voltage 7 – 11 V
4 Defective transmission controller 1 and 2 are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (13) and ground F1/R1 Voltage Max. 1 V

40-120 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SEMA] ECMV 1st clutch: Malfunction

Circuit diagram related to 1st clutch ECMV 40-121

GD555-5,GD655-5,GD675-5 40-121
(01)
Troubleshooting by failurecode
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF

Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command
signal is OFF 40-12
Action code Failure code ECMV 2nd clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SFL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 2nd clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F3, F4 and R2 is available
machine
q Command current value output to 2nd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
mation q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 2nd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 2nd clutch ECMV fill
2
switch (internal short circuit)
Ground fault of wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SFL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T40 and connect T-adapter to male side.
Between T40 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T40.
ness or transmission controller is defective.
(If failure code [15SFL1] is not displayed, 2nd clutch fill switch is defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T40, and connect T-adapter to female
side of one of them.
Between TM40 (female) (3) or T40 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (3) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (3) and ground F3 Voltage Max. 1 V

40-122 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SFL1] ECMV 2nd clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 2nd clutch ECMV 40-123

GD555-5,GD655-5,GD675-5 40-123
(01)
Troubleshooting by failurecode
Failure code [15SFMA] ECMV 2nd clutch: Malfunction

Failure code [15SFMA] ECMV 2nd clutch: Malfunction 40-124

Action code Failure code ECMV 2nd clutch: Malfunction
Failure
(Transmission controller system)
E02 15SFMA
q Signal from fill switch remains turned OFF even after power is output to 2nd clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 2nd clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 2nd clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1, F2, F5 to F8, R1, R3, and R4 is available.
machine
q Command current value output to 2nd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31603-ECMV 2 DIR, TRANSMISSION1-31613-ECMV 2)
Related infor-
q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F3, F4, and
R2).

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 2nd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T40 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T40 (male) (1) and ground Resistance Min. 1 Mz
Defective 2nd clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T40 (male) (1) and ground F3 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T40, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (3) and T40 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (3) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (3) and ground F3 Voltage Max. 1 V

40-124 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SFMA] ECMV 2nd clutch: Malfunction

Circuit diagram related to 2nd clutch ECMV 40-125

GD555-5,GD655-5,GD675-5 40-125
(01)
Troubleshooting by failurecode
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF

Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command
signal is OFF 40-126
Action code Failure code ECMV 3rd clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SGL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 3rd clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F5, F6, and R3 is available
machine
q Command current value output to 3rd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
mation q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 3rd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 3rd clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SGL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T41 and connect T-adapter to male side.
Between T41 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T41.
ness or transmission controller is defective.
(If failure code[15SGL1] is not displayed, 3rd clutch fill switch is defective)
a If cause 3 is not cause for faulure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T41, and connect T-adapter to female
side of one of them.
Between TM40 (female) (2) or T40 (female) (1) and
Resistance Min. 1 Mz
ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (2) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (2) and ground F5 Voltage Max. 1 V

40-126 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SGL1] ECMV 3rd clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 3rd clutch ECMV 40-127

GD555-5,GD655-5,GD675-5 40-127
(01)
Troubleshooting by failurecode
Failure code [15SGMA] ECMV 3rd clutch: Malfunction

Failure code [15SGMA] ECMV 3rd clutch: Malfunction 40-128

Action code Failure code ECMV 3rd clutch: Malfunction
Failure
(Transmission controller system)
E02 15SGMA
q Signal from fill switch remains turned OFF even after power is output to 3rd clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 3rd clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 3rd clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1 to F4, F7, F8, R1, R2, and R4 is available.
machine
q Command current value output to 3rd clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31604-ECMV 3 DIR, TRANSMISSION1-31614-ECMV 3)
Related infor-
q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F5, F6 and
R3)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 3rd clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T41 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T41 (male) (1) and ground Resistance Min. 1 Mz
Defective 3rd clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T41 (male) (1) and ground F5 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T41, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (2) and T41 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (2) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (2) and ground F5 Voltage Max. 1 V

40-128 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SGMA] ECMV 3rd clutch: Malfunction

Circuit diagram related to 3rd clutch ECMV 40-129

GD555-5,GD655-5,GD675-5 40-129
(01)
Troubleshooting by failurecode
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF

Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command
signal is OFF 40-130
Action code Failure code ECMV 4th clutch: Fill signal is sent when command signal is not
Failure sent
E01 15SHL1 (Transmission controller system)

q Signal from fill switch remains turned ON even after power output to 4th clutch ECMV solenoid is
Detail of failure
turned OFF, and clutch is not released.
Action of con- q None in particular. (Sets gear speed to Neutral when double engagement is detected.)
troller q If cause of failure disappears, system resets itself.
Problem on
q Travel at F7, F8, and R4 is available
machine
q Command current value output to 4th clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
mation q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked by using monitoring function.
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 4th clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".

1. Turn starting switch to OFF position.

Defective 4th clutch ECMV fill
2
switch (internal short circuit)
Ground fault in wiring harness or 3. Start engine.
3
defective transmission controller If failure code [15SHL1] is still displayed, there is ground fault in wiring har-
Ground fault in wiring harness
4
(contact with ground circuit)
5 Defective transmission controller 4. Start engine.
2. Disconnect connector T42 and connect T-adapter to male side.
Between T42 (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch OFF)
1. Turn starting switch to OFF position.
2. Disconnect connector T42.
ness or transmission controller is defective.
(If failure code [15SHL1] does not appear anymore, 4th clutch fill switch is
defective)
a If cause 3 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T42, and connect T-adapter to female
side of one of them.
Between TM40 (female) (38) or T42 (female) (1)
Resistance Min. 1 Mz
and ground
If "check result of cause 3 is abnormal" and "check result of cause 4 is nor-
mal", transmission controller is defective.
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Lift machine body to run drive wheel idle.
3. Insert T-adapter into connector TM40.
a Maintain gear shift lever at N position.
Between TM40 (38) and ground Voltage 7 – 11 V
1 to 4 are same as above.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (38) and ground F7 Voltage Max. 1 V

40-130 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SHL1] ECMV 4th clutch: Fill signal is ON when command signal is OFF

Circuit diagram related to 4th clutch ECMV 40-131

GD555-5,GD655-5,GD675-5 40-131
(01)
Troubleshooting by failurecode
Failure code [15SHMA] ECMV 4th clutch: Malfunction

Failure code [15SHMA] ECMV 4th clutch: Malfunction 40-132

Action code Failure code ECMV 4th clutch: Malfunction
Failure
(Transmission controller system)
E03 15SHMA
q Signal from fill switch remains turned OFF even after power is output to 4th clutch ECMV solenoid,
and clutch engagement is not made.
Detail of failure q When power is output to 4th clutch ECMV solenoid, clutch slip is detected from engine speed sig-
nal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains no output of power to 4th clutch ECMV solenoid.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
q Travel at F1 to F6 and R1 to R3 is available
machine
q Command current value output to 4th clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
(Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
Related infor-
q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked by using monitoring function.
mation
(Code: TRANSMISSION2-31520-FILL R1234LH)
q Method of reproducing failure code: Start engine and operate gear shift lever (any of F7, F8 and
R4)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective 4th clutch oil pressure
1 2. Then check that clutch pressure is normal by referring to Testing and
and mechanical systems
adjusting, "Testing power train oil pressure".
1. Turn starting switch to OFF position.
2. Disconnect connector T42 and connect T-adapter to male side.
3. Start engine.
a Maintain gear shift lever at N position.
Between T42 (male) (1) and ground Resistance Min. 1 Mz
Defective 4th clutch ECMV fill
2 1. and 2. are same as above.
switch (It is not turned ON)
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between T42 (male) (1) and ground F7 Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T42, and connect T-adapter to each
3 (wire breakage or defective con- female side.
tact)
Between TM40 (female) (38) and T42 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
3. Start engine.
a Maintain gear shift lever at N position.
Between TM40 (38) and ground Voltage 7 – 11 V
4 Defective transmission controller 1. and 2. are same as above.
3. Lift machine body to run drive wheel idle.
4. Start engine.
5. Operate gear shift lever (travel gear speed) and troubleshoot (run drive
wheel idle).
Between TM40 (38) and ground F7 Voltage Max. 1 V

40-132 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [15SHMA] ECMV 4th clutch: Malfunction

Circuit diagram related to 4th clutch ECMV 40-13

GD555-5,GD655-5,GD675-5 40-133
(01)
Troubleshooting by failurecode
Failure code [15SJMA] ECMV lockup clutch: Malfunction

Failure code [15SJMA] ECMV lockup clutch: Malfunction 40-134

Action code Failure code ECMV lockup clutch: Malfunction
Failure
(Transmission controller system)
E03 15SJMA
q When power is output to lockup clutch ECMV solenoid, clutch slip is detected from engine speed
Detail of failure signal, transmission input shaft speed sensor signal, transmission intermediate shaft speed sensor
signal and transmission output shaft speed sensor signal.
q Blinks centralized warning lamp and turns on alarm buzzer.
Action of con-
q Maintains output of power to lockup clutch ECMV solenoid turned OFF.
troller
q Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on q Automatic mode (torque conveter mode) is always turned on even when manual mode is selected
machine through transmission mode selector switch.
q Command current value output to lockup clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation
q Method of reproducing failure code:
Start engine and operate transmission mode selector switch (Manual mode)

Cause Procedure, measuring location, criteria and remarks

1. Check transmission oil filter for clogging, etc.

Defective lockup switch oil pres-
1 2. Check that clutch pressure is normal by referring to Testing and adjusting,
sure and mechanical systems
"Testing power train oil pressure".

Defective lockup clutch ECMV Perform troubleshooting for failure codes [DXH1KA], [DXH1KB] and
2
solenoid system [DXH1KY].

Failure code [15UONT] Inching clutch: Overheating 40-134

Action code Failure code Inching clutch: Overheating
Failure
(Transmission controller system)
E02 15U0NT
Detail of failure q Clutch temperature estimated from inching clutch oil temperature sensor has exceeded 200°C
Action of con- q Blinks centralized warning lamp, sounds alarm buzzer for 2 seconds and disengages lockup clutch.
troller q If cause of failure disappears, system resets itself.
Problem on
q Lockup clutch is disengaged.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Since overheating of inching clutch can be experienced now or has been
Overload on inching clutch experienced in the past, investigate cause and damage condition resulted
1
(when system is normal) from such cases to correct above failure.(including improper inching opera-
tion)
Defective transmission oil temper-
2 Perform troubleshooting for failure code [DGF1KX].
ature sensor system

40-134 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [2G42ZG] Front accumulater: Oil pressure drop

Failure code [2G42ZG] Front accumulater: Oil pressure drop 40-135

Action code Failure code Front accumulator: Pressure drop
Failure
(Machine monitor system)
E03 2G42ZG
q While engine is running, front accumulator oil pressure switch detects drop of front accumulator
Detail of failure
pressure.
Action of con- q Blinks centralized warning lamp and turns on alarm buzzer.
troller q If cause of failure disappears, system resets itself.
Problem on
q Brake oil pressure caution lamp lights up while engine is running.
machine
q Input (ON/OFF) from front accumulator OIL pressure switch can be checked by using monitoring
Related infor-
function. (Code: MONITOR-40921-D-IN-4)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Since drop of front accumulator pressure can be experienced now or has been
Drop of front accumulator pres-
1 experienced in the past, investigate cause and damage condition resulted
sure (when system is normal)
from such cases to correct above failure.
Defective brake oil pressure cau- Perform troubleshooting for brake oil pressure caution lamp system being
2
tion lamp system listed in E-mode "E-6 Emergency stop lamp lights up while engine is running".

Failure code [2G43ZG] Rear accumulater: Pressure drop 40-135

Action code Failure code Rear accumulator: Pressure drop
Failure
(Machine monitor system)
E03 2G43ZG
q While engine is running, rear accumulator oil pressure switch detects drop of rear accumulator
Detail of failure
pressure.
Action of con- q Blinks centralized warning lamp and turns on alarm buzzer.
troller q If cause of failure disappears, system resets itself.
Problem on
q Brake oil pressure caution lamp lights up while engine is operating.
machine
q Input (ON/OFF) from front accumulator OIL pressure switch can be checked by using monitoring
Related infor-
function. (Code: MONITOR-40921-D-IN-5)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Since drop of rear accumulator pressure can be experienced now or has been
Drop of rear accumulator pressure
1 experienced in the past, investigate cause and damage condition resulted
(when system is normal)
from such cases to correct above failure.
Defective brake oil pressure cau- Perform troubleshooting for brake oil pressure caution lamp system being
2
tion lamp system listed in E-mode "E-6 Emergency stop lamp lights up while engine is running".

GD555-5,GD655-5,GD675-5 40-135
(01)
Troubleshooting by failurecode
Failure code [AA1ANX] Air cleaner: Clogging

Failure code [AA1ANX] Air cleaner: Clogging 40-136

Action code Failure code Air cleaner: Clogging
Failure
(Machine monitor system)
E01 AA1ANX
Detail of failure q When engine is started, air cleaner clogging sensor circuit is closed.
Action of con- q Air cleaner clogging caution lamp lights up.
troller q If cause of failure disappears, system resets itself.
q Engine does not start easily, does not pick up smoothly, lacks output power and exhaust smoke is
Problem on
black.
machine
q If machine is operated as it is, engine may be damaged.
q Input (ON/OFF) from air cleaner clogging sensor can be checked by using monitoring function.
(Code: MONITOR PANEL-40921-D-IN-2)
Related infor-
q Since inside of dust indicator is composed of electronic circuit, judgment can not be done by resis-
mation
tance.
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Air cleaner clogging Air cleaner may be clogged. Check it for clogging and then clean or replace if
1
(When system is normal) clogged.
1. Turn starting switch to OFF position.
2. Disconnect connector SP32, and connect T-adapter to male side.
Resis-
Between SP32 (male) (1) and (2) 200 - 400 z
tance
Defective dust indicator relay
2 1. Turn starting switch to OFF position.
(internal failure)
2. Replace dust indicator relay (SP32) with another relay of the same model
(5-pin).
3. Start engine.
If engine starts up normally, original relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and SP32, and connect a T-adapter to female
side of them.
Resis-
Between FP1 (female) (9) and SP32 (female) (5) Max. 1 z
tance
Resis-
Between R20 (female) (1) and SP32 (female) (2) Max. 1 z
Open circuit in wiring harness tance
3 (Wire breakage or defective con- Resis-
Between R20 (female) (2) and ground Max. 1 z
tact of connector) tance
1. Turn starting switch to OFF position.
2. Disconnect connector SP32 and connect T-adapter to female side.
3. Turn starting switch ON.
Between SP32 (female) (1) and ground Voltage 20–30 V
Between SP32 (female) (3) and ground Voltage 20–30 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors FP1 and SP32, and connect T-adapter to female
4 side of either of them.
(Contact with ground circuit)
Between FP1 (female) (9) and ground or between Resis-
Min. 1 Mz
SP32 (female) (5) and ground tance
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R20.
3. Start engine.
Defective dust indicator (internal
5 Air cleaner:
failure) Voltage 20 – 30 V
When normal
Between R20 (1) and (2)
Air cleaner:
Voltage Max. 10 V
When clogged

40-136 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AA1ANX] Air cleaner: Clogging

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found by above checks, machine monitor is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
6 Defective machine monitor 3. Start engine.
Air cleaner:
Voltage Max. 1 V
When normal
Between FP1 (9) and (3)
Air cleaner:
Voltage 20 – 30 V
When clogged

Circuit diagram related to air cleaner clogging 40-137

GD555-5,GD655-5,GD675-5 40-137
(01)
Troubleshooting by failurecode
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.

Failure code [AB00L6] Alternator; Engine start and stop signals are not
matched. 40-138
Action code Failure code Alternator: Signal does not match engine running or stopped
Failure condition
E03 AB00L6 (Machine monitor system)

Detail of failure q When engine is stopped, alternator terminal R input voltage is 12 V or above.
q Turns on caution lamp for defective charge circuit.
Action of con-
q Turns on centralized warning lamp and alarm buzzer.
troller
q If cause of failure disappears, system resets itself.
Problem on q Engine does not start.
machine q Service meter reading advances only with starting switch turned to ON position.
q Input voltage from alternator can be checked by using monitoring function. (Code: MONITOR
Related infor-
04302 ALTERNATOR R).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator
(Internal failure)
Hot short in wiring harness
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
3 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect terminal E02.
3. Turn starting switch to ON position.
Between alternator terminal R (alternator side) and
Voltage Max. 1 V
ground
1. Turn starting switch to OFF position.
2. Disconnect terminal E02.
Between terminal E02 (on wiring harness) and
Voltage Max. 1 V
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP2.
3. Turn starting switch to ON position.
Between FP2 (9) and ground Voltage Max. 1 V

40-138 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AB00L6] Alternator; Engine start and stop signals are not matched.

Circuit diagram related to alternator 40-139

GD555-5,GD655-5,GD675-5 40-139
(01)
Troubleshooting by failurecode
Failure code [AB00MA] Alternator: Malfunction

Failure code [AB00MA] Alternator: Malfunction 40-140

Action code Failure code Alternator: Defective mechanical system
Failure
(Machine monitor system)
E03 AB00MA
Detail of failure q When engine is running, alternator terminal R input voltage becomes 5 V or below.
q Turns on charge circuit failure caution lamp.
Action of con-
q Turns on centralized warning lamp and alarm buzzer.
troller
q If cause of failure disappears, system resets itself (12 V or above is secured).
Problem on
q Deterioration of battery or insufficient charging
machine
q Input voltage from alternator can be checked by using monitoring function. (Code: MONITOR
Related infor-
04302 ALTERNATOR R).
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Deteriorated battery Battery may be deteriorated. Check it directly.
1. Turn starting switch to ON position and perform troubleshooting.
2. Start engine and perform troubleshooting.
Defective alternator
2 Engine at medium
(Internal failure) Between alternator ter- speed or higher Voltage 27.5 – 29.5 V
minal E02 and ground
Engine stopped Voltage Max. 1 V
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect terminal E02 and connector FP2.
3 (Wire breakage or defective con- 3. Connect T-adapter to female side of FP2.
tact of connector)
Between terminal E02 and FP2 (female) (9) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect terminal R34 and connector FP2.
Ground fault in wiring harness
4 3. Connect T-adapter to female side of FP2.
(Contact with ground circuit)
Between terminal E02 or FP2 (female) (9) and
Resistance Max. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP2.
3. Start engine.
5 Defective machine monitor Engine at medium
Between FP2 (9) and Voltage 27.5 – 29.5 V
speed or higher
ground
Engine stopped Voltage Max. 1 V

40-140 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [AB00MA] Alternator: Malfunction

Circuit diagram related to alternator 40-141

GD555-5,GD655-5,GD675-5 40-141
(01)
Troubleshooting by failurecode
Failure code: [B@BAZG] Derating in speed due to engine oil pressure drop

Failure code: [B@BAZG] Derating in speed due to engine oil pressure

drop 40-142
Action code Failure code Engine is derated due to engine oil pressure drop.
Failure
(Engine controller system)
E03 B@BAZG
q Engine controller detects abnormal drop of engine oil pressure when voltage from engine oil pres-
Detail of failure
sure switch drops to ground level while engine is running.
Action of con- q Turns on engine oil pressure caution lamp on machine monitor.
troller q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Signal of engine oil pressure switch is input to engine controller and then this code is transmitted
to machine monitor through CAN communication.
Related infor-
q For troubleshooting of engine oil pressure switch while engine is not running, see failure code
mation
[CA435].
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Drop of engine oil pressure Engine oil pressure may be low. Check pressure and remove cause of prob-
1
(when system is normal) lem.
Defective engine oil pressure sen- If no failure is found by check on cause 1, engine oil pressure sensor system
2
sor system may be defective. Perform troubleshooting for failure codes [CA435].

Failure code: [B@BCNS] Engine coolant overheat 40-142

Action code Failure code Engine coolant overheating
Failure
(Engine controller system)
E02 B@BCNS
Detail of failure q While engine is running, engine coolant temperature exceeds operating range.
Action of con- q Turns on engine coolant temperature caution lamp on machine monitor.
troller q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, engine may seize up.
machine
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 04105 COOLANT TEMP).
mation
q Temperature sensed by engine coolant sensor can be checked by using monitoring function
(Code: ENGINE 04104 COOLANT TEMP).
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Engine coolant overheat
1 Engine coolant may be overheating. If it is overheated, remove cause.
(when system is normal)
Defective engine coolant tempera- If no cause is found by check on cause 1, engine coolant sensor system may
2
ture sensor system be defective. Perform troubleshooting for failure codes [CA144] and [CA145].

40-142 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@CENS] Torque converter oil overheat

Failure code: [B@CENS] Torque converter oil overheat 40-143

Action code Failure code Torque converter oil overheating
Failure
(Machine monitor system)
E02 B@CENS
q While engine is running, voltage of torque converter oil temperature sensor drops and transmission
Detail of failure
controller detects overheating (approximately 120°C or above) of torque converter oil.
q Lights up torque converter oil temperature caution lamp on machine monitor.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated at it is, torque converter may seize up.
machine
q Signal of torque converter oil temperature sensor is input to transmission controller and then data
is transmitted to machine monitor through CAN communication system.
Related infor- q Input voltage and temperature from torque converter oil temperature sensor can be checked by
mation using of monitoring function.
(Code: TRANSMISSION1-30101-T/C OIL TEMP (V), 30100-T/C OIL TEMP (°C))
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Overheating of torque converter
1 Torque converter oil may be overheated. If it is overheated, remove cause.
oil (When system is normal)
Defective torque converter oil tem-
2 Perform troubleshooting for failure code [DGT1KX].
perature sensor system

GD555-5,GD655-5,GD675-5 40-143
(01)
Troubleshooting by failurecode
Failure code: [B@CKNS] Differential case: Overheat

Failure code: [B@CKNS] Differential case: Overheat 40-14

Action code Failure code Differential case oil overheat
Failure
(Machine monitor system)
E02 B@CKNS
Detail of failure q Differential oil temperature caution appears (differential oil temperature above 120 °C)
q Turns on centralized warning lamp and alarm buzzer.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Lights up differential oil temperature caution lamp.
Problem on
q Differential may seize up if used as is.
machine
q Input voltage and temperature from differential oil temperature sensor can be checked by using of
Related infor- monitoring function.
mation (Code: TRANSMISSION1-31910-DIFF TEMP(V), 31909-DIFF TEMP(°C))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Since differential case oil overheating can be experienced now or has been
Differential case oil overheating
1 experienced in the past, investigate cause and damages for such cases in
(when system is normal)
order to correct above failure.
1. Turn starting switch to OFF position.
2. Disconnect connector R8 and connect T-adapter to male side.
Between R8 (male) (1) 25°C Resistance 38 – 49 kz
Defective differential oil tempera- and (2)
2 ture sensor (internal open circuit a Temperature charac-
teristics of oil temper- 100°C Resistance 3.7 – 4.0 kz
or short circuit)
ature sensor
Between each of R8
(male) (1), (2) and All range Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (14) and ground
3
ing harness a Resistance is the same as that shown in Oil tem-
Resistance 3.7 – 49 kz
perature sensor temperature characteristics of
cause 1 (25 – 100°C).
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and R8, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (3) and R8 (female) (1) Resistance Max. 1 z
Between R8 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R8 and TM39, and connect T-adapter to female
5 side of one of them.
(Contact with ground circuit)
Between R8 (female) (1) or TM39 (female) (14) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Hot short or short circuit in wiring 2. Disconnect connector R8 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Between R8 (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, transmission controller is defective.
7 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

40-144 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@CKNS] Differential case: Overheat

Circuit diagram related to differential oil temper-

ature sensor 40-145

GD555-5,GD655-5,GD675-5 40-145
(01)
Troubleshooting by failurecode
Failure code: [B@HANS] Hydraulic oil: Overheating

Failure code: [B@HANS] Hydraulic oil: Overheating 40-146

Action code Failure code Hydraulic oil overheat
Failure
(Machine monitor system)
E02 B@HANS
q While engine is running, voltage of hydraulic oil temperature sensor drops and transmission con-
Detail of failure
troller detects overheating (approximately 100°C or above) of hydraulic oil temperature.
q Lights up hydraulic oil temperature caution lamp on machine monitor.
Action of con-
q If cause of failure disappears, system resets itself.
troller
q Turns on centralized warning lamp and alarm buzzer.
Problem on
q If machine is operated as it is, hydraulic components may be damaged.
machine
q Signal of hydraulic oil temperature sensor is input to transmission controller and then data is trans-
mitted to machine monitor through CAN communication system.
Related infor- q Input voltage value and temperature from hydraulic oil temperature sensor can be checked by us-
mation ing monitoring function.
(Code: TRANSMISSION1-04402-HYD OIL TEMP(V), 04410-HYD OIL TEMP(°C))
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Hydraulic oil overheat Check hydraulic oil for overheating. If it is overheated, remove cause to
1
(when system is normal) restore system.
1. Turn starting switch to OFF position.
2. Disconnect connector R17 and connect T-adapter to male side.
Between R17 (male) (1) 25°C Resistance 38 – 49 kz
Defective hydraulic oil tempera- and (2)
2 ture sensor (Internal open circuit a Temperature charac-
teristics of oil temper- 100°C Resistance 3.7 – 4.0 kz
or short circuit)
ature sensor
Between each of R17
(male) (1), (2) and All range Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open or short circuit in wiring har- Between TM39 (female) (20) and (21)
3
ness a Resistance is the same as that shown in Oil tem-
Resistance 3.7 – 49 kz
perature sensor temperature characteristics of
cause 1 (25 – 100°C).
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and R17, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (20) and R17 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and R17 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors R17 and TM39, and connect T-adapter to female
5 side of one of them.
(Contact with ground circuit)
Between R17 (female) (1) or TM39 (female) (20)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short or short circuit in wiring 2. Disconnect connector R17 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Between R17 (female) (1) and (2) Voltage Approx. 5 V
If cause is not found by above checks, transmission controller is defective.
7 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

40-146 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code: [B@HANS] Hydraulic oil: Overheating

Circuit diagram related to hydraulic oil tempera-

ture sensor 40-147

GD555-5,GD655-5,GD675-5 40-147
(01)
Troubleshooting by failurecode
Failure code [CA111] Engine controller internal error

Failure code [CA111] Engine controller internal error 40-148

Action code Failure code Engine controller internal failure
Failure
(Engine controller system)
E03 CA111
Detail of failure q Memory or power supply circuit in engine controller is defective.
Action of con-
q None in particular
troller
Problem on q Engine may stop suddenly or may not be able to start.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

1 Failure in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

40-148 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA115] Engine Ne, Bkup speed sensor error

Failure code [CA115] Engine Ne, Bkup speed sensor error 40-149
Action code Failure code Engine Ne and Bkup speed sensor failure
Failure
(Engine controller system)
E03 CA115
Detail of failure q Both signals from engine Ne speed sensor and engine Bkup speed sensor are abnormal.
Action of con-
q None in particular
troller
q Engine stops.
Problem on
q Engine does not start.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective connection of sensor Connections of harness connectors to Ne speed sensor and Bkup speed sen-
1
connector sor may be inverted. Check harness connector connections.
Defective Ne speed sensor sys-
2 Perform troubleshooting for Items 1 to 10 of failure code [CA689].
tem
Defective Bkup speed sensor sys-
3 Perform troubleshooting for failure code [CA778].
tem
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-149
(01)
Troubleshooting by failurecode
Failure code [CA122] Charge pressure sensor high error

Failure code [CA122] Charge pressure sensor high error 40-150

Action code Failure code Charged air pressure sensor voltage is high.
Failure
(Engine controller system)
E03 CA122
Detail of failure q High voltage is detected in pressure signal circuit of charge (boost) pressure/temperature sensor.
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from charge (boost) pressure sensor can be checked by using monitoring function
(Code: ENGINE 36502 CHG PRESS-A).
q Boost pressure from charge pressure sensor can be checked by using monitoring function (Code:
Related infor-
ENGINE 36500 CHG PRESS-A).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If sensor connector is disconnected, "Low error" code, namely [CA123] ,is displayed, even in nor-
mal condition.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective sensor power supply 2
2 If failure code [CA227] is also indicated, perform troubleshooting for it first.
line
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT.
3. Turn starting switch to ON position.
Defective charge pressure/tem- If failure code changes from [CA122] to [CA123] ,charge pressure sensor is
3
perature sensor defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of
sensor.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (37) and (44) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect T-adapter to
Hot short in wiring harness connector ECM.
5 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
(Contact with 24 V circuit)
disconnected).
Between ECM (44) and (47) Voltage Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-150 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA122] Charge pressure sensor high error

Circuit diagram related to charge pressure sensor 40-151

GD555-5,GD655-5,GD675-5 40-151
(01)
Troubleshooting by failurecode
Failure code [CA123] Charge pressure sensor low error

Failure code [CA123] Charge pressure sensor low error 40-152

Action code Failure code Charged air pressure sensor voltage is low.
Failure
(Engine controller system)
E03 CA123
Detail of failure q Low voltage is detected in pressure signal circuit of charge (boost) pressure/temperature sensor.
Action of con-
q Fixes charge pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from charge (boost) pressure sensor can be checked by using monitoring function
(Code: ENGINE 36502 CHG PRESS-A).
q Boost pressure from charge (boost) pressure sensor can be checked by using monitoring function
Related infor- (Code: ENGINE 36500 CHG PRESS-A).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q Since T-adapter for sensor connector is "socket", open circuit in the wiring harness or voltage at
sensor connector cannot be checked for.
q If sensor connector is disconnected, this code is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective power supply system of If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
charge (boost) pressure sensor for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM.
Between ECM (female) (37) and (47) Resistance Min. 100 kz
Between ECM (female) (44) and (47) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Between ECM (female) (44) and ground Resistance Min. 100 kz
If no failure is found by the above checks, wiring harness may be discon-
5 Open circuit in wiring harness
nected. (*)
a If causes 1 to 5 are not cause for failure and check result in cause 6 indi-
cates failure, sensor is defective.
Defective boost pressure/temper-
1. Turn starting switch to OFF position.
ature sensor
6 2. Insert T-adapter to connector ECM.
(Improper input voltage to engine
controller) 3. Turn starting switch to ON position.
Sensor out- Min. 0.3 -
Between ECM (44) and (47) Voltage
put 4.7 V
If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" in "Related in-
formation to troubleshooting".

40-152 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA123] Charge pressure sensor low error

Circuit diagram related to charge pressure sensor 40-153

GD555-5,GD655-5,GD675-5 40-153
(01)
Troubleshooting by failurecode
Failure code [CA131] Throttle sensor high error

Failure code [CA131] Throttle sensor high error 40-154

Action code Failure code Throttle sensor voltage is high
Failure
(Engine controller system)
E03 CA131
Detail of failure q High voltage is detected in throttle sensor signal circuit.

Action of con- q Runs engine at 0% throttle when accelerator pedal is released , and at 50% throttle when acceler-
troller ator pedal is depressed.

Problem on q The engine power does not reach full throttle power.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from throttle sensor can be checked by using monitoring function (Code: ENGINE
31707 THROTTLE POS).
Related infor-
q Information on throttle position detected by throttle sensor can be checked by using monitoring
mation
function (Code: ENGINE 31701 THROTTLE POS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective throttle sensor power
2 If failure code [CA2185] is also indicated, perform troubleshooting for it first.
supply system
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between EC2 (female) (9) and (22), or between
Resistance Min. 1 Mz
T9A (female) (1) and (2)
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector T9A and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(contact with 24V circuit)
Between T9A (female) (2) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON postion.
Defective accelerator pedal (throt-
5 Depress decelerator
tle sensor) Voltage 3.7 – 4.0 V
Between T9A (2) and pedal.
(3) Release decelerator
Voltage 0.5 – 0.8 V
pedal.
If no failure is found by above checks, engine controller is defective. (Since
failure is in it, troubleshooting cannot be performed.)
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
3. Turn starting switch to ON position.
4. Operate accelerator pedal and troubleshoot.
6 Defective engine controller
Between EC2 (22) and
Power supply Voltage 4.75 – 5.25 V
(23)
Depress accelerator
Voltage 3.7 – 4.0 V
Between EC2 (9) and pedal.
(23) Release accelerator
Voltage 0.5 – 0.8 V
pedal.

40-154 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA131] Throttle sensor high error

Circuit diagram related to throttle sensor 40-15

GD555-5,GD655-5,GD675-5 40-155
(01)
Troubleshooting by failurecode
Failure code [CA132] Throttle sensor low error

Failure code [CA132] Throttle sensor low error 40-156

Action code Failure code Throttle sensor voltage is low.
Failure
(Engine controller system)
E03 CA132
Detail of failure q Low voltage is detected in throttle sensor signal circuit.

Action of con- q Runs engine at 0% throttle when accelerator pedal is released, and at 50% throttle when acceler-
troller ator pedal is depressed.

Problem on q The engine power does not reach full throttle power.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input voltage from throttle sensor can be checked by using monitoring function (Code: ENGINE
31707 THROTTLE POS).
Related infor-
q Information on accelerator pedal position detected by throttle sensor can be checked by using mon-
mation
itoring function (Code: ENGINE31701 THROTTLE POS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.

If failure code [CA2186] is also indicated, perform troubleshooting for it first.

1. Turn starting switch and disconnect switch to OFF position.

2. Disconnect connector T9A and T9B, and connect T-adapters to female
Defective throttle sensor power sides.
2
supply system 3. Turn starting switch to ON position.

Between T9A (female) (1) and (3) Voltage 4.75 – 5.25 V

Between T9B (female) (1) and (2) Voltage 4.75 – 5.25 V

1. Turn starting switch and disconnect switch to OFF position.

2. Disconnect connectors EC2, T9A, T9B, TM39 and TM41, and connect
T-adapter to each female side.
a If cause 2 is not cause for failure, this check
is not required.
Resistance Max. 1 Mz
Between EC2 (female) (22) and T9A (female)
(1)
Open circuit in wiring harness a If cause 2 is not cause for failure, this check
3 (Wire breakage or defective con- is not required.
tact of connector) Resistance Max. 1 z
Between EC2 (female) (23) and T9A (female)
(3)
Between EC2 (female) (9) and T9A (female) (2) Resistance Max. 1 z
Between TM39 (female) (4) and T9B (female)
Resistance Max. 1 z
(2)
Between TM41 (female) (34) and T9B (female)
Resistance Max. 1 z
(1)
a If cause 2 is not cause for failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side
4 Short circuit in wiring harness of one of them.
Between EC2 (female) (9) and (23), or between
Resistance Min. 1 Mz
T9A (female) (2) and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female side
5 of one of them.
(Contact with ground circuit)
Between EC2 (female) (9) or T9A (female) (2)
Resistance Min. 1 Mz
and ground

40-156 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA132] Throttle sensor low error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
Defective accelerator pedal (throt-
6 Depress accelerator
tle sensor) Voltage 3.7 – 4.0 V
Between T9A (2) and pedal.
(3) Release accelerator
Voltage 0.5 – 0.8 V
pedal.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference: Followings are standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
3. Turn starting switch to ON position.
7 Defective engine controller 4. Operate accelerator pedal and troubleshoot.
Between EC2 (22) and
Power supply Voltage 4.75 – 5.25 V
(23)
Depress accelerator
Voltage 3.7 – 4.0 V
Between EC2 (9) and pedal.
(23) Release accelerator
Voltage 0.5 – 0.8 V
pedal.

Circuit diagram related to throttle sensor 40-157

GD555-5,GD655-5,GD675-5 40-157
(01)
Troubleshooting by failurecode
Failure code [CA144] Coolant sensor high error

Failure code [CA144] Coolant sensor high error 40-158

Action code Failure code Coolant temperature sensor voltage is high
Failure
(Engine controller system)
E01 CA144
Detail of failure q Signal circuit of coolant temperature sensor detects high voltage.
Action of con-
q Fixes coolant temperature value and continues operation.
troller

Problem on q Engine does not start easily at low temperature.

machine q Overheat prevention function does not work.

q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
(Code: ENGINE 04105 COOLANT TEMP).
q Temperature detected by engine coolant sensor can be checked by using monitoring function
Related infor- (Code: ENGINE 04104 COOLANT TEMP).
mation q Method of reproducing failure code: Turn starting switch to ON position.
q This failure code is displayed if temperature sensor connector is disconnected.
q Since T-adapter for sensor connector is "socket", T-adapter cannot be connected to wiring har-
ness.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side
of connector.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor
as normal.
Defective coolant temperature
2 0°C Resistance 30 – 37 kz
sensor
Between COOLANT
25°C Resistance 9.3 – 10.7 kz
TEMP (male) (A) and (B)
a Coolant temperature- 50°C Resistance 3.2 – 3.8 kz
Resistance character-
80°C Resistance 1.0 – 1.3 kz
istics
95°C Resistance 700 – 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open or short circuit in wiring har- Between ECM (female) (15) and (38) (Coolant tem-
3 perature: Min. 0°C)
ness Resis-
a Use "Coolant temperature-Resistance charac- 700 z - 37 kz
tance
teristics" table shown above as resistance crite-
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-158 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA144] Coolant sensor high error

Circuit diagram related to coolant temperature sensor 40-159

GD555-5,GD655-5,GD675-5 40-159
(01)
Troubleshooting by failurecode
Failure code [CA145] Coolant sensor low error

Failure code [CA145] Coolant sensor low error 40-160

Action code Failure code Coolant temperature sensor voltage is low.
Failure
(Engine controller system)
E01 CA145
Detail of failure q Signal circuit of coolant temperature sensor detected low voltage.
Action of con-
q Fixes coolant temperature value and continues operation.
troller

Problem on q Engine does not start easily at low temperature.

machine q Overheat prevention function does not work.

q Input voltage from engine coolant temperature sensor can be checked by using monitoring function
(Code: ENGINE 04105 COOLANT TEMP).
q Temperature detected by engine coolant sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 04104 COOLANT TEMP).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for High Error is displayed.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP, and connect socket to male side
of connector.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor
as normal.
0°C Resistance 30 – 37 kz
Defective coolant temperature Between COOLANT
2 25°C Resistance 9.3 – 10.7 kz
sensor TEMP (male) (A) and (B)
a Coolant temperature 50°C Resistance 3.2 – 3.8 kz
-Resistance charac-
80°C Resistance 1.0 – 1.3 kz
teristics
95°C Resistance 700 – 800 z
Whole cool-
Between TWTR (male)
ant temper- Resistance Min. 100 kz
(B) – ground
ature range
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Between ECM (female) (15) and (38) (Coolant tem-
3 Short circuit in wiring harness perature: Min. 0°C)
Resis-
a Use "Coolant temperature-Resistance charac- 700 z – 37 kz
tance
teristics" table shown above as resistance crite-
ria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and COOLANT TEMP, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Resis-
Between ECM (female) (15) and ground Min. 100 kz
tance
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-160 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA145] Coolant sensor low error

Circuit diagram related to coolant temperature sensor 40-161

GD555-5,GD655-5,GD675-5 40-161
(01)
Troubleshooting by failurecode
Failure code [CA153] Charge temperature sensor high error

Failure code [CA153] Charge temperature sensor high error 40-162

Action code Failure code Charged air temperature sensor voltage is high.
Failure
(Engine controller system)
E01 CA153
q High voltage is detected in temperature signal circuit of charge (boost) pressure/temperature sen-
Detail of failure
sor.
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem on
q Engine protection function based on charge air temperature does not work.
machine
q Input voltage from charge temperature sensor can be checked by using monitoring function (Code:
ENGINE 18501 CHG TEMP).
q Temperature detected by charge temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 18500 CHG TEMP).
mation
q Method of reproducing failure code: Turn starting switch to ON position.
q Since T-adapter for sensor connector is "socket", T-adapter cannot be connected.
q This failure code is displayed if temperature sensor connector is disconnected.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.

-40°C Resistance 41 kz – 48 kz
-20°C Resistance 14 kz – 16 kz
Defective charge temperature Between BOOST
2
sensor PRESS & IMT (male) (3) 0°C Resistance 5.4 kz – 6.1 kz
and (4)
30°C Resistance 1.6 kz – 1.8 kz
a Charge temperature
-Resistance charac- 60°C Resistance 560 – 600 z
teristic
90°C Resistance 230 – 250 z
130°C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or short circuit in wir- Between ECM (female) (23) and (47)
3
ing harness a Use "Charge temperature-Resistance charac- 80 z -
Resistance
teristics" table shown above as resistance crite- 48 kz
ria.
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-162 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA153] Charge temperature sensor high error

Circuit diagram related to charge temperature sensor 40-163

GD555-5,GD655-5,GD675-5 40-163
(01)
Troubleshooting by failurecode
Failure code [CA154] Charge temperature sensor low error

Failure code [CA154] Charge temperature sensor low error 40-164

Action code Failure code Charged air temperature sensor voltage is low.
Failure
(Engine controller system)
E01 CA154
q Low voltage is detected in temperature signal circuit of charge (boost) pressure/temperature sen-
Detail of failure
sor.
Action of con-
q Fixes charge temperature value and continues operation.
troller
Problem on
q Engine protection function based on charge air temperature does not work
machine
q Input voltage from charge temperature sensor can be checked by using monitoring function (Code:
ENGINE 18501 CHG TEMP).
q Temperature detected charge temperature sensor can be checked by using monitoring function
Related infor-
(Code: ENGINE 18500 CHG TEMP).
mation
q If temperature sensor connector is disconnected, this failure code is not displayed but failure code
for "High Error" is displayed.
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.

-40°C Resistance 41 kz – 48 kz
-20°C Resistance 14 kz – 16 kz
Defective charge temperature Between BOOST
2
sensor PRESS & IMT (male) (3) 0°C Resistance 5.4 kz – 6.1 kz
and (4)
30°C Resistance 1.6 kz – 1.8 kz
a Charge temperature
-Resistance charac- 60°C Resistance 560 – 600 z
teristic
90°C Resistance 230 – 250 z
130°C Resistance 80 – 90 z
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
3 Short circuit in wiring harness Between ECM (female) (23) and (47)
a Use "Charge temperature-Resistance charac- 80 z –
Resistance
teristics" table shown above as resistance crite- 48 kz
ria.
a If no failure is found by checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and BOOST PRESS & IMT, and connect
4
(Contact with ground circuit) T-adapter to female side of ECM.
Between ECM (female) (23) and ground Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
5 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-164 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA154] Charge temperature sensor low error

Circuit diagram related to charge temperature sensor 40-165

GD555-5,GD655-5,GD675-5 40-165
(01)
Troubleshooting by failurecode
Failure code [CA155] Speed derating error by high charge temperature

Failure code [CA155] Speed derating error by high charge temperature 40-16
Action code Failure code Charged air temperature is high and power drops
Failure
(Engine controller system)
E03 CA155
q Charge air temperature sensed by charge (boost) pressure/temperature sensor indicates that tem-
Detail of failure
perature exceeded upper limit of control temperature.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine stops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Charge air temperature sensed by charge (boost) pressure/temperature sensor can be checked
Related infor-
by using monitoring function (Code: ENGINE 18500 CHG TEMP)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

The deterioration of aftercooler cooling performance is suspected. Directly
check the following points:
Drop of cooling performance of
1 q Looseness and damage of fan belt
aftercooler
q Insufficient cooling air
q Clogging of aftercooler fins
Unusual rise of turbocharger outlet Outlet temperature of turbocharger may be unusually high. Check related
2
temperature parts directly.
If no failure is not found by above checks, charge temperature sensor system
3 Defective engine controller may be defective. Perform troubleshooting for failure codes [CA153] and
[CA154].

40-166 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA155] Speed derating error by high charge temperature

GD555-5,GD655-5,GD675-5 40-167
(01)
Troubleshooting by failurecode
Failure code [CA187] Sensor power supply 2 low error

Failure code [CA187] Sensor power supply 2 low error 40-168

Action code Failure code Sensor power supply 2 voltage is low.
Failure
(Engine controller system)
E03 CA187
Detail of failure q Low voltage is detected in sensor power supply 2 circuit.
Action of con- q Runs engine with charge (boost) pressure and charge (boost) temperature set to fixed values.
troller q Limits engine output and allows engine to run.
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
1 Defective wiring harness connector of "Check before troubleshooting" of "Related information to troubleshooting",
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors sequentially one by one and turn starting
switch to ON position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when a connector is disconnected, that sen-
sor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because connector is discon-
2 Defective sensor or wiring harness nected. Ignore failure codes other than [CA187].
Sensor or harness Connector
Boost pressure/temperature sensor BOOST PRESS & IMT
Common rail pressure sensor FUEL RAIL PRESS
Bkup speed sensor CAM SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness discon-
nected.
Between ECM (male) (37) and (47) Voltage 4.75 – 5.25 V

40-168 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA187] Sensor power supply 2 low error

Circuit diagram related to sensor power supply 2 40-169

GD555-5,GD655-5,GD675-5 40-169
(01)
Troubleshooting by failurecode
Failure code [CA221] Atmospheric pressure sensor high error

Failure code [CA221] Atmospheric pressure sensor high error 40-170

Action code Failure code Ambient air pressure sensor voltage is high.
Failure
(Engine controller system)
E01 CA221
Detail of failure q High voltage is detected in signal circuit of ambient air pressure sensor.
Action of con-
q Fixes ambient air pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient air pressure sensor can be checked by using monitoring function
(Code: ENGINE 37402 AMBIENT PRESS).
Related infor-
q Ambient air pressure sensed by ambient air pressure sensor can be checked by using monitoring
mation
function (Code: ENGINE 37400 AMBIENT PRESS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective sensor power supply 1 If failure code [CA352] or [CA386] is displayed simultaneously, troubleshoot it
2
system
Defective ambient air pressure
3 3. Turn starting switch to ON position.
sensor
4 Short circuit in wiring harness
Hot short in wiring harness
5
(Contact with 24 V circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
first.
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
If failure code changes from [CA221] to [CA222] ,sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
T-adapter to female side of one of them.
Between ECM (female) (33) and (3), or between
Resistance Min. 100 kz
AMB. AIR PRESSURE (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapter to female side of connector AMB. AIR PRESSURE or
insert T-adapter in connector ECM.
4. Turn starting switch to ON position (with connector AMB. AIR PRESSURE
disconnected).
Between ECM (3) and (38), or between AMB. AIR
Voltage Max. 1 V
PRESSURE (female) (3) and (2)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-170 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA221] Atmospheric pressure sensor high error

Circuit diagram related to ambient pressure sensor 40-171

GD555-5,GD655-5,GD675-5 40-171
(01)
Troubleshooting by failurecode
Failure code [CA222] Atmospheric pressure sensor low error

Failure code [CA222] Atmospheric pressure sensor low error 40-172

Action code Failure code Ambient air pressure sensor voltage is low.
Failure
(Engine controller system)
E01 CA222
Detail of failure q Low voltage is detected in signal circuit of ambient air pressure sensor.
Action of con-
q Fixes ambient air pressure value and continues operation.
troller
Problem on q Engine output drops.
machine q Engine starting performance becomes deteriorated.
q Input voltage from ambient air pressure sensor can be checked by using monitoring function
(Code: ENGINE 37402 AMBIENT PRESS).
Related infor-
q Ambient air pressure sensed by ambient air pressure sensor can be checked by using monitoring
mation
function (Code: ENGINE 37400 AMBIENT PRESS).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Defective power supply system of 2. Disconnect connector AMB. AIR PRESSURE and connect T-adapter to
2
ambient air pressure sensor female side.
3. Turn starting switch to ON position.
Between AMB. AIR PRESSURE
Power input Voltage 4.75 – 5.25 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors AMB. AIR PRESSURE and ECM, and connect
T-adapter to each female side.
a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resis-
Max. 10 z
Short circuit in wiring harness Between ECM (female) (33) and AMB. AIR tance
3 (wire breakage or defective con- PRESSURE (female) (1)
tact of connector) a If power supply input in checks on cause 2 is nor-
mal, this check is not required. Resis-
Max. 10 z
Between ECM (female) (38) and AMB. AIR tance
PRESSURE (female) (2)
Between ECM (female) (3) and AMB. AIR PRES- Resis-
Max. 10 z
SURE (female) (3) (sensor output) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
Ground fault in wiring harness T-adapter to female side of one of them.
4
(contact with ground circuit)
Between ECM (female) (3) and ground, or between Resis-
Min. 100 kz
AMB. AIR PRESSURE (female) (3) and ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and AMB. AIR PRESSURE, and connect
5 Short circuit in wiring harness T-adapter to female side of one of them.
Between ECM (female) (3) and (38), or between Resis-
Min. 100 kz
AMB. AIR PRESSURE (female) (2) and (3) tance
a If cause items 1 to 5 are not cause for failure and check result of cause 6 is
abnormal, sensor is defective.
Defective ambient air pressure 1. Turn starting switch to OFF position.
6 sensor (improper input voltage to 2. Insert T-adapter to connector ECM.
engine controller) 3. Turn starting switch to ON position.
Sensor out-
Between ECM (3) and (38) Voltage 0.5 – 4.5 V
put

40-172 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA222] Atmospheric pressure sensor low error

Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, engine controller is defective. (Since
7 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor 40-173

GD555-5,GD655-5,GD675-5 40-173
(01)
Troubleshooting by failurecode
Failure code [CA227] Sensor power supply 2 high error

Failure code [CA227] Sensor power supply 2 high error 40-174

Action code Failure code Sensor power supply 2 voltage is high.
Failure
(Engine controller system)
E03 CA227
Detail of failure q High voltage is detected in sensor power supply 2 circuit.

Action of con- q Fixes charge air pressure and charge air temperature values and continues operation.
troller q Restrains engine output and allows engine to run.

q Engine output drops.

Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA187].

Failure code [CA234] Engine overspeed 40-174

Action code Failure code Engine overspeed
Failure
(Engine controller system)
E02 CA234
Detail of failure q Engine speed exceeds controlled upper speed limit.
Action of con-
q Stops injection until engine speed lowers to normal level.
troller
Problem on q Engine speed fluctuates.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Engine speed can be checked by using monitoring function.
Related infor-
(Code: 01002 Engine speed)
mation
q Method of reproducing failure code: Run engine at high idle.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly

2 Improper use of machine Machine may be used improperly. Instruct operator proper way to use.

If causes 1 and 2 are not detected, engine controller may be defective. (Since
3 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-174 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA238] Ne speed sensor power supply error

Failure code [CA238] Ne speed sensor power supply error 40-175

Action code Failure code Ne speed sensor power supply voltage is low.
Failure
(Engine controller system)
E03 CA238
Detail of failure q Low voltage is detected in power supply circuit of engine Ne speed sensor.
Action of con-
q Controls engine with signal from engine Bkup speed sensor.
troller
q Running engine stops (when Bkup speed sensor is also failed).
q Stopped engine cannot be started (when Bkup speed sensor is also failed).
Problem on
q Starting performance is poor.
machine
q Engine hunts.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when a sensor is disconnected, sensor or
engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor CRANK SENSOR
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller
nected.

Between ECM (male) (16) and (48) Voltage 4.75 – 5.25 V

Circuit diagram related to engine Ne speed sensor 40-175

GD555-5,GD655-5,GD675-5 40-175
(01)
Troubleshooting by failurecode
Failure code [CA271] IMV/IMA: Short circuit

Failure code [CA271] IMV/IMA: Short circuit 40-176

Action code Failure code IMV/IMA short circuit
Failure
(Engine controller system)
E03 CA271
Detail of failure q Short circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine speed does not increase from low idle.
Problem on q Engine output drops.
machine q Common rail fuel pressure rises above commanded value.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
2 Defective supply pump actuator
Short circuit or ground fault in wir-
3
ing harness
4 Short circuit in wiring harness
Ground fault in wiring harness
5 T-adapter to female side of either connector.
(contact with ground circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
3. Turn starting switch to ON position.
If failure code changes from [CA271] to [CA272] ,supply pump actuator is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Between ECM (female) (2) and (32) Resistance 1-5z
Between ECM (female) (2) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapter to female side of either connector.
Between ECM (female) (2) and (32), or between
Resistance Min. 100 kz
CP3 PUMP REGULATOR (female) (1) and (2)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
Between ECM (female) (2) and ground or between
Resistance Min. 100 kz
CP3 PUMP REGULATOR (female) (1) and ground
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-176 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA271] IMV/IMA: Short circuit

Circuit diagram related to IMV/IMA 40-17

GD555-5,GD655-5,GD675-5 40-177
(01)
Troubleshooting by failurecode
Failure code [CA272] IMV/IMA open circuit

Failure code [CA272] IMV/IMA open circuit 40-178

Action code Failure code IMV/IMA open circuit
Failure
(Engine controller system)
E03 CA272
Detail of failure q Open circuit is detected in drive circuit of supply pump actuator.
Action of con-
q None in particular
troller
q Engine runs but it does not stabilize.
Problem on
q Common rail fuel pressure rises above commanded value.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
2 Defective supply pump actuator
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
Hot short in wiring harness
5 4. Turn starting switch to ON position and perform troubleshooting after one
(Contact with 24 V circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
Between CP3 PUMP REGULATOR (male) (1) and
Resistance Max. 5 z
(2)
1. Turn starting switch to OFF position.
Between ECM (female) (2) and (32) Resistance Max. 5 z
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CP3 PUMP REGULATOR and connect
T-adapters to each female side.
Between ECM (female) (2) and CP3 PUMP REGU-
Resistance Max. 10 z
LATOR (1)
Between ECM (female) (32) and CP3 PUMP REG-
Resistance Max. 10 z
ULATOR (2)
1. Turn starting switch to OFF position.
2. Disconnect connector CP3 PUMP REGULATOR.
3. Insert T-adapter in connector ECM, or connect T-adapter to female side of
CP3 PUMP REGULATOR.
minute or longer (with connector CP3 PUMP REGULATOR disconnected).
a Average voltage is displayed because of PWM.
Between ECM (2) and (32), or between CP3 PUMP
Voltage Max. 3 V
REGULATOR (female) (1) and (2)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-178 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA272] IMV/IMA open circuit

Circuit diagram related to IMV/IMA 40-179

GD555-5,GD655-5,GD675-5 40-179
(01)
Troubleshooting by failurecode
Failure code [CA322] Injector #1 (L#1) open/short

Failure code [CA322] Injector #1 (L#1) open/short 40-180

Action code Failure code Injector #1 (L#1) has open or short circuit
Failure
(Engine controller system)
E03 CA322
Detail of failure q Open or short circuit is detected in drive circuit of No. 1 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of about 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 1 injector
Between INJECTOR CYL 1&2 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (45) and (53) Resistance Max. 2 z
Between ECM (female) (45) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (45) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (3)
Between ECM (female) (53) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (4)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (45) or INJECTOR CYL
1&2 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective injectors in other cylin-
7
ders or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (45) and each pin other No continuity (no sound
than (45) is heard)
Between ECM (female) (53) and each pin other No continuity (no sound
than (53) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them, too.
If causes 1 to 7 are not causes for failure, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-180 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA322] Injector #1 (L#1) open/short

Circuit diagram related to injector #1 40-181

GD555-5,GD655-5,GD675-5 40-181
(01)
Troubleshooting by failurecode
Failure code [CA323] Injector #5 (L#5) open/short

Failure code [CA323] Injector #5 (L#5) open/short 40-182

Action code Failure code Injector #5 (L#5) has open or short circuit
Failure
(Engine controller system)
E03 CA323
Detail of failure q Open or short circuit is detected in drive circuit of No. 5 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approximately 65 V is supplied to injector (+)
mation
side but cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective No. 5 injector
Between INJECTOR CYL 5&6 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (46) and (60) Resistance Max. 2 z
Between ECM (female) (46) and ground Resistance Min. 100 kz
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (46) and INJECTOR
tact of connector) Resistance Max. 2 z
CYL 5&6 (female) (3)
Between ECM (female) (60) and INJECTOR
Resistance Max. 2 z
CYL 5&6 (female) (4)
a If no failure is found in checks on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (46) or INJECTOR CYL
5&6 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective injectors in other cylin-
7
ders or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (46) and each pin other No continuity (no sound is
than (46) heard)
Between ECM (female) (60) and each pin other No continuity (no sound is
than (60) heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-182 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA323] Injector #5 (L#5) open/short

Circuit diagram related to injector #5 40-183

GD555-5,GD655-5,GD675-5 40-183
(01)
Troubleshooting by failurecode
Failure code [CA324] Injector #3 (L#3) open/short

Failure code [CA324] Injector #3 (L#3) open/short 40-184

Action code Failure code Injector #3 (L#3) has open or short circuit.
Failure
(Engine controller system)
E03 CA324
Detail of failure q Open or short circuit is detected in drive circuit of No. 3 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 3 injector
Between INJECTOR CYL 3&4 (male) (3) and (4) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (3) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (55) and (52) Resistance Max. 2 z
Between ECM (female) (55) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (55) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (3)
Between ECM (female) (52) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (4)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (55) or INJECTOR CYL
3&4 (female) (3) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (55) and each pin other No continuity (no sound
than (55) is heard)
Between ECM (female) (52) and each pin other No continuity (no sound
than (52) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-184 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA324] Injector #3 (L#3) open/short

Circuit diagram related to injector #3 40-185

GD555-5,GD655-5,GD675-5 40-185
(01)
Troubleshooting by failurecode
Failure code [CA325] Injector #6 (L#6) open/short

Failure code [CA325] Injector #6 (L#6) open/short 40-186

Action code Failure code Injector #6 (L#6) has open or short circuit.
Failure
(Engine controller system)
E03 CA325
Detail of failure q Open or short circuit is detected in drive circuit of No. 6 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of apporx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5&6 and connect T-adapter to male
side.
2 Defective injector No. 6
Between INJECTOR CYL 5&6 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 5&6 (male) (1) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (57) and (59) Resistance Max. 2 z
Between ECM (female) (57) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
4 (Wire breakage or defective con- T-adapter to female side of one of them.
Between ECM (female) (57) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
5&6 (female) (1)
Between ECM (female) (59) and INJECTOR CYL
Resistance Max. 2 z
5&6 (female) (2)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (57) or INJECTOR CYL
Resistance Min. 100 kz
5&6 (female) (1) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and INJECTOR CYL 5&6 and connect
T-adapter to female side of ECM.
6 Short circuit in wiring harness a Check by using multimeter in continuity mode.
Between ECM (female) (57) and each pin other No continuity (no sound
than (57) is heard)
Between ECM (female) (59) and each pin other No continuity (no sound
than (59) is heard)
Defective other cylinder injectors If failure codes for other injectors are displayed, perform troubleshooting for
7
or wiring harness them as well.
If no failure is found by above checks, engine controller is defective. (Since
8 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-186 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA325] Injector #6 (L#6) open/short

Circuit diagram related to injector #6 40-187

GD555-5,GD655-5,GD675-5 40-187
(01)
Troubleshooting by failurecode
Failure code [CA331] Injector #2 (L#2) open/short

Failure code [CA331] Injector #2 (L#2) open/short 40-18

Action code Failure code Injector #1 (L#1) has open or short circuit.
Failure
(Engine controller system)
E03 CA331
Detail of failure q Open or short circuit is detected in drive circuit of No. 2 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapter to male
side.
2 Defective No. 2 injector
Between INJECTOR CYL 1&2 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 1&2 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (54) and (51) Resistance Max. 2 z
Between ECM (female) (54) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (54) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
1&2 (female) (2)
Between ECM (female) (51) and INJECTOR CYL
Resistance Max. 2 z
1&2 (female) (1)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (54) or INJECTOR CYL
1&2 (female) (2) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 1&2 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (54) and each pin other No continuity (no sound
than (54) is heard)
Between ECM (female) (51) and each pin other No continuity (no sound
than (51) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-188 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA331] Injector #2 (L#2) open/short

Circuit diagram related to injector #2 40-189

GD555-5,GD655-5,GD675-5 40-189
(01)
Troubleshooting by failurecode
Failure code [CA332] Injector #4 (L#4) open/short

Failure code [CA332] Injector #4 (L#4) open/short 40-190

Action code Failure code Injector #4 (L#4) has open or short circuit.
Failure
(Engine controller system)
E03 CA332
Detail of failure q Open or short circuit is detected in drive circuit of No. 4 injector.
Action of con-
q None in particular
troller
q Combustion becomes irregular or engine hunts.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
Related infor-
q While engine is running normally, pulse voltage of approx. 65 V is supplied to injector (+) side but
mation
cannot be measured by using multimeter because it cannot measure pulse voltages.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3&4 and connect T-adapter to male
side.
2 Defective No. 4 injector
Between INJECTOR CYL 3&4 (male) (1) and (2) Resistance Max. 2 z
Between INJECTOR CYL 3&4 (male) (2) and
Resistance Min. 100 kz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Open circuit or ground fault in wir-
3
ing harness Between ECM (female) (56) and (58) Resistance Max. 2 z
Between ECM (female) (56) and ground Resistance Min. 100 kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
4 (Wire breakage or defective con- T-adapter to each female side.
Between ECM (female) (56) and INJECTOR CYL
tact of connector) Resistance Max. 2 z
3&4 (female) (2)
Between ECM (female) (58) and INJECTOR CYL
Resistance Max. 2 z
3&4 (female) (1)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
5 T-adapter to female side of one of them.
(Contact with ground circuit)
Between ECM (female) (56) or INJECTOR CYL
3&4 (female) (2) and ground Resistance Min. 100 kz

1. Turn starting switch to OFF position.

6 Short circuit in wiring harness
Defective other cylinder injectors
7
or wiring harness
8 Defective engine controller
2. Disconnect connectors ECM and INJECTOR CYL 3&4 and connect
T-adapter to female side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (56) and each pin other No continuity (No sound
than (56) is heard)
Between ECM (female) (58) and each pin other No continuity (No sound
than (58) is heard)
If failure codes for other injectors are displayed, perform troubleshooting for
them as well.
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-190 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA332] Injector #4 (L#4) open/short

Circuit diagram related to injector #4 40-191

GD555-5,GD655-5,GD675-5 40-191
(01)
Troubleshooting by failurecode
Failure code [CA342] Data compatibility error in engine controller

Failure code [CA342] Data compatibility error in engine controller 40-192

Action code Failure code Data inconsistency in engine controller
Failure
(Engine controller system)
E03 CA342
Detail of failure q Data inconsistency occurres in engine controller.
Action of con-
q None in particular
troller
Problem on q Engine continues to run normaly, but it may stop or it may not restart if it stops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

40-192 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA351] Injector drive circuit error

Failure code [CA351] Injector drive circuit error 40-193

Action code Failure code Injector drive circuit error
Failure
(Engine controller system)
E03 CA351
Detail of failure q Error occurs in power circuit to drive injectors.
Action of con-
q Limits engine output and allows engine to run.
troller
q Exhaust gas becomes black.
q Combustion becomes irregular.
Problem on
q Engine output drops.
machine
q Engine cannot be started.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Defective power supply voltage

2 Perform troubleshooting for failure code [CA441].
system

GD555-5,GD655-5,GD675-5 40-193
(01)
Troubleshooting by failurecode
Failure code [CA352] Sensor power supply 1 low error

Failure code [CA352] Sensor power supply 1 low error 40-194

Action code Failure code Sensor power supply 1 voltage is low.
Failure
(Engine controller system)
E03 CA352
Detail of failure q Low voltage is detected in sensor power supply 1 circuit.
Action of con-
q Takes ambient air pressure to be fixed value and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. After troubleshooting, return to step 1.
If this failure code is not displayed when connector is disconnected, separated
sensor or engine wiring harness is defective.
2 Defective sensor or wiring harness a Other failure codes are displayed as well. This is because connector is un-
plugged. Ignore all failure codes except for [CA352].
Sensor or harness Connector
Ambient pressure sensor AMB. AIR PRESSURE
Engine wiring harness ECM
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to male side.
3. Turn starting switch to ON position with engine wiring harness discon-
3 Defective engine controller
nected.

Between ECM (male) (33) and (38) Voltage 4.75 – 5.25 V

Circuit diagram related to sensor power 1 circuit 40-194

40-194 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA386] Sensor power supply 1 high error

Failure code [CA386] Sensor power supply 1 high error 40-195

Action code Failure code Sensor power supply 1 voltage is high.
Failure
(Engine controller system)
E03 CA386
Detail of failure q High voltage is detected in sensor power supply 1 circuit.
Action of con-
q Takes ambient air pressure to be fixed value and allows engine to run.
troller
q Engine output drops.
Problem on
q Engine starting performance becomes deteriorated.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA352]

GD555-5,GD655-5,GD675-5 40-195
(01)
Troubleshooting by failurecode
Failure code [CA428] Water-in-fuel sensor high error

Failure code [CA428] Water-in-fuel sensor high error 40-196

Action code Failure code Voltage of water-in-fuel sensor is high.
Failure
(Engine controller system)
E01 CA428
Detail of failure q High voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor does not work correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800 WATER IN FUEL)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" to "Related information to troubleshooting",
tor
Defective water-in-fuel sensor
2 a If water is in water separator, drain it.
installed to fuel prefilter
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector WIF1 and connect T-adapter to female side.
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
Between ECM (female) (14) and (47)
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to each
female side.
Between ECM (female) (14) and WIF1 (female) (1) Resistance Max. 10 z
Between ECM (female) (47) and WIF1 (female) (2) Resistance Max. 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard)
If no failure is found by above checks, engine controller is defective. (Since
tihis is internal failure, troubleshooting cannot be performed.)

40-196 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA428] Water-in-fuel sensor high error

Circuit diagram related to water-in-fuel sensor 40-197

GD555-5,GD655-5,GD675-5 40-197
(01)
Troubleshooting by failurecode
Failure code [CA429] Water-in-fuel sensor low error

Failure code [CA429] Water-in-fuel sensor low error 40-198

Action code Failure code Voltage of water-in-fuel sensor is low.
Failure
(Engine controller system)
E01 CA429
Detail of failure q Low voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
Action of con-
q None in particular
troller
Problem on
q Water separator monitor does not woek correctly.
machine
q Signal (ON/OFF) from water-in-fuel sensor can be checked by using monitoring function.
Related infor-
(Code: 18800 WATER IN FUEL)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective water-in-fuel sensor
2
installed to fuel prefilter
Short circuit or ground fault in wir-
3 Between ECM (female) (14) and (47)
ing harness
4 Short circuit in wiring harness
Ground fault in wiring harness
5
(Contact with ground circuit)
6 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector WIF1 and connect T-adapter to female side.
a If water is in water separator, drain it.
Between WIF1 (female) (1) and (2) Resistance Min. 100 kz
Between WIF1 (female) (1) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector ECM and connect T-adapter to female side.
Resistance Min. 100 kz
(Resistance of water-in-fuel sensor)
Between ECM (female) (14) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of ECM.
a Check by using multimeter in continuity mode.
Between ECM (female) (14) and each pin other No continuity (no sound
than (14) is heard)
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and WIF1, and connect T-adapter to female
side of one of them.
Between ECM (female) (14) or WIF1 (female) (1)
Resistance Min. 100 kz
and ground
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-198 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA429] Water-in-fuel sensor low error

Circuit diagram related to water-in-fuel sensor 40-19

GD555-5,GD655-5,GD675-5 40-199
(01)
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

Failure code [CA431] Idle validation switch error 40-20

Action code Failure code Idle validation switch error
Failure
(Engine controller system)
E01 CA431
Detail of failure q Signals 1 and 2 (IVS1 and IVS2) from idle validation switch are unusual.
Action of con-
q Runs engine at the throttle opening decided based on signal from throttle sensor.
troller
Problem on
machine
q Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function
(Code: ENGINE 18300 IVS 1)
Related infor-
q Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function
mation
(Code: ENGINE 18301 IVS 2)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 ment" of "Checks before troubleshooting" in "General information on trouble-
tor
2 Defective power supply system
Defective accelerator pedal
3 is not abnormal, accelerator pedal is defective.
(internal failure)
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
See the descriptions of wiring harness and connectors in "c: Electrical equip-
shooting" , and check them directly.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9B.
3. Turn starting switch to ON position.
a If abnormal, go to cause 4.
Between T9B (1) and (2) Voltage 4.75 – 5.25 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
a If abnormal, check wiring harness for causes 4 and 5. When wiring harness
See IVS1 in the figure 1
Between T9A (5) and (4)
on the next page.
See IVS2 in the figure 1
Between T9A (6) and (4)
on the next page.
1. Turn starting switch and disconnect switch to OFF position.
2. Disconnect connectors T9A, T9B, EC2, TM39 and TM41, and connect
T-adapters to female side of them.
Resis-
Between EC2 (female) (32) and T9A (female) (4) Max. 1 z
tance
Resis-
Between EC2 (female) (11) and T9A (female) (5) Max. 1 z
tance
Between EC2 (female) (1) and T9A (female) (6) Resis- Max. 1 z
tance
Between TM41 (female) (34) and T9B (female) (1) Resis- Max. 1 z
tance
Between TM39 (female) (4) and T9B (female) (2) Resis- Max. 1 z
tance
1. Turn starting switch and disconnect switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of connector EC2.
Between EC2 (female) (1) and each pin other than Resis-
Min. 1 Mz
(1) tance
Between EC2 (female) (11) and each pin other than Resis-
Min. 1 Mz
(11) tance

40-200 GD555-5,GD655-5,GD675-5
(01)

Cause
Defective transmission controller
6
(internal failure)
Defective engine controller
7 3. Turn starting switch to ON position.
(internal failure)
Circuit diagram related to idle validation
GD555-5,GD655-5,GD675-5
(01)
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error
Procedure, measuring location, criteria and remarks
1. Turn starting switch and disconnect switch to OFF position.
2. Insert T-adapter into connectors TM39 and TM41.
3. Turn disconnect switch to ON position.
4. Turn starting switch to ON position.
Between TM41 (34) and TM39 (4) Voltage 4.75 – 5.25 V
If no abnormality is found in the above, engine controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector EC2.
See IVS1 in the figure 1 on the next
Between EC2 (11) and (32)
page.
See IVS2 in the figure 1 on the next
Between EC2 (1) and (32)
page.
40-201
40-201
Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

Pedal stroke: Accelerator pedal stroke

Output voltage: Output voltage (Pin 2 of connector
T9A, pin 9 of EC2)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Area where both signals of IVS1 and
IVS2 are OFF

Fig. 1

40-202 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA431] Idle validation switch error

GD555-5,GD655-5,GD675-5 40-203
(01)
Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Failure code [CA432] Idle validation action error 40-204

Action code Failure code Idle validation action error
Failure
(Engine controller system)
E03 CA432
Detail of failure q Idle validation switch signal and throttle sensor signal are inconsistent.
1. In the case where controller judges that signal from idle validation switch shows "release" of accel-
erator pedal and signal from throttle sensor shows "depression" of accelerator pedal: Runs engine
at 0 % throttle when accelerator pedal is released, and at 50 % throttle when accelerator pedal is
Action of con-
depressed.
troller
2. In the case where controller judges that signal from idle validation switch shows "depression" of
accelerator pedal and signal from throttle sensor shows "release" of accelerator pedal: Runs
engine at 0 % throttle (Fixes throttle position for low idle operation).
Problem on q Engine speed does not rise from low idling.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Input (ON/OFF) from the idle validation switch 1 can be checked by using monitoring function
(Code: ENGINE 18300 IVS 1)
q Input (ON/OFF) from the idle validation switch 2 can be checked by using monitoring function
(Code: ENGINE 18301 IVS 2)
Related infor-
q Input voltage from the throttle sensor can be checked by using monitoring function (Code: ENGINE
mation
31707 THROTTLE POS)
q Accelerator pedal position sensed by the throttle sensor can be checked by using monitoring func-
tion (Code: ENGINE 31701 THROTTLE POS)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

As for idle validation switch, perform troubleshooting for failure code [CA431].
1
(For throttle sensor, perform troubleshooting for causes 2 and after.)
2 Defective power supply system
Defective accelerator pedal
3 a If abnormal, check wiring harness for causes 4 and 5. When wiring harness
(internal failure)
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact of connector)
5 Short circuit in wiring harness
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
a If abnormal, go to cause 4.
4.75 – 5.25
Between T9A (1) and (3) Voltage
V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector T9A.
3. Turn starting switch to ON position.
is not abnormal, accelerator pedal is defective.
See output voltage in the figure 1 on
Between T9A (2) and (3)
the next page.
1. Turn starting switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of them.
Between EC2 (female) (22) and T9A (female) (1) Resistance Max. 1 z
Between EC2 (female) (9) and T9A (female) (2) Resistance Max. 1 z
Between EC2 (female) (23) and T9A (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors T9A and EC2, and connect T-adapter to female side
of connector EC2.
Between EC2 (female) (9) and each pin other than
Resistance Min. 1 Mz
(9)

40-204 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found in the above, engine controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
Defective engine controller
6 2. Insert T-adapter into connector EC2.
(internal failure)
3. Turn starting switch to ON position.
See output voltage in the figure 1 on
Between EC2 (9) and (23)
the next page.

Circuit diagram related to idle validation 40-205

GD555-5,GD655-5,GD675-5 40-205
(01)
Troubleshooting by failurecode
Failure code [CA432] Idle validation action error

Pedal stroke: Accelerator pedal stroke

Output voltage: Output voltage (Pin 2 of connector
T9A, pin 9 of EC2)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Area where both signals of IVS1 and
IVS2 are OFF

Fig. 1

40-206 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA435] Engine oil pressure switch error

Failure code [CA435] Engine oil pressure switch error 40-207

Action code Failure code Engine oil pressure switch error
Failure
(Engine controller system)
E01 CA435
Detail of failure q Abnormality is detected in signal circuit of engine oil pressure switch.
Action of con-
q None in particular
troller
Problem on q Engine protection function based on engine oil pressure does not work.
machine q Engine oil pressure monitor does not work correctly.
q Method of reproducing failure code: Turn starting switch to ON position or start engine.
q Engine oil pressure switch is closed (turned ON) when oil pressure is low (when engine is stopped),
and is open (turned OFF) when high (when engine is running).
Related infor-
q As for generation of this failure code, engine controller checks engine oil pressure switch only when
mation
engine is not running. It checks whether the switch is closed (ON) or not, in other words, the signal
potential is ground level or not.
q When engine is running, failure of engine oil pressure switch is shown by failure code [B@BAZG].

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
Defective engine oil pressure 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapter to
2 male side.
switch
Between OIL PRESSURE SWITCH (male) (1) and
Resistance Max. 10 z
ground
1. Turn starting switch to OFF position.
Open circuit or short circuit in wir- 2. Disconnect connector ECM and connect T-adapter to female side.
3
ing harness
Between ECM (female) (17) and ground Resistance Max. 10 z
If no failure is found by above checks, engine controller is defective. (Since
4 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure switch 40-207

GD555-5,GD655-5,GD675-5 40-207
(01)
Troubleshooting by failurecode
Failure code [CA441] Power supply voltage low error

Failure code [CA441] Power supply voltage low error 40-208

Action code Failure code Power supply voltage is low.
Failure
(Engine controller system)
E03 CA441
Detail of failure q Low voltage is detected in controller power supply circuit.
Action of con-
q None in particular
troller
q Engine stops.
Problem on
q Starting performance is poor.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Loose or corroded battery cable
1 Battery cable terminal may be loose or corroded. Check it directly.
terminal
1) Turn starting switch to OFF position.
Loose terminal or partial wire
2 Check terminals of alternator, battery relay, ground (ET103) etc. for loose-
breakage at terminal
ness.
See descriptions of wiring harness and connectors in "c: Electrical equip-
Defective wiring harness connec-
3 ment" of "Check before troubleshooting" of "Related information to trouble-
tor
shooting", and check them.
1. Turn starting switch to OFF position.
2. Perform troubleshooting with starting switch at OFF position, and at engine
4 Low battery voltage cranking.
Between battery terminals (+) and (-). Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ET104.
5 Defective alternator 3. Start engine (run engine at middle or faster speed).
Between ET104 (1) and ground Voltage 27 – 29.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)
q Reference: Use following criteria to check that power supply system is nor-
mal.
1. Turn starting switch to OFF position and disconnect ground strap.
2. Insert T-adapter between male and female sides of EC3.
6 Defective engine controller
3. Connect ground cable.
4. Measure voltage with starting switch at OFF position, and when engine is
cranked.
Between EC3 (3) and (1) Voltage 20 – 30 V
Between EC3 (4) and (2) Voltage 20 – 30 V

40-208 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA441] Power supply voltage low error

Circuit diagram related to power supply voltage 40-209

GD555-5,GD655-5,GD675-5 40-209
(01)
Troubleshooting by failurecode
Failure code [CA442] Power supply voltage high error

Failure code [CA442] Power supply voltage high error 40-210

Action code Failure code Power supply voltage is high.
Failure
(Engine controller system)
E03 CA442
Detail of failure q High voltage (36 V or higher) is detected in controller power supply circuit.
Action of con-
q None in particular
troller
Problem on q Engine may stop.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA441].

40-210 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA449] Common rail pressure high error 2

Failure code [CA449] Common rail pressure high error 2 40-21

Action code Failure code Common rail pressure is high.
Failure
(Engine controller system)
E03 CA449
Detail of failure q High pressure error (2) is detected in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine sound becomes large when engine is running with no load or light load.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 RAIL PRESS)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Air in low pressure circuit
3 Defective fuel return circuit parts
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
5 Defective pressure limiter
6 Defective supply pump
Air may be in low pressure circuit. Check it directly according to following pro-
cedure.
1. Remove pressure pickup port plug (outlet side) in fuel main filter head.
2. Operate feed pump near fuel pre-filter.
3. Check leakage of fuel and air from pressure pickup port.
a For check of fuel return circuit pressure, see Testing and adjusting, Check-
ing fuel pressure.
Max. 0.02 MPa
Fuel return circuit pres-
At low idle or cranking
sure {Max. 0.19 kg/cm2}
a For check of leakage from pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
Leakage from pressure
At low idle 0 cc (No leakage)
limiter
If no failure is found by above checks, supply pump may be defective.

GD555-5,GD655-5,GD675-5 40-211
(01)
Troubleshooting by failurecode
Failure code [CA451] Common rail pressure sensor high error

Failure code [CA451] Common rail pressure sensor high error 40-212
Action code Failure code Common rail pressure sensor voltage is high
Failure
(Engine controller system)
E03 CA451
Detail of failure q High voltage is detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine speed or output lowers.
Problem on
q Engine does not start
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Signal voltage of common rail pressure sensor can be checked by using monitoring function.
(Code: 36401 RAIL PRESS)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position.
mation q This code is displayed if common rail pressure sensor connector is disconnected.
q Since T-adapter for sensor connector is "socket", open circuit in the wiring harness or voltage at
sensor connector cannot be checked.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective common rail pressure
2
sensor power supply line
3 Short circuit in wiring harness
Hot short in wiring harness
4
(Contact with 24 V circuit)
5 Open circuit in wiring harness
Defective common rail pressure
sensor
6 2. Insert T-adapter to connector ECM.
(Improper input voltage to engine
controller)
7 Defective engine controller
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
If failure code [CA227] or [CA187] is also displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
2. Disconnect connectors CAM SENSOR, FUEL RAIL PRESS, BOOST
PRESS & IMT and ECM.
3. Connect T-adapter to female side of ECM.
Between ECM (female) (25) and (37) Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to
connector ECM.
3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
disconnected).
a Pin (25) of ECM is connected to 5V line via resistor inside engine controller.
Between ECM (25) and (47) Voltage Approx. 5 V
If no abnormality is found by above checks, wiring harness may be discon-
nected. (*)
a If no abnormality is found by checks on causes 1 to 5 and check result for
cause 6 is abnormal, sensor is defective.
1. Turn starting switch to OFF position.
3. Turn starting switch to ON position.
Sensor out-
Between ECM (25) and (47) Voltage 0.2 – 4.6 V
put
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "Related in-
formation to troubleshooting".

40-212 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA451] Common rail pressure sensor high error

Circuit diagram related to common rail pressure sensor 40-213

GD555-5,GD655-5,GD675-5 40-213
(01)
Troubleshooting by failurecode
Failure code [CA452] Common rail pressure sensor low error

Failure code [CA452] Common rail pressure sensor low error 40-214
Action code Failure code Common rail pressure sensor voltage is low.
Failure
(Engine controller system)
E03 CA452
Detail of failure q Low voltage is detected in signal circuit of common rail pressure sensor.
Action of con-
q Limits engine output and allows engine to run.
troller
q Engine speed or output lowers.
Problem on
q Engine does not start.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Signal voltage of common rail pressure sensor can be checked by using monitoring function.
(Code: 36401 RAIL PRESS)
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
q If sensor connector is disconnected, this failure code is not displayed but failure code [CA451] for
High Error is displayed even if there is no high voltage problem.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective common rail pressure If failure code [CA187] (ground fault in sensor power supply line) or [CA227] is
2
sensor power supply line indicated, perform troubleshooting for it first.
a Check that failure code [CA187] (Ground fault in sensor power supply line)
is not displayed.
Defective common rail pressure 1. Turn starting switch to OFF position.
3 2. Disconnect connector FUEL RAIL PRESS.
sensor
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451] , sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
4 T-adapter to female side of ECM.
(Contact with ground circuit)
Between ECM (female) (25) and ground Resistance Min. 100 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and FUEL RAIL PRESS, and connect
5 Short circuit in wiring harness T-adapter to female side of ECM.
Between ECM (female) (25) and (47) Resistance Min. 100 kz
If no failure is found by above checks, engine controller is defective. (Since
6 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

40-214 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA452] Common rail pressure sensor low error

Circuit diagram related to common rail pressure sensor 40-215

GD555-5,GD655-5,GD675-5 40-215
(01)
Troubleshooting by failurecode
Failure code [CA488] Torque derating error by high charge temperature

Failure code [CA488] Torque derating error by high charge temperature40-216

Action code Failure code Charged air temperature is abnormality high and engine is der-
Failure ated.
E03 CA488 (Engine controller system)

Detail of failure q Temperature signal of boost pressure and temperature sensor exceeds upper limit of temperature.
Action of con-
q Limits engine output and allows engine to run.
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Boost temperature can be checked by using monitoring function.
Related infor-
(Code: 18500 CHG TEMP)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may lower. Directly check following points:
Lowered cooling performance of
1 q Insufficient cooling air
aftercooler
q Clogging of aftercooler fins

Abnormal rise of turbocharger out- Outlet temperature of turbocharger may be abnormally high. Check related
2
let temperature parts directly.
Defective boost temperature sen-
3 Perform troubleshooting for failure codes [CA153] and [CA154].
sor

40-216 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA553] Common rail pressure high error 1

Failure code [CA553] Common rail pressure high error 1 40-217

Action code Failure code Common rail pressure is high.
Failure
(Engine controller system)
E03 CA553
Detail of failure q High pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
q Engine sound becomes large when engine is running with no load or light load.
Problem on
q Engine output drops.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 RAIL PRESS)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

Cable connection to ground terminal may be incorrect. Check following termi-

nals directly.
Defective connection at ground q Ground terminal of machine ((–) terminal of battery)
2
terminal q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor
Damaged O-ring of supply pump
3 O-ring of supply pump actuator may be broken. Check it directly.
actuator
Defective common rail pressure
4 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system

GD555-5,GD655-5,GD675-5 40-217
(01)
Troubleshooting by failurecode
Failure code [CA559] Supply pump pressure low error 1

Failure code [CA559] Supply pump pressure low error 1 40-218

Action code Failure code Common rail pressure is low.
Failure
(Engine controller system)
E03 CA559
Detail of failure q Low pressure error (1) is detected in common rail circuit.
Action of con-
q None in particular
troller
q Engine does not start at all or does not start easily.
Problem on q Exhaust gas becomes black.
machine q Engine output drops.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Use of improper fuel Fuel used may be improper. Check it directly.
Fuel may be leaking to outside. Check it directly (check visually while running
2 Fuel leakage to outside
engine at low idle).
a For checking method, see “Note 1”. To check pressure of low-pressure fuel
line, see Testing and adjusting, “Testing fuel pressure”.
Negative pressure at fuel
At high idle Max. -50.7 MPa
supply pump inlet (outlet
(if engine can be started) {Max. -380 mmHg}
side of fuel pre-filter)
3 Defect in low pressure circuit parts
During cranking 0.3 – 1.1 MPa
Fuel pressure in low-pres- (if engine cannot be
sure circuit started) {3.1 – 11.3 kg/cm2}
(Inlet pressure of fuel main 0.5 – 1.3 MPa
At low idle
filter)
(if engine can be started) {5.1 – 13.3 kg/cm2}
a For check of leakage through pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
4 Defective pressure limiter
Leakage from pressure
At low idle 0 cc (no leakage)
limiter
a For check of return rate from injector, see Testing and adjusting, “Checking
fuel return rate and leakage”.
Defective injector During cranking
5 (including high-pressure pipe in (if engine cannot be Max. 90 cc/min
cylinder head) Return rate from injector started)
At low idle
Max. 180 cc/min
(if engine can be started)
a For check of return rate from supply pump, see Testing and adjusting,
“Checking fuel return rate and leakage”.
During cranking
6 Defective supply pump (if engine cannot be Max. 140 cc/min
Return rate from supply
started)
pump
At low idle
Max. 1,000 cc/min
(if engine can be started)
Defective common rail pressure
7 Perform troubleshooting for failure codes [CA451] and [CA452]
sensor system
Note 1: Check the low-pressure line parts for the following.
1) Remaining fuel level
2) Clogging of fuel tank breather
3) Fuel leakage through and clogging of low-pressure pipe
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
6) Replace the fuel filter if problem is not removed by clearing clogging.

40-218 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA689] Engine Ne speed sensor error

Failure code [CA689] Engine Ne speed sensor error 40-219

Action code Failure code Engine Ne speed sensor error
Failure
(Engine controller system)
E03 CA689
Detail of failure q Signal from engine Ne speed sensor is abnormal.
Action of con-
q Continues to control engine by using signal from engine Bkup speed sensor.
troller
q Engine hunts.
Problem on q Starting performance is poor.
machine q Engine output drops.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not composed of coil but Hall sensor and electronic circuit, speed
sensor cannot be determined to be normal by measuring its resistance with multimeter.
Related infor-
q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured with
mation
multimeter.
q Speed sensor senses holes of speed sensing wheel that is installed on inside of crankshaft vibra-
tion damper and rotated by crankshaft.

Cause Procedure, measuring location, criteria and remarks

Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
Defective Ne speed sensor power
2 If failure code [CA238] is also displayed, perform troubleshooting for it first.
supply line
Breakage or improper installation
3 (looseness) of engine Ne speed
sensor
Defective power supply input to
4
Ne speed sensor
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
6 Short circuit in wiring harness
Ground fault in wiring harness
7
(Contact with ground circuit)
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
Engine Ne speed sensor may be broken or may have improper installation
(looseness). Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connector CRANK SENSOR and connect T-adapter to female
side.
3. Turn starting switch to ON position.
Between CRANK SENSOR (female) Power
Voltage 4.75 – 5.25 V
(1) and (2) input
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (16) and CRANK tance
SENSOR (female) (1)
a If no failure is found by check on cause 4, this
check is not required. Resis-
Max. 10 z
Between ECM (female) (48) and CRANK tance
SENSOR (female) (2)
Between ECM (female) (27) and CRANK SEN- Resis-
Max. 10 z
SOR (female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (16) and (27) or CRANK Resis-
Min. 100 kz
SENSOR (female) (1) and (3) tance
Between ECM (female) (27) and (48) or CRANK Resis-
Min. 100 kz
SENSOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CRANK SENSOR.
Between ECM (female) (27) or CRANK SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance

GD555-5,GD655-5,GD675-5 40-219
(01)
Troubleshooting by failurecode
Failure code [CA689] Engine Ne speed sensor error

1. Turn starting switch to OFF position.

2. Disconnect connector CRANK SENSOR.
Hot short circuit in wiring harness
8 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between CRANK SENSOR (female) (3) and
Voltage Max. 1 V
ground
Cause Procedure, measuring location, criteria and remarks
Damaged or loose speed sensing
9 Inspect speed sensing ring directly.
ring
If no failure is found by above checks, Ne speed sensor is defective. (Since
10 Defective Ne speed sensor
this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
11 Defective engine controller
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor 40-2 0

40-220 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA731] Engine Bkup speed sensor phase error

Failure code [CA731] Engine Bkup speed sensor phase error 40-2 1
Action code Failure code Engine Bkup speed sensor phase error
Failure
(Engine controller system)
E03 CA731
q Phase error is detected between signals from engine Ne speed sensor and engine Bkup speed
Detail of failure
sensor
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Engine does not start at all or does not start easily.
Problem on q Idle speed is unstable.
machine q Exhaust gas becomes black.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Breakage of engine Ne speed
1 Engine Ne speed sensor may be broken. Check it directly.
sensor
Breakage of engine Bkup speed
2 Engine Bkup speed sensor may be broken. Check it directly.
sensor
Defective installation or breakage
3 of speed sensing wheel on crank-
shaft side
Defective installation or breakage
4 of speed sensing ring on camshaft
side
Defective timing of crankshaft and
5 Timing of crankshaft and camshaft may be defective. Check it directly.
camshaft
Defective connection at ground
6
terminal
Speed sensing wheel on crankshaft side may be installed defectively or bro-
ken. Check it according to following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
a Do not align with mark of No. 1 cylinder compression top dead center.
(Approx. 80 ° before compression top dead center)
2. If center of oblong hole (WS) of speed sensing wheel aligns with Ne speed
sensor top (M2), installation is correct.
Speed sensing ring on camshaft side may be installed defectively or broken.
Check it according to following procedure.
1. Align paint mark (M1) on damper with Ne speed sensor top (M2).
a Do not align with mark of No. 1 cylinder compression top dead center.
(Approx. 80 ° before compression top dead center)
2. Remove Bkup speed sensor.
3. If you can see double-slot part (with one crest) on speed sensing ring (B)
through sensor mounting hole (H), speed sensing ring is installed correctly.
Cable connection to ground terminal may be incorrect. Check following termi-
nals directly.
q Ground terminal of machine ((-) terminal of battery)
q Ground terminal of engine
q Ground terminal of engine controller
q Ground terminal of starting motor

GD555-5,GD655-5,GD675-5 40-221
(01)
Troubleshooting by failurecode
Failure code [CA757] All continuous data lost error

Failure code [CA757] All continuous data lost error 40-2 2

Action code Failure code All continuous data lost error
Failure
(Engine controller system)
E03 CA757
Detail of failure q All data in engine controller are lost.
Action of con-
q None in particular
troller
q Engine may stop and may not restart.
Problem on
q Monitoring function of machine monitor (engine controller system) may not work normally.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defect in related system If another failure code is displayed, perform troubleshooting for it.

2 Perform troubleshooting for failure code [CA441].

40-222 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

Failure code [CA778] Engine Bkup speed sensor error 40-2 3

Action code Failure code Engine Bkup speed sensor error
Failure
(Engine controller system)
E03 CA778
Detail of failure q Abnormal engine Bkup speed (cam) sensor signal is detected.
Action of con-
q Continues to control engine by using signal from engine Ne speed sensor.
troller
q Starting performance is poor.
Problem on
q Engine output lowers.
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Method of reproducing failure code: Start engine.
q Since inside of speed sensor is not coil but Hall sensor and electronic circuit, speed sensor cannot
Related infor- be determined to be normal by measuring its resistance with multimeter.
mation q Since speed sensor outputs 5 V pulse voltage during normal operation, it cannot be measured by
using multimeter.
q Speed sensor detects rotating slot on speed sensing ring installed on camshaft.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
Defective sensor power supply 2
2 If failure code [CA187] or [CA227] is also displayed, troubleshoot it first.
line
Damage or incorrect (loose) instal-
Check engine Bkup speed (cam) sensor directly as it may be damaged or
3 lation of engine Bkup speed (cam)
incorrectly (loosely) installed.
sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CAM SENSOR , and connect T-adapter to female
Defective power supply input to side.
4
engine Bkup speed sensor 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (1) Power sup-
Voltage 4.75 – 5.25 V
and (2) ply
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
each female side.
Open circuit in wiring harness Between ECM (female) (37) and CAM SENSOR Resis-
5 (Wire breakage or defective con- Max. 10 z
(female) (1) tance
tact of connector) Between ECM (female) (47) and CAM SENSOR Resis-
Max. 10 z
(female) (2) tance
Between ECM (female) (26) and CAM SENSOR Resis-
Max. 10 z
(female) (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
female side of either connector.
6 Short circuit in wiring harness Between ECM (female) (26) and (37) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (1) and (3) tance
Between ECM (female) (26) and (47) or CAM SEN- Resis-
Min. 100 kz
SOR (female) (2) and (3) tance
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM and CAM SENSOR, and connect T-adapter to
Ground fault in wiring harness female side of either connector.
7
(Contact with ground circuit)
Between ECM (female) (26) or CAM SENSOR Resis-
Min. 100 kz
(female) (3) and ground tance

GD555-5,GD655-5,GD675-5 40-223
(01)
Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

1. Turn starting switch to OFF position.

2. Disconnect connector CAM SENSOR, and connect T-adapter to female
Hot short circuit in wiring harness side.
8
(Contact with 24 V circuit) 3. Turn starting switch to ON position.
Between CAM SENSOR (female) (3) and ground Voltage Max. 1 V
Remove engine Bkup speed (cam) sensor, and check ring directly through
hole (H).
9 Loose speed sensing ring
a If speed sensing ring (B) is loosely installed, follow instructions given in the
"Reference" column.

Cause Procedure, measuring location, criteria and remarks

Defective engine Bkup speed
10
(cam) sensor
11 Defective engine controller
If no failure is found by above checks, engine Bkup speed (cam) sensor is
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor 40-2 4

40-224 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA778] Engine Bkup speed sensor error

Reference for troubleshooting for CA778 (107 5. Check mounting bolt (4) of camshaft ring (5) for
series engine) looseness.
Checking camshaft ring for loose installation 3 Mounting bolt (4): 10 ± 2 Nm
Remove the front cover and check the camshaft ring (DP): Dowel pin
for looseness.
a See "Removal and installation of front seal" in
Disassembly and assembly.
a Keep the front seal, liquid gasket LG-7 and front
seal tool (795-799-6400) on hand.
Removal 40-2 5
1. Remove the fan and fan belt. For details, see
"Removal and installation of front seal" in Disas-
sembly and assembly.
2. Remove damper assembly (1).
(DP): Dowel pin

Installation 40-2 5
a See the figures in "Removal" for installation.
1. Install front cover (2).
3 Front cover: Liquid gasket LG-7
2. Install the front seal according to the following
procedure. For details, see "Removal and instal-
lation of front seal" in Disassembly and
assembly.
1) Install front seal (3).
2) Install dowel pin (DP), and install the damper
assembly.
3. Remove front cover (2). 3) Install the fan and fan belt.
4. Remove front seal (3). 4) Install the cooling system assembly.
(RING): Ring

GD555-5,GD655-5,GD675-5 40-225
(01)
Troubleshooting by failurecode
Failure code [CA1633] KOMNET (CAN communication) error

Failure code [CA1633] KOMNET (CAN communication) error 40-2 6

Action code Failure code KOMNET (CAN communication) error
Failure
(Engine controller system)
E03 CA1633
q Engine controller detects communication error in KOMNET communication circuit between engine
Detail of failure
controller and transmission controller or machine monitor.

Action of con- q Controls engine in default mode, and holds state at the time of abnormally.
troller q If cause of failure disappears, system resets itself.

q Information may not be transmitted normally through CAN (KOMNET) communication lines and
Problem on
consequently machine may not operate normally. (Symptom depends on failed section.)
machine
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [DB2RKR].

40-226 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA1633] KOMNET (CAN communication) error

GD555-5,GD655-5,GD675-5 40-227
(01)
Troubleshooting by failurecode
Failure code [CA2185] Throttle sensor power supply high error

Failure code [CA2185] Throttle sensor power supply high error 40-2 8
Action code Failure code Throttle sensor power supply volaget is high
Failure
(Engine controller system)
E03 CA2185
Detail of failure q High voltage (5.25 V or higher) is detected in throttle sensor power supply circuit.

Action of con- q Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle
troller when pedal is depressed, and allows engine to run.

Problem on q Engine does not run at full throttle.

machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and turn starting switch to ON position.
Defective throttle sensor (acceler-
2 If this failure code is not displayed, throttle sensor is defective.
ator pedal)
a Other failure codes are displayed, too. This is because connector is discon-
nected. Ignore failure codes other than [CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2, EC3 and T9A, and connect T-adapters to
female sides of EC2 and EC3.
3 Short circuit in wiring harness Between EC2 (female) (22) and each pin other than Resis-
Min. 1 Mz
EC2 (22) tance
Resis-
Between EC2 (female) (22) and EC3 (female) (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and connect T-adapter to female side.
Hot short circuit in wiring harness
4 3. Turn starting switch to ON position.
(Contact with 24 V)
Between T9A (female) (1) and ground Voltage 4.75 – 5.25 V

1. Turn starting switch to OFF position.

2. Disconnect connector EC2 and connect T-adapter to female side.
5 Defective engine controller 3. Turn starting switch to ON position.

Between EC2 (female) (22) and (23) Voltage 4.75 – 5.25 V

40-228 GD555-5,GD655-5,GD675-5
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 Troubleshooting by failurecode
Failure code [CA2185] Throttle sensor power supply high error

Circuit diagram related to throttle sensor 40-2 9

GD555-5,GD655-5,GD675-5 40-229
(01)
Troubleshooting by failurecode
Failure code [CA2186] Throttle sensor power supply low error

Failure code [CA2186] Throttle sensor power supply low error 40-230
Action code Failure code Throttle sensor power supply voltage is low
Failure
(Engine controller system)
E03 CA2186
Detail of failure q Low voltage is detected in throttle sensor power supply circuit.

Action of con- q Sets throttle opening to 0% when accelerator pedal is not depressed and to 50% of full throttle
troller when accelerator pedal is depressed, and allows engine to run.

Problem on q Engine does not run at full throttle.

machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting"
tor
, and check them directly.
1. Turn starting switch to OFF position.
2. Disconnect connector T9A and turn starting switch to ON position.
Defective throttle sensor (acceler-
2 If this failure code is not displayed, throttle sensor is defective.
ator pedal)
a Other failure codes are displayed too. This is because that connector is dis-
connected. Ignore failure codes other than [CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between EC2 (female) (22) or T9A (female) (1) and Resis-
Min. 1 Mz
ground tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC2 and T9A, and connect T-adapter to female
4 Short circuit in wiring harness side of EC2.
Between EC2 (female) (22) and each pin other than Resis-
Min. 1 Mz
EC2 (22) tance
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness disconnected.

Between EC2 (female) (22) and (23) Voltage 4.75 – 5.25 V

40-230 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2186] Throttle sensor power supply low error

Circuit diagram related to throttle sensor 40-231

GD555-5,GD655-5,GD675-5 40-231
(01)
Troubleshooting by failurecode
Failure code [CA2249] Supply pump pressure low error 2

Failure code [CA2249] Supply pump pressure low error 2 40-232

Action code Failure code Common rail pressure is abnormality low.
Failure
(Engine controller system)
E03 CA2249
Detail of failure q Low pressure error (2) is detected in common rail circuit.
Action of con-
q Limits engine output and allows engine to run.
troller
q Starting performance is poor.
Problem on q Exhaust gas becomes black.
machine q Engine output lowers.
q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
q Common rail pressure can be checked by using monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
q Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [CA559] .

40-232 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2311] Abnormality in IMV (IMA) solenoid

Failure code [CA2311] Abnormality in IMV (IMA) solenoid 40-23

Action code Failure code IMV solenoid error
Failure
(Engine controller system)
E03 CA2311
Detail of failure q Resistance of supply pump actuator circuit is abnormally high or low.
Action of con-
q None in particular
troller
Problem on q Engine output drops.
machine q Centralized warning lamp lights up, and alarm buzzer sounds (activated by machine monitor).
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure codes [CA271] and [CA272].

GD555-5,GD655-5,GD675-5 40-233
(01)
Troubleshooting by failurecode
Failure code [CA2555] Intake heater relay open circuit

Failure code [CA2555] Intake heater relay open circuit 40-234

Action code Failure code Preheat relay has open circuit
Failure
(Engine controller system)
E01 CA2555
Detail of failure q Open circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Boost temperature detected by charge air temperature sensor (boost temperature sensor) can be
checked by using monitoring function (code: ENGINE 18500 CHG TEMP).
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor-
is below -4 °C)
mation
q Troubleshooting of this failure code covers circuit from engine controller to primary (coil) circuit of
preheat relay SP40.
q For troubleshooting of secondary circuit of heater relay and preheat relay SP40, see E-mode E-2.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect relay SP40, and connect T-adapter to male side.

Between SP40 (male) (1) and (2) Resistance 200 - 400 z

2 Defective preheat relay SP40
Open circuit or short circuit in wir- 2. Disconnect connector EC2 and connect T-adapter to female side.
3
ing harness
4 Open circuit in wiring harness
5 Short circuit in wiring harness
6 Defective engine controller
1. Turn starting switch to OFF position.
2. Replace relay SP40 with another one.
3. Turn starting switch to ON postion.
If this failure code disappears, original preheat relay SP40 is defective.
1. Turn starting switch to OFF position.
Between EC2 (female) (40) and ground
Resistance 200 - 400 z
a Relay SP40 coil resistance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of them.
Between EC2 (female) (40) and SP40 (female) (1) Resistance Max. 1 z
Between SP40 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of EC2.
a Check by using multimeter in continuity mode.
Between EC2 (female) (40) and each pin other than No continuity
(40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-234 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2555] Intake heater relay open circuit

Circuit diagram related to preheat relay 40-235

GD555-5,GD655-5,GD675-5 40-235
(01)
Troubleshooting by failurecode
Failure code [CA2556] Intake heater relay short circuit

Failure code [CA2556] Intake heater relay short circuit 40-236

Action code Failure code Preheat relay has short circuit
Failure
(Engine controller system)
E01 CA2556
Detail of failure q Short circuit is detected in drive circuit (primary circuit) of preheat relay.
Action of con-
q None in particular
troller
Problem on q Intake air heater does not work in auto preheating (degraded starting performance at low temper-
machine ature and emission of white smokes)
q Boost temperature detected by charge air temperature sensor (boost temperature sensor) can be
checked by using monitoring function (code: ENGINE 18500 CHG TEMP).
q Method of reproducing failure code: Turn starting switch to ON position (when boost temperature
Related infor-
is below -4 °C)
mation
q Troubleshooting of this failure code covers circuit from engine controller to primary (coil) circuit of
preheat relay SP40.
q For troubleshooting of secondary circuit of heater relay and preheat relay SP40, see E-mode E-2.

Cause Procedure, measuring location, criteria and remarks

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring harness connec-
1 of "Check before troubleshooting" of "Related information to troubleshooting",
tor
and check them.
1. Turn starting switch to OFF position.
2. Disconnect relay SP40, and connect T-adapter to male side.

Between SP40 (male) (1) and (2) Resistance 200 - 400 z

2 Defective preheat relay SP40
3 Ground fault in wiring harness
4 Short circuit in wiring harness
5 Defective engine controller
1. Turn starting switch to OFF position.
2. Replace relay SP40 with another one.
3. Turn starting switch to ON position.
If this failure code disappears, original preheat relay SP40 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of one of them.
Between EC2 (female) (40) or SP40 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and relay SP40, and connect T-adapter to
female side of EC2.
a Check by using multimeter in continuity mode.
Between EC2 (female) (40) and each pin other than No continuity
(40) (No sound is heard)
If no failure is found by above checks, engine controller is defective. (Since
this is internal failure, troubleshooting cannot be performed.)

40-236 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [CA2556] Intake heater relay short circuit

Circuit diagram related to preheat relay 40-237

GD555-5,GD655-5,GD675-5 40-237
(01)
Troubleshooting by failurecode
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness

Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit
in wiring harness 40-238
Action code Failure code Backup lamp relay: Open circuit, hot short circuit in wiring har-
Failure ness
E01 D160KA (Transmission controller system)
q Transmission controller cannot activate backup lamp relay due to open circuit in backup lamp relay
primary circuit (coil side).
Detail of failure
q Backup lamp relay remains activated due to hot short circuit in backup lamp relay primary circuit
(coil side) regardless of output of transmission controller to backup lamp relay.
Action of con-
q Stops output to backup lamp relay.
troller
q Backup lamp does not light up (open circuit).
q Backup buzzer does not sound (open circuit).
Problem on q Backup lamp does not go off (hot short circuit).
machine q Backup buzzer does not stop (hot short circuit).
q Output state (ON/OFF) to backup lamp relay can be checked with monitoring function (Code:
TRANSMISSON1-40951-D-OUT-19)
Related infor- q Method of reproducing failure code: Turn starting switch to ON position and operate gear shift le-
mation ver.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to male side.

Between TM42 (male) (1) and (2) Resistance 200 - 400 z

Defective backup lamp relay 1. Turn starting switch to OFF position.

1
(TM42) (internal failure)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Hot short circuit in wiring harness
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
2. Replace backup lamp relay (TM42) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Set gear shift lever to R (reverse) position.
If condition becomes normal, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (18) and ground
Resistance 200 - 400 z
(resistance of backup lamp relay coil)
a If no abnormality is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM42, and connect T-adapters to female
side of them.
3. Turn starting switch to ON position.
Between TM42 (female) (1) and TM41 (female) (18) Resistance Max. 1 z
Between TM42 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
Between TM42 (female) (2) and ground Voltage Max. 1 V

40-238 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D160KA] Backup lamp relay: Open circuit, hot short circuit in wiring harness

Cause Procedure, measuring location, criteria and remarks

If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4 Defective transmission controller 4. Operate gear shift lever and troubleshoot.
Gear shift lever:
Voltage 20–30 V
Between TM41 (female) R (Reverse)
(18) and (31) Gear shift lever:
Voltage Max. 1 V
Other than the above

Circuit diagram related to backup lamp relay 40-239

GD555-5,GD655-5,GD675-5 40-239
(01)
Troubleshooting by failurecode
Failure code [D160KB] Backup lamp relay: Ground fault

Failure code [D160KB] Backup lamp relay: Ground fault 40-240

Action code Failure code Backup lamp relay: Ground fault
Failure
(Transmission controller system)
E01 D160KB
q Transmission controller cannot activate backup lamp relay due to ground fault in backup lamp relay
Detail of failure
primary circuit (coil side).
Action of con- q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller OFF position.
Problem on q Backup lamp does not light up.
machine q Backup buzzer does not sound.
q Method of reproducing failure code: Turn starting switch to ON position and operate gear shift le-
Related infor- ver.
mation q Output state (ON/OFF) to backup lamp relay can be checked with monitoring function (Code:
TRANSMISSON1-40951-D-OUT-19)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to male side.

Between TM42 (male) (1) and (2) Resistance 200 - 400 z

Defective backup lamp relay 1. Turn starting switch to OFF position.

1
(TM42) (internal failure)
Ground fault in wiring harness
2
(Contact with ground circuit)
3 Defective transmission controller
2. Replace backup lamp relay (TM42) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Set gear shift lever to R (reverse) position.
If condition becomes normal, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM42, and connect T-adapter to female
side of either of them.
Between TM42 (female) (1) and ground, or
Resistance Min. 1 Mz
between TM41 (female) (18) and ground
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate gear shift lever and troubleshoot.
Gear shift lever:
Voltage 20–30 V
Between TM41 (female) R (Reverse)
(18) and (31) Gear shift lever:
Voltage Max. 1 V
Other than the above

40-240 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D160KB] Backup lamp relay: Ground fault

Circuit diagram related to backup lamp relay 40-241

GD555-5,GD655-5,GD675-5 40-241
(01)
Troubleshooting by failurecode
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault

Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault40-242
For machine equipped with differential lock

Action code Failure code Differential lock relay: Open circuit or ground fault
Failure
(Transmission controller system)
E01 D19KKZ
Detail of failure q Differential lock relay primary circuit (coil side) has open circuit or ground fault.
q Stops output to differential lock-up relay.
Action of con- q When cause of failure is open circuit, system resets itself if cause of failure disappears.
troller q When cause of failure is ground fault, system does not reset itself even if cause of failure disap-
pears until starting switch is turned to OFF position.
Problem on
q Differential lock does not work correctly.
machine
q Output state (ON/OFF) to differential lock relay can be checked with monitoring function.
Related infor- (Code: TRANSMISSION1-31903-DIFF RELAY)
mation q Method of reproducing failure code: Turn starting switch to ON position and turn on differential lock
switch.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM43 and connect T-adapter to male side.

Between TM43 (male) (1) and (2) Resistance 200 - 400 z

Defective differetial lock relay 1. Turn starting switch to OFF position.

1
(TM43) (internal defect)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
2. Replace differential lock relay (TM43) with another relay of the same model
(5-pin).
3. Turn starting switch to ON position.
4. Turn on differential lock switch.
If condition becomes normal, original differential lock-up relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (8) and ground
Resistance 200 - 400 z
(resistance of differential lock relay coil)
a If no abnormality is found by above check, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM43, and connect T-adapters to
female side of them.
3. Turn starting switch to ON position.

Between TM43 (female) (1) and TM41 (female) (8) Resistance Max. 1 z

Between TM43 (female) (2) and ground Resistance Max. 1 z

1. Turn starting switch to OFF position.

Ground fault in wiring harness
3 side of either of them.
(Contact with ground circuit)
4 Short circuit in wiring harness
2. Disconnect connectors TM41 and TM43, and connect T-adapter to female
Between TM43 (female) (1) and ground, or
Resistance Min. 1 Mz
between TM41 (female) (8) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and TM43, and connect T-adapter to female
side of TM43.
3. Turn starting switch to ON position.
Between TM43 (female) (1) and (2) Resistance Min. 1 Mz

40-242 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D19KKZ] Differential lock relay: Open circuit, ground fault

Cause Procedure, measuring location, criteria and remarks

6 Defective transmission controller
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate differential lock switch and troubleshoot.
Differential lock switch:
Voltage 20 – 30 V
Between TM41 (female) OFF
(8) and (31) Differential lock switch:
Voltage Max. 1 V
ON

Circuit diagram related to differential lock relay 40-243

GD555-5,GD655-5,GD675-5 40-243
(01)
Troubleshooting by failurecode
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state

Failure code [D5ZHL6] C terminal signal: Signal does not match to actual
engine state 40-24
Action code Failure code C terminal signal: Signal does not match to actual engine state,
Failure running or stop.
E01 D5ZHL6 (Machine monitor system)
q Wire breakage or ground fault in C terminal circuit (engine speed is more than 500 rpm & alternator
R terminal has some voltage & No record that C terminal is 24 V)
Detail of failure
(Although engine is started, machine monitor can not recognize that starting switch has been set
to START position.)
Action of8* con- q None in particular.
troller q If cause of failure disappears, system resets itself.
Problem on
machine
q Since engine started, C terminal signal of starting switch between starting switch and starting motor
is regarded as normal.
q Normal startup of engine indicates that voltage of C terminal of starting switch is applied to starting
Related infor-
motor. Therefore, defective starting switch or ground fault of wiring is not probable as the cause.
mation
q Input state (ON/OFF) to machine monitor from C terminal of starting switch can be checked with
monitoring function (Code: 40921, D-IN-0).
q Method of reproducing failure code: Turn starting switch to START position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Turn starting switch sequentially to OFF, ON and START positions, and
troubleshoot.
Defective starting switch (internal Starting switch:
1 Voltage 20–30 V
failure) START
Between ST8 and
ground Starting switch:
OFF, ON Voltage Max. 1 V

1. Turn starting switch to OFF position.

Open circuit in wiring harness 2. Disconnect connectors TEL and FP1, and connect T-adapter to male and
2 (Wire breakage or defective con- female side.
tact of connector)
Between TEL (male) (8) and FP1 (female) (7) Resistance Max. 1 z
If no abnormality is found by above checks, machine monitor is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch sequentially to OFF, ON and START positions, and
3 Defective machine monitor troubleshoot.
Starting switch:
START Voltage 20–30 V
Between FP1 (female)
(7) and (3) Starting switch:
OFF, ON Voltage Max. 1 V

40-244 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [D5ZHL6] C terminal signal: Signal does not match to actual engine state

Circuit diagram related to C terminal signal 40-245

GD555-5,GD655-5,GD675-5 40-245
(01)
Troubleshooting by failurecode
Failure code [DAFRKR] CAN communication failure (monitor panel)

Failure code [DAFRKR] CAN communication failure (monitor panel) 40-246

Action code Failure code CAN communication is disabled (with machien nonitor)
Failure
(Transmission controller system)
E03 DAFRKR
q Because CAN communication is disabled, transmission controller is not capable of getting infor-
Detail of failure
mation from machine monitor.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Uses CAN information obtained from machine monitor just before failure occurs.
troller
q If cause of failure disappears, system resets itself.
Problem on
q Machine monitor does not display correct information.
machine
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is displayed on machine monitor by CAN communication. Accordingly, if CAN com-
munication of machine monitor fails, code [DAFRKR] is not displayed on machine monitor and it
Related infor-
can be observed only through KOMTRAX system.
mation
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective power supply to machine
1 Perform troubleshooting for E mode, "E-3".
monitor
2 Defective CAN communication Perform troubleshooting for cause 2 and after of failure code [DAQRKR].

40-246 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAFRKR] CAN communication failure (monitor panel)

GD555-5,GD655-5,GD675-5 40-247
(01)
Troubleshooting by failurecode
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)

Failure code [DAQ0KK] Transmission controller: Power supply voltage

low error (input) 40-248
Action code Failure code Transmission controller: Power supply voltage drops (input)
Failure
(Transmission controller system)
E03 DAQ0KK
Detail of failure q While engine running, the voltage of controller power supply circuit becomes 18 V or below.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps gear shift to NEUTRAL position.
troller q If cause of failure disappears, system resets itself (however, gear shift is kept NEUTRAL until gear
shift lever is set to NEUTRAL position).
Problem on
q Machine stops.
machine
Related infor-
q Method of reproducing failure code: Start engine.
mation

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuses (holder If slow-blow fuse is broken, circuit probably has ground fault. In this case,
1
1, 30A)
2 Defective fuse (FB1, No.3)
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
perform troubleshooting for cause 3 first.
If fuse has blown out, the circuit probably has ground fault. In this case, per-
form troubleshooting for cause item 3 first.
q Ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
a Looseness or rust on ground terminal ET89
Between TM41 (female) (21) and ground, and
Resistance Max. 1 z
between (31) - (33) and ground
1. Turn starting switch to OFF position.
2. Set disconnect swithc to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
4. Set disconnect switch to ON.

Between TM41 (female) (1) and (21) Voltage 20–30 V

Between TM41 (female) (11) and (32) Voltage 20–30 V

a If slow-blow fuse or fuse is not blown, this check is not required.

1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Set disconnect switch to OFF.
4
(Contact with ground circuit) 3. Disconnect connector TM41 and connect T-adapter to female side.

Between TM41 (female) (1) and ground Resistance Min. 1 Mz

5 Defective alternator
6 Defective transmission controller
Perform troubleshooting for failure code [AB00MA].
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between TM41 (1) and (21), and between TM41 (1)
Voltage 20–30 V
and (31)
Between TM41 (11) and (32), and between TM41
Voltage 20–30 V
(11) and (33)

40-248 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ0KK] Transmission controller: Power supply voltage low error (input)

Circuit diagram related to transmission controller power supply 40-249

GD555-5,GD655-5,GD675-5 40-249
(01)
Troubleshooting by failurecode
Failure code [DAQOKT] Transmission controller: Non-volatile memory error

Failure code [DAQOKT] Transmission controller: Non-volatile memory

error 40-250
Action code Failure code Transmission controller: Non-volatile memory error
Failure
(Transmission controller system)
E01 DAQ0KT
Detail of failure q Information in the ROM (non-volatile memory) of transmission controller is abnormal.
q Sets memory data on ROM (non-volatile memory) to default values.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
q Transmission shifting feel may become bad.
Problem on
q Feel of inching may degrade.
machine
q Travel speed in R8 travel may deviate from the set value.
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Since this is internal failure, troubleshooting cannot be performed.
1 Defective transmission controller (When recognizable problem does not appear on machine, you may use con-
troller after performing initial setting and adjustment for it.)

40-250 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQOKT] Transmission controller: Non-volatile memory error

GD555-5,GD655-5,GD675-5 40-251
(01)
Troubleshooting by failurecode
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)

Failure code [DAQ2KK] Transmission controller load power line: Power

supply voltage drop (input) 40-252
Action code Failure code Transmission controller: Actuator solenoid power supply voltage
Failure drop (input)
E03 DAQ2KK (Transmission controller system)
q When starting switch is turned to ON position (with engine stopped or running), voltage of solenoid
Detail of failure
power supply circuit is 18 V or lower though power supply circuit voltage of controller is normal.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains gear speed in Neutral position.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Machine stops.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (holder 1, If slow-blow fuse is broken, circuit probably has ground fault. In this case, per-
1
60 A)
2 Defective fuses (FB1, No.11)
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
form troubleshooting for cause 3 first.
If fuse blows, circuit may have ground fault. In this case, perform trouble-
shooting for cause 3 first.
q Ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
a Looseness or rust on ground terminal ET89
Between ground and TM41 (female) (21), (31) to
Resistance Max. 1 z
(33)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.
4. Set disconnect switch to ON.
5. Turn starting switch ON.

Between TM41 (female) (2) and (31) Voltage 20 – 30 V

Between TM41 (female) (12) and (33), between

Voltage 20 – 30 V
(22) and (33)

Ground fault in wiring harness
4
(Contact with ground circuit)
a If slow-blow fuse or fuse is not blown out, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41 and connect T-adapter to female side.

Between TM41 (female) (2) and ground Resistance Min. 1 Mz

5 Defective alternator Perform troubleshooting for failure code [AB00MA].

40-252 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ2KK] Transmission controller load power line: Power supply voltage drop (input)

Cause Procedure, measuring location, criteria and remarks

6 Defective transmission controller
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.

Between TM41 (2) and (21), between (2) and (31) Voltage 20 – 30 V

Between TM41 (12) and (32) Voltage 20 – 30 V

Between TM41 (22) and (33) Voltage 20 – 30 V

Circuit diagram related to transmission controller power supply 40-253

GD555-5,GD655-5,GD675-5 40-253
(01)
Troubleshooting by failurecode
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement

Failure code [DAQ9KQ] Transmission controller model selection: Model

selection signal disagreement 40-254
Action code Failure code Transmission controller model selection: Model selection signal
Failure disagreement
E03 DAQ9KQ (Machine monitor system)
q Model setting ID on controller is not correct.
q Model information obtained from machine monitor disagrees with model information stored on con-
Detail of failure
troller.
q Information of model stored on controller is one for which model setting is disabled.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Even if failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective transmission controller Since this is internal failure, troubleshooting cannot be performed.

3 Defective machine monitor Since this is internal failure, trouble shooting cannot be performed.

40-254 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQ9KQ] Transmission controller model selection: Model selection signal disagreement

GD555-5,GD655-5,GD675-5 40-255
(01)
Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Failure code [DAQRKR] Transmission controller CAN communication:

Communication error 40-256
Action code Failure code Transmission controller cannot communicate through CAN
Failure
(Machine monitor system)
E03 DAQRKR
Detail of failure q In CAN communication, machine monitor cannot recognize transmission controller.
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on q Machine monitor may not operate normally or may not display correct information.
machine q Machine monitor uses values obtained through CAN just before failure occurs.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q If failure code [DB2RKR] is also displayed, engine controller may be defective. In such case, per-
Related infor- form troubleshooting for [DB2RKR] first.
mation q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since CAN communication line signal in operation is pulse voltage, it cannot be measured by using
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective power supply to trans-
1 Perform troubleshooting for failure codes [DAQ0KK] and [DAQ2KK] first.
mission controller
Defective CAN terminating resistor
2 (Internal open or short circuit in
wiring)
Open circuit or short circuit in wir-
3 to see if there is short circuit between wiring harnesses or in controller.
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connectors CAN1 and FP2, and connect T-adapter to male
side.
Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
Between FP2 (male) (6) and (3) Resistance 120 ± 12 z
qCAN communication line
a Machine monitor also has 120 z CAN terminating resistor. Since 120 z re-
sistors are connected in parallel, if paralled resistance measured at con-
nector of controller other than machine monitor is 60 z, wiring harness is
not open.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors of EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of connector disconnected.
a If connectors are short-circuited (resistance between terminals is 1 z or
below), disconnect all of EC2, TM40, L80, CAN1 and FP2, and check again
Approx.
Between EC2 (female) (46) and (47) Resistance
60 z
Approx.
Between TM40 (female) (32) and (22) Resistance
60 z
Approx.
Between L80 (female) (8) and (7) Resistance
60 z
Approx.
Between CAN1 (female) (A) and (B) Resistance
120 z
Approx.
Between FP2 (female) (3) and (1) Resistance
120 z

40-256 GD555-5,GD655-5,GD675-5
(01)

Failure code [DAQRKR] Transmission controller CAN communication: Communication error
Cause
Isolating open-circuited wiring har- Between TM40 (female) (22) and FP2 (female) (3) Resistance
ness
4 Between TM40 (female) (32) and EC2 (female) (46) Resistance
(Wire breakage or defective con-
tact of connector)
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
Ground fault of wiring harness
6
(contact with ground circuit)
GD555-5,GD655-5,GD675-5
(01)
Troubleshooting by failurecode
Procedure, measuring location, criteria and remarks
a If check result of cause 3 is normal, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of each connector.
Between TM40 (female) (32) and FP2 (female) (6),
Resistance Max. 1 z
between (32) and (1)
Max. 1 z
Max. 1 z
Between TM40 (female) (22) and EC2 (female) (47) Resistance Max. 1 z
Between TM40 (female) (32) and L80 (female) (8) Resistance Max. 1 z
Between TM40 (female) (22) and L80 (female) (7) Resistance Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A) Resistance Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect swithc to OFF.
2. Insert T-adapter into connectors TM41, L80, FP1 and EC2.
3. Turn starting switch to ON position, and set disconnect switch to ON.
Between TM41 (14) and (31), or between (24) and
Voltage 20 – 30 V
(31)
Between L80 (26) and (37), or between (36) and
Voltage 20 – 30 V
(37)
Between FP1 (1) and (3), or between (2) and (3) Voltage 20 – 30 V
Between EC2 (39) and ground Voltage 20 – 30 V
q CAN communication line
a If check result of cause 3 is normal (there is no open circuit), measure at
only 1 place.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM40, L80, FP2 and EC2, and connect T-adapter
to female side of one of them.
Between ground and either one of TM40 (female)
(32), L80 (female) (8), FP2 (female) (1), (6) and Resistance Min. 1 Mz
EC2 (female) (46)
Between ground and either one of TM40 (female)
(22), L80 (female) (7), FP2 (female) (3), (6) and Resistance Min. 1 Mz
EC2 (female) (47)
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41, L80 and FP1, and connect T-adapter to
female side of one of them.
3. Disconnect connector EC2 and connect T-adapter to female side.
Between ground and either one of TM41 (female)
(14), (24), L80 (female) (26), (36) and FP1 (female) Resistance Min. 1 Mz
(1), (2)
Between EC2 (female) (39) and ground Resistance Min. 1 Mz
40-257
Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

a If check result of cause 3 is normal (there is no open circuit), measure at
only 1 place in each of the above.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connector to either of TM40, L80, FP2 and EC2.
3. Set disconnect switch to ON.
Short circuit or hot short circuit 4. Turn starting switch ON.
7 a Since voltages of CAN H and CAN L are 2.5 ± 1 V even while communi-
(Contact with 24 V circuit)
cation is continued, they are judged to be normal if they are 1 - 4 V.
Between ground and either one of TM40 (32), L80
Voltage 1–4V
(8), FP2 (1), (6) and EC2 (46)
Between ground and either one of TM40 (22), L80
Voltage 1–4V
(7), FP2 (3) and EC2 (47)
If cause is not found by above checks and another failure code related to CAN
communication such as [DB2RKR] is not displayed, identify which controller
is defective according to following procedure.
q Step 1
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect KOMTRAX controller (connector L80).
3. Turn starting switch to ON position, and set disconnect switch to ON.
Defective KOMTRAX
YES
controller
Defective engine controller, trans-
Has this failure code disappeared? Defective transmission
8 mission controller or KOMTRAX
NO controller or engine con-
controller
troller
q Step 2
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect engine controller (connector EC2).
3. Turn starting switch to ON position, and set disconnect switch to ON.
Defective transmission
NO
controller
Is failure code [DB2RKR] displayed?
Defective engine control-
YES
ler
If no abnormality is found by above diagnoses, machine monitor is defective.
9 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

40-258 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DAQRKR] Transmission controller CAN communication: Communication error

Circuit diagram related to CAN communication circuit 40-259

GD555-5,GD655-5,GD675-5 40-259
(01)
Troubleshooting by failurecode
Failure code [DAQRMA] Transmission controller option setting: Malfunction

Failure code [DAQRMA] Transmission controller option setting:

Malfunction 40-260
Action code Failure code Transmission controller option setting: Malfunction
Failure
(Machine monitor system)
E03 DAQRMA
q Option setting ID on controller is not correct..
Detail of failure q Differential setting information obtained from machine monitor disagrees with differential setting in-
formation stored on controller.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Even if failure disappears, system does not reset itself until starting switch is turned OFF.
Problem on
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation

Cause Procedure, measuring location, criteria and remarks

1 Defective transmission controller Since this is an internal defect, it cannot be diagnosed.

40-260 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Failure code [DB2RKR] Engine controller CAN communication: Commu-

nication error 40-261
Action code Failure code Transmission controller cannot communicate through CAN
Failure
(Transmission controller system)
E03 DB2RKR
Detail of failure 1)Transmission controller cannot recognize engine controller in CAN communication.
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on q Machine monitor may not function normally or may not display correct information.
machine q Machine monitor uses values obtained through CAN just before failure occurs.
q Method of reproducing failure code: Turn starting switch to ON position.
q Start of CAN communication is notified to each controller by ACC signal from starting switch.
q Failure code is sent to machine monitor by CAN communication. Accordingly, if failure code
[DB2RKR] is displayed on machine monitor, CAN communication between transmission controller
Related infor- and machine monitor is normal.
mation That is, there cannot be short circuit, ground fault or hot short in CAN communication line.
q Since each controller and machine monitor receive power from battery directly, they are kept ON
even while starting switch is OFF position.
q Since signal of CAN communication line in operation is pulse voltage, it cannot be measured with
multimeter.

Cause Procedure, measuring location, criteria and remarks

Defective fuse for engine controller
1 If fuse blows, short circuit is probably occurred in controller.
or fuse (4) of FB2
Defective engine controller
2
(Internal short circuit)
Improper power supply to engine
3
controller
Defective fuse for ACC of engine
4
controller or fuse (15) of FB1
Defective CAN terminating resistor
5 (Internal open circuit or short cir-
cuit)
a If fuse does not blow, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC3 and connect T-adapter to male side.
a Measured value: approx. 9 – 20 kz
a If measured resistance is 10 z or below, engine controller is defective (in-
ternal short circuit).
Between EC3 (male) (3) and (1) Resistance Min. 10 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC3 and connect T-adapter to female side.
3. If fuse blows, replace it.
4. Set disconnect switch to ON.
a If result is abnormal, perform troubleshooting for failure code [DB2RKR]
(Detail of failure 2).
Between EC3 (female) (3) and (1), or between (3)
Voltage 20 – 30 V
and ground
Between EC3 (female) (4) and (2), or between (4)
Voltage 20 – 30 V
and ground
If fuse blows, circuit may have ground fault. In this case, perform trouble-
shooting for cause 9 first.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors CAN1 and FP2, and connect T-adapter to male
side.
Between CAN1 (male) (A) and (B) Resistance 120 ± 12 z
Between FP2 (male) (6) and (3) Resistance 120 ± 12 z

GD555-5,GD655-5,GD675-5 40-261
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error
Cause
Open circuit or short circuit in wir-
6 to see if there is short circuit between wiring harnesses or in controller.
ing harness
Isolating open-circuited wiring har- Between TM40 (female) (22) and FP2 (female) (3) Resistance
ness
7 Between TM40 (female) (32) and EC2 (female) (46) Resistance
(Wire breakage or defective con-
tact of connector)
Open circuit in wiring harness
8 (Wire breakage or defective con-
tact of connector)
Ground fault of wiring har-
9 3. Disconnect connector EC2 and connect T-adapter to female side.
ness(Contact with ground circuit)
10 Defective engine controller
40-262
Procedure, measuring location, criteria and remarks
q CAN communication line
a There is 120 z CAN terminating resistor inside machine monitor, too.
Since 120 z resistor is connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is com-
bined resistance, wiring harness is not open cricuited.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect one of connectors of EC2, TM40, L80, CAN1 and FP2, and
connect T-adapter to female side of connector disconnected.
a If connectors are short-circuited (resistance between terminals is1 z or be-
low), disconnect all of EC2, TM40, L80, CAN1 and FP2, and check again
Approx.
Between EC2 (female) (46) and (47) Resistance
60 z
Approx.
Between TM40 (female) (32) and (22) Resistance
60 z
Approx.
Between L80 (female) (8) and (7) Resistance
60 z
Approx.
Between CAN1 (female) (A) and (B) Resistance
120 z
Approx.
Between FP2 (female) (3) and (1) Resistance
120 z
a If check result of cause 6 is normal, this check is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC2, TM40, L80, CAN1 and FP2, and connect
T-adapter to female side of each connector.
Between TM40 (female) (32) and FP2 (female) (6),
Resistance Max. 1 z
between (32) and (1)
Max. 1 z
Max. 1 z
Between TM40 (female) (22) and EC2 (female) (47) Resistance Max. 1 z
Between TM40 (female) (32) and L80 (female) (8) Resistance Max. 1 z
Between TM40 (female) (22) and L80 (female) (7) Resistance Max. 1 z
Between EC2 (female) (46) and CAN1 (female) (A) Resistance Max. 1 z
Between EC2 (female) (47) and CAN1 (female) (B) Resistance Max. 1 z
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connectors TM41, L80, FP1 and EC2.
3. Set disconnect switch to ON, and turn starting switch to ON position.
Between TM41 (14) and (31), or between (24) and
Voltage 20 – 30 V
(31)
Between L80 (26) and (37), or between (36) and
Voltage 20 – 30 V
(37)
Between FP1 (1) and (3), or between (2) and (3) Voltage 20 – 30 V
Between EC2 (39) and ground Voltage 20 – 30 V
q ACC signal from starting switch
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41, L80 and FP1, and connect T-adapter to
female side of one of them.
Between ground and either one of TM41 (female)
(14), (24), L80 (female) (26), (36) and FP1 (female) Resistance Min. 1 Mz
(1), (2)
Between EC2 (female) (39) and ground Resistance Min. 1 Mz
If no abnormality is found by above diagnosis, engine controller is defective.
(Since this is internal failure, troubleshooting cannot be performed.)
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

If no abnormality is found by above diagnoses, transmission controller is
11 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to CAN communication circuit 40-263

GD555-5,GD655-5,GD675-5 40-263
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error
Detail of failure 2) Defective power supply circuit to engine controller
Cause
Loose or corroded battery termi-
1
nals or ground terminal
Defective wiring harness connec-
2 of "Check before troubleshooting" of "Related information of troubleshooting",
tor
3 Defective battery voltage
Defective relay for engine control-
4
ler power supply
5 Defective diode (SP36, SP37)
Open circuit in wiring harness
6 (Wire breakage or defective con-
tact of connector)
40-264
Procedure, measuring location, criteria and remarks
Check battery terminals and ground (ET103) terminal directly for loose and
corrosion.
See descriptions of wiring harness and connectors in "c: Electrical equipment"
and check them.
1. Turn starting switch to OFF position.
2. Start engine and perform diagnosis.
Between (+) and (-) terminals of battery (2 pieces) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Exchange relays (SP30) for engine controller power supply with another
relay.
3. Turn starting switch to ON position.
If this failure code goes off, original relay SP30 is defective.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Remove diodes SP36 and SP37 and connect T-adapter to male side.
a Check the continuity in diode range.
Between SP36 (male) (2) (+) and (1) (-) Continuity
Between SP36 (male) (1) (+) and (2) (-) No continuity
Between SP37 (male) (2) (+) and (1) (-) Continuity
Between SP37 (male) (1) (+) and (2) (-) No continuity
q Ground circuit
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors EC2, EC3 and SP30, and connect T-adapter to
each female side of them.
Between EC3 (female) (1) and ground
Resistance Max. 1 z
a Rusted or loose ground terminal (ET103)
Between EC3 (female) (2) and ground
Resistance Max. 1 z
a Rusted or loose ground terminal (ET103)
Between EC2 (female) (33) and SP36 (6) Resistance Max. 1 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapters into SP37, SP30, and EC3.
3. Set disconnect switch to ON, and turn starting switch to ON position.
a Check to where 24 V is supplied to identify open place.
Between SP37 (2) and ground Voltage 20 – 30 V
Between SP37 (1) and ground Voltage 20 – 30 V
Between SP30 (5) and (6) Voltage 20 – 30 V
Between SP30 (1) and (6) Voltage 20 – 30 V
Between SP30 (3) and (6) Voltage 20 – 30 V
Between EC3 (3) and (2) Voltage 20 – 30 V
Between EC3 (4) and (1) Voltage 20 – 30 V
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors SP30, SP37 and EC3, and connect T-adapter to
each female side of them.
Between SP37 (female) (1) and ground Resistance Min. 1 Mz
Ground fault in wiring harness
7 Between EC3 (female) (3) and ground Resistance Min. 1 Mz
(Contact with ground circuit)
Between EC3 (female) (4) and ground Resistance Min. 1 Mz
Between ground and SP30 (1), (3) Resistance Min. 1 Mz
Between ground and SP30 (2), (4) Resistance Min. 1 Mz
If no abnormality is found by above diagnosis, engine controller is defective.
8 Defective engine controller
(Since this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-265
(01)
Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

Circuit diagram related to engine controller power supply 40-26

40-266 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DB2RKR] Engine controller CAN communication: Communication error

GD555-5,GD655-5,GD675-5 40-267
(01)
Troubleshooting by failurecode
Failure code [DD1NLD] Fan reverse switch signal: Short circuit

Failure code [DD1NLD] Fan reverse switch signal: Short circuit 40-268
Action code Failure code Fan reverse switch circuit has short circuit
Failure
(Transmission controller system)
E01 DD1NLD
q Since fan manual reverse switch system has hot short circuit, fan reverse switch stay in ON posi-
Detail of failure
tion. (When it stays over 30 second, state is judged as failure.)
Action of con-
q None in particular.
troller
Problem on
q Fan keeps rotating reverse.
machine
q Input from fan manual reverse switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-40905-D-IN-6)
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector TM31 and connect T-adapter to male side.
Defective fan reverse switch (inter-
1 Fan reverse switch: ON Resistance Max. 1 z
nal short circuit) Between TM31 (male)
(5) and (6)
Fan reverse switch: OFF Resistance Min. 1 Mz

1. Turn starting switch to OFF position.

Hot short circuit in wiring harness 2. Disconnect connector TM31 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TM31 (female) (6) and ground Voltage Max. 1 V
If cause is not found by the above checks, transmission controller is defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3 Defective transmission controller 3. Turn starting switch to ON position.

Fan reverse switch: ON Voltage 20 – 30 V

Between TM39 (12) and
(4)
Fan reverse switch: OFF Voltage Max. 1 V

40-268 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1NLD] Fan reverse switch signal: Short circuit

Circuit diagram related to fan reverse switch 40-269

GD555-5,GD655-5,GD675-5 40-269
(01)
Troubleshooting by failurecode
Failure code [DD1PKB] RPM set switch power supply short circuit

Failure code [DD1PKB] RPM set switch power supply short circuit 40-270
Action code Failure code RPM set switch power supply short circuit
Failure
(Transmission controller system)
E03 DD1PKB
q "SET" and "RESUME" functions of RPM set switch become active simultaneously.
Detail of failure
q When operating RPM set switch, both “SET” and “RESUME” functions are kept active.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Sets RPM set mode to "OFF".
Problem on
q RPM set mode is kept “OFF” and RPM set function is disabled.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors TM38 and TM41, and connect T-adapter to female
side of TM41.
Wiring harness between TM41 (female) (2) and
1 Short circuit in wiring harness Resistance Min. 1 Mz
(20)
Between TM41 (female) (2) and (30) Resistance Min. 1 Mz
Between TM41 (female) (20) and (30) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM38.
3. Insert T-adapter into connector TM41.
Hot short circuit in wiring harness
2 4. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between TM41 (female) (20) and (21) Voltage Max. 1 V
Between TM41 (female) (30) and (31) Voltage Max. 1 V
If no abnormality is found in cause 1 and 2, transmission controller may be
3 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-270 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1PKB] RPM set switch power supply short circuit

Circuit diagram related to RPM set switch and RPM set mode switch 40-271

GD555-5,GD655-5,GD675-5 40-271
(01)
Troubleshooting by failurecode
Failure code [DD1QKB] RPM set mode switch short circuit

Failure code [DD1QKB] RPM set mode switch short circuit 40-272
Action code Failure code RPM set mode switch short circuit
Failure
(Power train controller system)
E03 DD1QKB
q "AUTO" and "MANUAL" functions of RPM set mode switch are turned on simultaneously.
Detail of failure
q When operating set mode switch, both “AUTO” and “MANUAL” functions are kept ON.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Sets RPM set function to "OFF" mode.
Problem on
q RPM set mode is kept “OFF” and RPM set function is disabled.
machine
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1 Short circuit in wiring harness
Hot short circuit in wiring harness
2
(Contact with 24 V circuit)
3 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors TM37 and TM39, and connect T-adapter to female
side of TM37.
Between TM37 (female) (4) and (5) Resistance Min. 1 Mz
Between TM37 (female) (4) and (6) Resistance Min. 1 Mz
Between TM37 (female) (5) and (6) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM37 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between TM37 (female) (4) and (2) Voltage Max. 1 V
Between TM37 (female) (6) and (2) Voltage Max. 1 V
If no abnormality is found in cause 1 and 2, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-272 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DD1QKB] RPM set mode switch short circuit

Circuit diagram related to RPM switch and RPM mode switch 40-273

GD555-5,GD655-5,GD675-5 40-273
(01)
Troubleshooting by failurecode
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error

Failure code [DDB6L4] Transmission gearshift lever: Parking brake

signal error 40-274
Action code Failure code Impossible parking brake signal from gearshift lever
Failure
(Transmission controller system)
E03 DDB6L4
Detail of failure q Both of “P” signal and “NOT P” signal are ON or OFF at the same time.
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q Resets system if combination of “P” signal and possible signal is input from gearshift lever.
q When gearshift lever is in NEUTRAL or PARK position and travel speed is 1.0 km/h or below, park-
Problem on
ing brake is applied automatically.
machine
q When gearshift lever is in a position other than NEUTRAL and PARK, parking brake is not applied.
q Input (ON/OFF and gear position) from gearshift lever can be checked by using monitoring func-
Related infor- tion.
mation (Code: TRANSMISSION1-91101-SFT PNFR_NP)
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

Defective fuse No.11 in fuse box
1 If fuse is blown, circuit may have ground fault. (See cause 3.)
FB1
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 Resistance Min. 1 Mz
(Contact with ground circuit)
4 Short circuit in wiring harness
Hot short circuit in wiring harness
5 4. Set disconnect switch to ON.
(Contact with 24 V circuit)
Defective gear shift lever (internal
6 See failure code [DF10KA] to perform troubleshooting.
failure)
1. Turn starting switch to OFF position.
2. Disconnect connectors TM36 and TM41, and connect T-adapters to
female side of them.
Between No.11 in fuse box FB1 and TM36 (female)
Resistance Max. 1 z
(1)
Between TM36 (female) (2) and ground Resistance Max. 1 z
Between TM36 (female) (5) and TM41 (female)
Resistance Max. 1 z
(40)
Between TM36 (female) (6) and TM41 (female)
Resistance Max. 1 z
(39)
1. Turn starting switch to OFF position.
2. Disconnect connectors TM36 and TM41, and connect T-adapters to
female side of them.
Between No.11 in fuse box FB1 and ground or
between TM36 (female) (1) and ground
Between TM36 (female) (5) and ground or between
Resistance Min. 1 Mz
TM41 (female) (40) and ground
Between TM36 (female) (6) and ground or between
Resistance Min. 1 Mz
TM41 (female) (39) and ground
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM36.
Between TM36 (female) (5) and each pin other than
Resistance Min. 1 Mz
(5)
Between TM36 (female) (6) and each pin other than
Resistance Min. 1 Mz
(6)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM36 and connect T-adapter to female side (leave
gearshift lever disconnected).
5. Turn starting switch to ON position.
Between TM36 (female) (5) and (2) Voltage Max. 1 V
Between TM36 (female) (6) and (2) Voltage Max. 1 V

40-274 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDB6L4] Transmission gearshift lever: Parking brake signal error

Cause Procedure, measuring location, criteria and remarks

If cause is not found by the above checks, transmission controller is defective.
7 Defective transmission controller
q Reference: See failure code [DF10KA] before performing voltage check.

Circuit diagram related to transmission gearshift lever 40-275

GD555-5,GD655-5,GD675-5 40-275
(01)
Troubleshooting by failurecode
Failure code [DDTHKA] Fill switch for FH clutch: Open circuit

Failure code [DDTHKA] Fill switch for FH clutch: Open circuit 40-276
Action code Failure code Fill switch for FH clutch has open circuit
Failure
(Transmission controller system)
E01 DDTHKA
q When outputting current to FH clutch ECMV solenoid, clutch is engaged but signal from FH clutch
Detail of failure
fill switch does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from FH clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F2, F4, F6, or F8).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SCMA].

Failure code [DDTJKA] Fill switch for FL clutch: Open circuit 40-276
Action code Failure code Fill switch for FL clutch has open circuit
Failure
(Transmission controller system)
E01 DDTJKA
q When outputting current to FL clutch ECMV solenoid, clutch is engaged but signal from FL clutch
Detail of failure
fill switch does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from FL clutch ECMV fill switch can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F1, F3, F5, or F7).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SDMA].

40-276 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit

Failure code [DDTKKA] Fill switch for 1st clutch: Open circuit 40-27
Action code Failure code Fill switch for 1st clutch has open circuit
Failure
(Transmission controller system)
E01 DDTKKA
q When outputting current to 1st clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 1st clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F1, F2, or R1).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SEMA].

Failure code [DDTLKA] Fill switch for 2nd clutch: Open circuit 40-27
Action code Failure code Fill switch for 2nd clutch has open circuit
Failure
(Transmission controller system)
E01 DDTLKA
q When outputting current to 2nd clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 2nd clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F3, F4, or R2).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SFMA].

GD555-5,GD655-5,GD675-5 40-277
(01)
Troubleshooting by failurecode
Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit

Failure code [DDTMKA] Fill switch for 3rd clutch: Open circuit 40-278
Action code Failure code Fill switch for 3rd clutch has open circuit
Failure
(Transmission controller system)
E01 DDTMKA
q When outputting current to 3rd clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 3rd clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of F5, F6, or R3).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SGMA].

40-278 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DDTNKA] Fill switch for R clutch: Open circuit

Failure code [DDTNKA] Fill switch for R clutch: Open circuit 40-279
Action code Failure code Fill switch for R clutch has open circuit
Failure
(Transmission controller system)
E01 DDTNKA
q When outputting current to R clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from R clutch ECMV fill switch can be checked with monitoring function.
Related infor-
(Code: TRANSMISSION2-31520-FILL R1234LH)
mation
q Method of reproducing failure code: Start engine, operate gearshift lever (any of R1 through R4).

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SBMA].

GD555-5,GD655-5,GD675-5 40-279
(01)
Troubleshooting by failurecode
Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit

Failure code [DDTPKA] Fill switch for 4th clutch: Open circuit 40-280
Action code Failure code Fill switch for 4th clutch has open circuit
Failure
(Transmission controller system)
E01 DDTPKA
q When outputting current to 4th clutch ECMV solenoid, clutch is engaged but signal from fill switch
Detail of failure
does not turn to ON.
q None in particular.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on
q Gearshift shock is large.
machine
q Input (ON/OFF) from 4th clutch ECMV fill switch can be checked with monitoring function.
Related infor- (Code: TRANSMISSION2-31520-FILL R1234LH)
mation q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, or
R4)

Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for failure code [15SHMA].

40-280 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Failure code [DF10KA] Transmission gearshift lever: No gear speed

signal is input 40-281
Action code Failure code Transmission gearshift lever: No gear speed signal is input
Failure
(Transmission controller system)
E03 DF10KA
q Impossible combination of signal voltages is input to transmission controller with gearshift lever at
intermediate position between two gear speed positions.
Detail of failure q Signal is not input from gearshift lever due to ground fault or open circuit.
(Although voltage appears at “NOT P” signal terminal of controller, no voltage appears at any of
gear speed signal terminals.)
q Blinks centralized warning lamp and sounds alarm buzzer.
q Keeps gear speed at NEUTRAL when travel speed is decreased below 1.0 km/h for 0.5 second by
applying brake, etc.
Action of con-
q Holds possible combination of gear speed and travel direction signals input most recently.
troller
q If cause of failure disappears, system resets itself.
q Note that system does not reset itself until starting switch is turned to OFF position if failure code
[DF10L4] is also detected.
Problem on
q Shifting gears is not possible.
machine
q Input (ON/OFF) from gearshift lever can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-91101-SFT PNFR_NP, TRANSMISSION1-91104-SFT 12345678)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

q Gearshift lever is pressed by force other than control effort.
1 Wrong operation
q Gearshift lever is stopped midway between two gear speed positions.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapters to
female side of them.
Between TM36 (female) (3) and TM40 (25) Resistance Max. 1 z
Between TM36 (female) (4) and TM40 (15) Resistance Max. 1 z
Between TM36 (female) (7) and TM40 (35) Resistance Max. 1 z
Open circuit in wiring harness Between TM36 (female) (8) and TM40 (5) Resistance Max. 1 z
2 (Wire breakage or defective con-
tact of connector) Between TM36 (female) (9) and TM40 (36) Resistance Max. 1 z
Between TM36 (female) (10) and TM40 (26) Resistance Max. 1 z
Between TM36 (female) (11) and TM40 (16) Resistance Max. 1 z
Between TM36 (female) (12) and TM40 (6) Resistance Max. 1 z
Between TM36 (female) (13) and TM41 (9) Resistance Max. 1 z
Between TM36 (female) (14) and TM41 (19) Resistance Max. 1 z
Between TM36 (female) (15) and TM41 (29) Resistance Max. 1 z

GD555-5,GD655-5,GD675-5 40-281
(01)
Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring harness
3
(Contact with ground circuit)
Defective gearshift lever (internal
4
failure)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM40 and TM41.
Between TM40 (female) (5) and ground Resistance Min. 1 Mz
Between TM40 (female) (6) and ground Resistance Min. 1 Mz
Between TM40 (female) (15) and ground Resistance Min. 1 Mz
Between TM40 (female) (16) and ground Resistance Min. 1 Mz
Between TM40 (female) (25) and ground Resistance Min. 1 Mz
Between TM40 (female) (26) and ground Resistance Min. 1 Mz
Between TM40 (female) (35) and ground Resistance Min. 1 Mz
Between TM40 (female) (36) and ground Resistance Min. 1 Mz
Between TM41 (female) (9) and ground Resistance Min. 1 Mz
Between TM41 (female) (19) and ground Resistance Min. 1 Mz
Between TM41 (female) (29) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM36.
3. Turn starting switch to ON position.
4. Operate gearshift lever and troubleshoot.
Between TM36 each pin Lever position marked Voltage 20 – 30 V
and ground with q
a See the output table Lever position marked
of gearshift lever. Voltage Max. 1 V
withQ
If cause is not found by the above checks, transmission controller is defective.
q Reference: To measure input voltage at each pin of transmission controller
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Turn starting switch to ON position.
4. Operate gearshift lever and troubleshoot.
Between TM41 each pin Lever position marked Voltage 20 – 30 V
and ground with q
a See output table of Lever position marked
Voltage Max. 1 V
gearshift lever. with Q

40-282 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Circuit diagram related to transmission gearshift lever 40-283

GD555-5,GD655-5,GD675-5 40-283
(01)
Troubleshooting by failurecode
Failure code [DF10KA] Transmission gearshift lever: No gear speed signal is input

Output table of gearshift lever

Gearshift lever signal
F R Not P p N 1st 2nd 3rd 4th 5th 6th 7th 8th
F8 q Q q Q Q Q Q Q Q Q Q Q q
F7 q Q q Q Q Q Q Q Q Q Q q Q
F6 q Q q Q Q Q Q Q Q Q q Q Q
q Q q Q Q Q Q Q Q q Q Q Q
Gearshift lever position

F5
F4 q Q q Q Q Q Q Q q Q Q Q Q
F3 q Q q Q Q Q Q q Q Q Q Q Q
F2 q Q q Q Q Q q Q Q Q Q Q Q
F1 q Q q Q Q q Q Q Q Q Q Q Q
N Q Q q Q q Q Q Q Q Q Q Q Q
p Q Q Q q q Q Q Q Q Q Q Q Q
R1 Q q q Q Q q Q Q Q Q Q Q Q
R2 Q q q Q Q Q q Q Q Q Q Q Q
R3 Q q q Q Q Q Q q Q Q Q Q Q
R4 Q q q Q Q Q Q Q q Q Q Q Q
TM36
(gear
(3) (4) (5) (6) (7) (5) (9) (10) (11) (12) (13) (14) (15)
shift
lever)
Pin No.

TM40
(Cotroll (25) (15) – – (35) – (36) (26) (16) (6) – – –
er)
TM41
(Cotroll – – (40) (39) – – – – – – (9) (19) (29)
er)
Note: q voltage: 20 - 30 V, Q voltage: Max. 1 V

40-284 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel

direction signal error 40-285
Action code Failure code Transmission gearshift lever: Gear speed and travel direction sig-
Failure nal is incorrect
E03 DF10L4 (Transmission controller system)
q Impossible combination of signal voltage for travel direction (any of F, N or R) and signal for gear
Detail of failure
speed (any of 1st to 8th gear) is input to transmission controller from gearshift lever.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Keeps gear speed at NEUTRAL when travel speed is decreased below 1.0 km/h for 0.5 second by
Action of con- applying brake, etc.
troller q Holds possible combination of gear speed and travel direction signals input most recently.
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q Shifting gears is not possible.
machine
q Input (ON/OFF) from gearshift lever can be checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-91101-SFT PNFR_NP, TRANSMISSION1-91104-SFT 12345678)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate gearshift lever.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connectors TM36, TM40 and TM41, and connect T-adapter to
female side of TM36.
Between TM36 (female) (3) and each pin other than
Resistance Min. 1 Mz
(3)
Between TM36 (female) (4) and each pin other than
Resistance Min. 1 Mz
(4)
Between TM36 (female) (7) and each pin other than
Resistance Min. 1 Mz
(7)
Between TM36 (female) (8) and each pin other than
Resistance Min. 1 Mz
(8)
1 Short circuit in wiring harness Between TM36 (female) (9) and each pin other than
Resistance Min. 1 Mz
(9)
Between TM36 (female) (10) and each pin other
Resistance Min. 1 Mz
than (10)
Between TM36 (female) (11) and each pin other
Resistance Min. 1 Mz
than (11)
Between TM36 (female) (12) and each pin other
Resistance Min. 1 Mz
than (12)
Between TM36 (female) (13) and each pin other
Resistance Min. 1 Mz
than (13)
Between TM36 (female) (14) and each pin other
Resistance Min. 1 Mz
than (14)
Between TM36 (female) (15) and each pin other
Resistance Min. 1 Mz
than (15)

GD555-5,GD655-5,GD675-5 40-285
(01)
Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM36 and connect T-adapter to female side (leave
gearshift lever disconnected).
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Hot short circuit in wiring harness Between TM36 (female) (3) and (2) Voltage Max. 1 V
2
(Contact with 24 V circuit)
Between TM36 (female) (4) and (2) Voltage Max. 1 V
Between TM36 (female) (7) and (2) Voltage Max. 1 V
Between TM36 (female) (8) and (2) Voltage Max. 1 V
Between TM36 (female) (9) and (2) Voltage Max. 1 V
Between TM36 (female) (10) and (2) Voltage Max. 1 V
Between TM36 (female) (11) and (2) Voltage Max. 1 V
Between TM36 (female) (12) and (2) Voltage Max. 1 V
Hot short circuit in wiring harness
2 Between TM36 (female) (13) and (2) Voltage Max. 1 V
(Contact with 24 V circuit)
Between TM36 (female) (14) and (2) Voltage Max. 1 V
Between TM36 (female) (15) and (2) Voltage Max. 1 V
Defective gear shift lever (internal
3 See the failure code [DF10KA] and troubleshoot.
failure)
If cause is not found by the above checks, transmission controller is defective.
4 Defective transmission controller q Reference: See failure code [DF10KA] before performing the voltage
check.

40-286 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DF10L4] Transmission gearshift lever: Gear speed/travel direction signal error

Circuit diagram related to transmission gearshift lever 40-287

GD555-5,GD655-5,GD675-5 40-287
(01)
Troubleshooting by failurecode
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range

Failure code [DGF1KX] Transmission oil temperature sensor: Input

signal out of range 40-28
Action code Failure code Transmission oil temperature sensor: Input signal is out of range
Failure
(Transmission controller system)
E03 DGF1KX
Detail of failure q Transmission oil temperature sensor signal is out of normal range (0.9 to 4.5 V).
Action of con- q Blinks centralized warning lamp and sounds alarm buzzer.
troller q If failure disappears, system resets itself.
Problem on
q Gearshift shock is large.
machine
q Input voltage value and temperature from transmission oil temperature sensor can be checked by
Related infor- using monitoring function.
mation (Code: TRANSMISSION1-32501-T/M OIL TEMP(V), 32500-T/M OIL TEMP(°C))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T35 and connect T-adapter to male side.
Between T35 (male) (1) 25°C Resistance 38 – 49 kz
Defective transmission oil temper- and (2)
1 ature sensor (Internal open circuit a Thermal characteris-
or short circuit) tics of oil temperature 100°C Resistance 3.7 – 4.0 kz
sensor
Between ground and T35
All range Resistance Min. 1 Mz
(male) (1), (2)
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (3) and (21)
2
ing harness a Resistance is the same as thermal characteris-
Resistance 3.7 – 49 kz
tics of oil temperature sensor in cause 1 (25°C
- 100°C) in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and T35, and connect T-adapters to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (3) and T35 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and T35 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors T35 and TM39, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and T35 (female) (1) or TM39
Resistance Min. 1 Mz
(female) (3)
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connector T35 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between T35 (female) (1) and (2) Voltage Approx. 5 V
If no abnormality is found in above diagnoses, transmission controller is
6 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

40-288 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGF1KX] Transmission oil temperature sensor: Input signal out of range

Circuit diagram related to transmission oil temperature sensor 40-289

GD555-5,GD655-5,GD675-5 40-289
(01)
Troubleshooting by failurecode
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault

Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault 40-290
Action code Failure code Hydraulic oil temperature sensor: Ground fault
Failure
(Transmission controller system)
E01 DGH2KB
q Hydraulic oil temperature of 150°C or above (0.97 V or below) is detected (ground fault is detect-
Detail of failure
ed in hydraulic oil temperature signal circuit).
Action of con- q Fixes hydraulic oil temperature used for hydraulic fan control to 90°C.
troller q If cause of failure disappears, system resets itself.
Problem on
q Hydraulic fan speed increases.
machine
q Input voltage and temperature from hydraulic oil temperature sensor can be checked by using
Related infor- monitoring function.
mation (Monitoring code: TRANSMISSION1 - 04410 HST OIL TEMP (°C))
(Monitoring code: TRANSMISSION1 - 04402 - HST OIL TEMP (V))

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector R17 and connect T-adapter to male side.
Between R17 (male) (1) 25°C Resistance 38 – 49 kz
and (2)
Defective hydraulic oil tempera-
1 a Thermal characteris-
ture sensor (Internal defect) 100°C Resistance 3.7 – 4.0 kz
tics of oil temperature
sensor
Between ground and
– (Anytime) Resistance Min. 1 Mz
R17 (male) (1), (2)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R17, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between ground and TM39 (female) (10) or R17
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
3 Defective transmission controller Hydraulic oil tempera-
Voltage 4.4 – 4.6 V
Between TM39 (20) and ture: 25°C
(21) Hydraulic oil tempera-
Voltage 2.1 – 2.3 V
ture: 100°C

40-290 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGH2KB] Hydraulic oil temperature sensor: Ground fault

Circuit diagram related to hydraulic oil temperature sensor 40-291

GD555-5,GD655-5,GD675-5 40-291
(01)
Troubleshooting by failurecode
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range

Failure code [DGT1KX] Torque converter oil temperature sensor: Input

signal out of range 40-292
Action code Failure code Torque converter oil temperature sensor: Input signal is out of
Failure range
E01 DGT1KX (Transmission controller system)

Detail of failure q Torque converter oil temperature sensor signal is out of normal range (0.9 to 4.5 V).
Action of con- q Transmits torque converter oil temperature as abnormal value to machine monitor.
troller q If failure disappears, system resets itself.
Problem on q Torque converter overheat cannot be detected.
machine q Large shock is generated when torque converter is locked up.
q Input voltage value and temperature from torque converter oil temperature sensor can be checked
Related infor- by using of monitoring function.
mation (Code: TRANSMISSION1-30100-T/C OIL TEMP(°C), 30101-T/C OIL TEMP(V))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T34 and connect T-adapter to male side.
Defective torque converter oil tem- Between T34 (male) (1) 25°C Resistance 38 – 49 kz
1 perature sensor (Internal open cir- and (2)
cuit or short circuit) 100°C Resistance 3.7 – 4.0 kz
Between ground and T34
All range Resistance Min. 1 Mz
(male) (1), (2)
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and connect T-adapter to female side.
Open circuit or short circuit in wir- Between TM39 (female) (9) and (21)
2
ing harness a Resistance is the same as thermal characteris-
Resistance 3.7 – 49 kz
tics of oil temperature sensor in cause 1 (25°C
- 100°C) in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM39 and T34, and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM39 (female) (9) and T34 (female) (1) Resistance Max. 1 z
Between TM39 (female) (21) and T34 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors T34 and TM39, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and T34 (female) (1) or TM39
Resistance Min. 1 Mz
(female) (3)
1. Turn starting switch to OFF position.
Hot short circuit or short circuit in 2. Disconnect connector T34 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
wiring harness
Between T34 (female) (1) and (2) Voltage Approx. 5 V
If no abnormality is found in above diagnoses, transmission controller is
6 Defective transmission controller defective.
(Since this is internal failure, troubleshooting cannot be performed.)

40-292 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGT1KX] Torque converter oil temperature sensor: Input signal out of range

Circuit diagram related to torque converter oil temperature sensor 40-293

GD555-5,GD655-5,GD675-5 40-293
(01)
Troubleshooting by failurecode
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault

Failure code [DGT7KB] Differential oil temperature sensor: Ground fault40-294

Action code Failure code Differential oil temperature sensor: Ground fault
Failure
(Transmission controller system)
E01 DGT7KB
q Differential oil temperature of 150°Cor above (0.97 V or below) is detected (ground fault is detect-
Detail of failure
ed in differential oil temperature signal circuit).
Action of con- q Does not detect overheat of differential oil.
troller q Outputs power to differential lock control relay.
Problem on
q Differential lock is turned off regardless of switch position.
machine
q Input voltage value and temperature from differential oil temperature sensor can be checked by us-
Related infor- ing of monitoring function.
mation (Monitoring code: TRANSMISSION1 - 31909 - DIFF TEMP (°C))
(Monitoring code: TRANSMISSION1 - 31910 - DIFF TEMP (V))

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector R8 and connect T-adapter to male side.
Between R8 (male) (1) 25°C Resistance 38 – 49 kz
and (2)
Defective differential oil tempera- a Thermal characteris-
1
ture sensor (Internal defect) tics of oil temperature 100°C Resistance 3.7 – 4.0 kz
sensor
Between each of R8
(male) (1) and (2) and – (Anytime) Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R8, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between ground and TM39 (female) (14) or R8
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
3 Defective transmission controller Differential oil tempera-
Voltage 4.4 – 4.6 V
Between TM39 (14) and ture: 25°C
ground Differential oil tempera-
Voltage 2.1 – 2.3 V
ture: 100°C

40-294 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DGT7KB] Differential oil temperature sensor: Ground fault

Circuit diagram related to differential oil temperature sensor 40-295

GD555-5,GD655-5,GD675-5 40-295
(01)
Troubleshooting by failurecode
Failure code [DJF1KA] Fuel level sensor: Open circuit

Failure code [DJF1KA] Fuel level sensor: Open circuit 40-296

Action code Failure code Fuel level sensor: Open circuit
Failure
(Machine monitor system)
E01 DJF1KA
Detail of failure q Open circuit is detected in fuel level sensor circuit.
Action of con-
q None in particular.
troller
Problem on
q Fuel level gauge does not indicate correct level.
machine
q Resistance and voltage values from fuel level sensor can be checked by using monitoring function.
Related infor- (Code: MONITOR PANEL-04201-FUEL SENSOR (z), MONITOR PANEL-04200-FUEL SENSOR
mation (V))
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector ET39, and connect T-adapter to male side.
FULL Resistance Max. 7 z
Defective fuel level sensor Between ET39 (male) (1) 3/4 Resistance (10 z)
1
(Internal open circuit) and (2)
1/2 Resistance 32 z
a Fuel level sensor
characteristics table 1/4 Resistance (50 z)
EMPTY Resistance Min. 85 z
1. Turn starting switch to OFF position.
Open circuit or short circuit in wir- 2. Disconnect connector FP2 and connect T-adapter to female side.
2 Between FP2 (female) (10) and ground
ing harness
a Resistance is the same as fuel level sensor Resistance 10 – 80 z
characteristics in cause 1 in the above.
a If cause 2 is not the cause of failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors FP2, and ET39 and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between FP2 (female) (10) and ET39 (female) (1) Resistance Max. 1 z
Between ET39 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector ET39, and connect T-adapter to female side.
Hot short circuit or short circuit in
4 3. Turn starting switch to ON position.
wiring harness
Approx. 3 -
Between ET39 (female) (1) and (2) Voltage
5V
If no abnormality is found by above diagnoses, machine monitor is defective.
5 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

40-296 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DJF1KA] Fuel level sensor: Open circuit

Circuit diagram related to fuel level sensor 40-297

GD555-5,GD655-5,GD675-5 40-297
(01)
Troubleshooting by failurecode
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range

Failure code [DK70KX] Inching pedal angle sensor: Input signal out of
range 40-298
Action code Failure code Inching pedal angle sensor: Input signal is out of range
Failure
(Transmission controller system)
E03 DK70KX
Detail of failure q Inching pedal angle sensor signal is out of normal range (0.4 - 4.5 V).
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Performs neutral processing to disable inching function.
troller
q If cause of failure disappears with gearshift lever in N position, system resets itself.
Problem on
q Inching function does not work.
machine
q Input voltage values from inching angle sensor can be checked by use of monitoring function.
Related infor-
(Code: TRANSMISSION1-44105-INCHING PEDAL)
mation
q Method of reproducing failure code: Turn starting switch to ON position and operate inching pedal).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector FL6 and connect T-adapter to male side.
Defective inching angle sensor
1 (Internal open circuit or short cir- Between FL6 (male) (A) and (C) Resistance 4.0 – 6.0 kz
cuit) Between FL6 (male) (B) and (A) Resistance 0.25 –5.0 kz *
Between FL6 (male) (B) and (C) Resistance 0.25 –5.0 kz *
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39, TM41, and FL6, and connect T-adapter to
Open circuit in wiring harness each female side.
2 (Wire breakage or defective con- Between TM39 (female) (21) and FL6 (female) (C) Resistance Max. 1 z
tact of connector)
Between TM39 (female) (7) and FL6 (female) (B) Resistance Max. 1 z
Between TM41 (female) (34) and FL6 (female) (A) Resistance Max. 1 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39, TM41, and FL6, and connect T-adapter to
Ground fault in wiring harness female side of one of them.
3 Between ground and TM41 (female) (34) or FL6
(Contact with ground circuit) Resistance Min. 1 Mz
(female) (A)
Between ground and TM39 (female) (7) or FL6
Resistance Min. 1 Mz
(female) (B)
1. Turn starting switch to OFF position.
2. Disconnect connector FL6 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(Contact with 24 V circuit) Between FL6 (female) (A) and (C) Voltage Approx. 5 V
Between FL6 (female) (B) and (C) Voltage Max. 2.5 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapters into connector TM39 and TM41.
3. Set disconnect switch to ON.
5 Defective transmission controller 4. Turn starting switch to ON position.
Between TM41 (34) and TM39 (21) Voltage 4.6 – 5.4 V
Between TM39 (7) and (21) Voltage 0.4 – 4.5 V

*: As inching pedal is pressed, resistance changes.

40-298 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DK70KX] Inching pedal angle sensor: Input signal out of range

Circuit diagram related to inching pedal angle sensor 40-29

GD555-5,GD655-5,GD675-5 40-299
(01)
Troubleshooting by failurecode
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range

Failure code [DKD0KX] Articulation angle sensor: Input signal out of

range 40-30
Action code Failure code Articulation angle sensor: Input signal is out of range
Failure
(Transmission controller system)
E01 DKD0KX
Detail of failure q Articulation angle sensor signal is out of normal range.
Action of con-
q If cause of failure disappears, system resets itself.
troller
Problem on
q Articulation angle sensor does not indicate correct articulation angle.
machine
q Input voltage from articulation angle sensor can be checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-43902-ARTICULATE)
mation q Method of reproducing failure code: Start engine and perform articulate operation.
q See E-mode troubleshooting, “E-9 Articulation angle indicator does not indicate correctly”.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to male side.
3. Perform troubleshooting with starting switch at OFF position, and then
connect connector B11.
Defective articulation angle sen- 4. Start engine, change articulation angle, and then return to step 1.
1 sor (internal open circuit or short Approx.
Straight Resistance
circuit) Between B11 (male) (A) 2.5 kz
and (B) Fully to left (25°) Approx. 1 –
Resistance
Fully to right (25°) 3.8 kz
Approx.
Between B11 (male) (A) and (C) Resistance
5 kz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM39 and B11, and connect T-adapter to each
Open circuit in wiring harness female side.
2 (Wire breakage or defective con- Between TM39 (female) (8) and B11 (female) (B) Resistance Max. 1 z
tact of connector)
Between TM39 (female) (21) and B11 (female) (A) Resistance Max. 1 z
Between TM39 (female) (22) and B11 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM39 and B11, and connect T-adapter to female
Ground fault in wiring harness side of one of them.
3 Between ground and TM39 (female) (8) or B11
(Contact with ground circuit) Resistance Min. 1 Mz
(female) (B)
Between ground and TM39 (female) (22) or B11
Resistance Min. 1 Mz
(female) (C)
1. Turn starting switch to OFF position.
2. Disconnect connector B11 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(Contact with 24 V circuit) Between FL06 (female) (B) and (A) Voltage Max. 3 V
Between FL06 (female) (C) and (A) Voltage Approx. 5 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position and perform troubleshooting.
4. Start engine, change articulation angle, and then return to step 3.
5 Defective transmission controller Approx. 2.4
Straight Voltage
Between TM39 (8) and V
(21) Fully to left (25°) Approx. 1 –
Voltage
Fully to right (25°) 3.8 V
Between TM39 (22) and (21) Voltage Approx. 5 V

40-300 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DKD0KX] Articulation angle sensor: Input signal out of range

Circuit diagram related to articulation angle sensor 40-301

GD555-5,GD655-5,GD675-5 40-301
(01)
Troubleshooting by failurecode
Failure code [DLF1KA] Transmission input shaft speed sensor: Open circuit

Failure code [DLF1KA] Transmission input shaft speed sensor: Open

circuit 40-302
Action code Failure code Transmission input shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLF1KA
Detail of failure q There is open circuit in transmission input shaft speed sensor circuit and speed signal is not input.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con-
q Keeps stopping output to lockup clutch.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission input shaft speed sensor can be check by using monitoring function
Related infor-
(Code: TRANSMISSION1-31200-T/M SPEED: IN).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

Defective transmission input shaft 1. Turn starting switch to OFF position.

1 speed sensor (Internal open cir-
cuit)
Defective adjustment of transmis- Transmission input shaft speed sensor may be adjusted defectively. Adjust it
2
sion input shaft speed sensor
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness
Open circuit in wiring harness
4 (Wire breakage or defective con-
tact)
6 Defective transmission controller
2. Disconnect connector T32 and connect T-adapter to male side.
Between T32 (male) (1) and (2) Resistance 500 – 1,000 z
according to Testing and adjusting, "Adjusting transmission speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (40) and (39) Resistance
1,000 z
a If causes 2 is not the cause of failure, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and T32, and connect T-adapter to each
female side.
Between TM40 (female) (40) and T32 (female) (1) Resistance Max. 1 z
Between TM40 (female) (39) and T32 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission input shaft speed sensor 40-302

40-302 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLF1LC] Transmission input shaft speed sensor: Speed signal does not match

Failure code [DLF1LC] Transmission input shaft speed sensor: Speed

signal does not match 40-303
Action code Failure code Transmission input shaft speed sensor: Speed signal error
Failure
(Transmission controller system)
E03 DLF1LC
q While each clutch of L/U, FH, FL, R, 1st, 2nd, 3rd and 4th clutches is activated normally, speed
Detail of failure
signal from transmission input shaft speed sensor is abnormal.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con-
q Keeps stopping output to lockup clutch.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission input shaft speed sensor can be check by using monitoring function
Related infor-
(Code: TRANSMISSION1-31200-T/M SPEED: IN).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission input shaft 2. Disconnect connector T32 and connect T-adapter to male side.
1 speed sensor (Internal open circuit 500 –
Between T32 (male) (1) and (2) Resistance
or short circuit) 1,000 z
Between T32 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (40) and (39) Resistance
1,000 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and T32, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between ground and TM40 (female) (40) or T32
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector T32 and connect T-adapter to female side.
Hot short in wiring harness
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T32 (female) (1) and (2) Voltage 3 – 4V

If no abnormality is found by above diagnoses, transmission controller may be

5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission input shaft speed sensor 40-303

GD555-5,GD655-5,GD675-5 40-303
(01)
Troubleshooting by failurecode
Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Open circuit

Failure code [DLF2KA] Transmission intermediate shaft speed sensor:

Open circuit 40-304
Action code Failure code Transmission intermediate shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLF2KA
Detail of failure q Transmission intermediate shaft speed sensor circuit has open circuit and no speed signal is input.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Fixes relative speed to 300 rpm and continues control.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Slip of clutch cannot be judged.
machine
q Shaft speed input from transmission intermediate shaft speed sensor can be checked by using
Related infor-
monitoring function. (Code: TRANSMISSION1-31300-T/M SPEED:MID 1)
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission intermedi-
1 ate shaft speed sensor (internal 2. Disconnect connector T47 and connect T-adapter to male side.
open circuit) 500 –
Between T47 (male) (1) and (2) Resistance
1,000 z
Defective adjustment of transmis- Transmission intermediate shaft speed sensor may be adjusted incorrectly.
2 sion intermediate shaft speed sen- Adjust it referring to Testing and adjustment, “Adjusting transmission speed
sor sensor”.
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (20) and (29) Resistance
1,000 z
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T47, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (20) and T47 (female) (1) Resistance Max. 1 z
Between TM40 (female) (29) and T47 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission intermediate shaft speed sensor 40-304

40-304 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Speed signal does not match

Failure code [DLF2LC] Transmission intermediate shaft speed sensor:

Speed signal does not match 40-305
Action code Failure code Transmission intermediate shaft speed sensor: Speed signal
Failure error
E03 DLF2LC (Transmission controller system)
q While each clutch of L/U, FH, FL, R, 1st, 2nd, 3rd and 4th clutches is activated normally, speed
Detail of failure
signal from transmission intermediate shaft speed sensor is abnormal.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Fixes relative speed to 300 rpm and continues control.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Slip of clutch cannot be judged.
machine
q Shaft speed input from transmission intermediate shaft speed sensor can be checked by using
Related infor-
monitoring function. (Code: TRANSMISSION1-31300-T/M SPEED:MID 1)
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission intermedi- 2. Disconnect connector T47 and connect T-adapter to male side.
1 ate shaft speed sensor (internal 500 –
Between T47 (male) (1) and (2) Resistance
open circuit or short circuit) 1,000 z
Between T47 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
2
ing harness is 1 z or below, wiring harness has short circuit.
500 –
Between TM40 (female) (20) and (29) Resistance
1,000 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and T47, and connect T-adapter to female
3 side of one of them.
(Contact with ground circuit)
Between TM40 (female) (20) or T47 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T47 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T47 (female) (1) and (2) Voltage 3–4V
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission intermediate shaft speed sensor 40-305

GD555-5,GD655-5,GD675-5 40-305
(01)
Troubleshooting by failurecode
Failure code [DLM3KA] Fan speed sensor: Open circuit

Failure code [DLM3KA] Fan speed sensor: Open circuit 40-306

Action code Failure code Fan speed sensor: Open circuit
Failure
(Transmission controller system)
E01 DLM3KA
q No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor system.
q This failure code appears under the following conditions.
Detail of failure 1) Input voltage is 3 - 4 V.
2) There is no record of pulse input.
3) Engine is running.
Action of con-
q None in particular.
troller
Problem on
q The fan speed fails to accurately meet the specified speed.
machine
Related infor- q Input speed from fan speed sensor can be checked by using monitoring function (Code: TRANS-
mation MISSION 1-10009, FAN SPEED).

Cause Procedure, measuring location, criteria and remarks

Defective fan speed sensor adjust- a Fan speed sensor may be adjusted defectively. Check it directly.
1
ment (See Testing and adjusting, "Adjusting hydraulic fan speed sensor".)
1. Turn starting switch to OFF position.
2. Disconnect connector RT8 and connect T-adapter to male side.
Defective fan speed sensor (Inter-
2
nal open circuit or short circuit) Between RT8 (male) (1) and (2) Resistance 2 – 3 kz
Between RT8 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM40 (female) (10) and (39) Resistance 2 – 3 kz
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and RT8, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (39) and RT8 (female) (2) Resistance Max. 1 z
Between TM40 (female) (10) and RT8 (female) (1) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan speed sensor 40-306

40-306 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLM3LC] Fan speed sensor: Short circuit

Failure code [DLM3LC] Fan speed sensor: Short circuit 40-307

Action code Failure code Fan speed sensor: Short circuit
Failure
(Transmission controller system)
E01 DLM3LC
q No pulse voltage is input from fan speed sensor due to ground fault in fan speed sensor system.
q This failure code appears under the following conditions.
Detail of failure 1) Failure code [DLM3KA] is not indicated.
2) Engine speed is 500 rpm or above.
3) Fan is not in reverse control.
Action of con-
q None in particular.
troller
Problem on
q The fan speed fails to accurately meet the specified speed.
machine
Related infor- q Input speed from fan speed sensor can be checked by using monitoring function (Code: TRANS-
mation MISSION 1-10009, FAN SPEED).

Cause Procedure, measuring location, criteria and remarks

Defective fan speed sensor adjust- a Fan speed sensor may be adjusted defectively. Check it directly.
1
ment (See Testing and adjusting, "Adjusting hydraulic fan speed sensor".)
1. Turn starting switch to OFF position.
2. Disconnect connector RT8 and connect T-adapter to male side.
Defective fan speed sensor (Inter-
2
nal open circuit or short circuit) Between RT8 (male) (1) and (2) Resistance 2 – 3 kz
Between RT8 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM40 (female) (10) and (39) Resistance 2 – 3 kz
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM40 and RT8, and connect T-adapter to female
4 side of one of them.
(Contact with ground circuit)
Between ground and TM40 (female) (10) or RT8
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector RT8 and connect T-adapter to female side.
5 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT8 (female) (1) and (2) Voltage 3–4V
If no abnormality is found by above diagnoses, transmission controller may be
6 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan speed sensor 40-307

GD555-5,GD655-5,GD675-5 40-307
(01)
Troubleshooting by failurecode
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit

Failure code [DLT3KA] Transmission output shaft speed sensor: Open

circuit 40-308
Action code Failure code Transmission output shaft speed sensor: Open circuit
Failure
(Transmission controller system)
E03 DLT3KA
Detail of failure q There is open circuit in transmission output shaft speed sensor circuit and speed signal is not input.
q Blinks centralized warning lamp and sounds alarm buzzer.
q Fixes relative speed to 300 rpm and continues control.
Action of con- q If in automatic shift mode, current gear speed is kept.
troller q Keeps stopping output to lockup clutch.
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Slip of clutch cannot be judged.
machine q Lockup system does not operate.
q Input speed from transmission output shaft speed sensor can be check by using monitoring func-
Related infor-
tion (Code: TRANSMISSION1-31400-T/M SPEED: OUT).
mation
q Method of reproducing failure code: Start engine and drive

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective transmission output 2. Disconnect connector T33 and connect T-adapter to male side.
1 shaft speed sensor (Internal open
circuit) Approx. 500
Between T33 (male) (1) and (2) Resistance
- 1000 z
Defective adjustment of transmis- Transmission output shaft speed sensor may be adjusted defectively. Adjust it
2
sion output shaft speed sensor according to Testing and adjusting, "Adjusting transmission speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector TM40 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
3 tance is 1 z or below, wiring harness has short circuit.
ing harness
Approx. 500
Between TM40 (female) (30) and (29) Resistance
- 1000 z
a If cause 3 is not the cause for the trouble, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM40 and T33, and connect T-adapter to each
4 (Wire breakage or defective con- female side.
tact) Between TM40 (female) (30) and T33 (female) (1) Resistance Max. 1 z
Between TM40 (female) (29) and T33 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to transmission output shaft speed sensor 40-308

40-308 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DLT3KA] Transmission output shaft speed sensor: Open circuit

GD555-5,GD655-5,GD675-5 40-309
(01)
Troubleshooting by failurecode
Failure code [DV00KB] Buzzer: Short circuit

Failure code [DV00KB] Buzzer: Short circuit 40-310

Action code Failure code Alarm buzzer: Short circuit
Failure
(Machine monitor system)
E01 DV00KB
Detail of failure q When machine monitor connects alarm buzzer circuit to GND, abnormal current flows.
Action of con-
q Machine monitor stops connecting alarm buzzer circuit to GND.
troller
Problem on
q Alarm buzzer does not sound.
machine
Related infor- q Method of reproducing failure code: Turn starting switch to ON position.
mation a If starting switch is turned to ON position, alarm buzzer operates (sounds) for two seconds.

Cause Procedure, measuring location, criteria and remarks

Defective alarm buzzer (internal
1 3. Turn starting switch to ON position.
open circuit or short circuit)
2 Short circuit in wiring harness
Hot short circuit in wiring harness
3 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
4 Defective machine monitor
1. Turn starting switch to OFF position.
2. Disconnect connector FP4.
If this failure code is not indicated, alarm buzzer is defective.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors FP1 and FP4, and connect T-adapter to each
female side.
Between FP4 (female) (1) and (2), or between FP1
Resistance Min. 1 Mz
(female) (1) and (18)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector FP4 and connect T-adapter to female side.
Between FP1 (female) (18) and ground Voltage Max. 1 V
If no abnormality is found by above diagnoses, machine monitor may be
defective.
q Reference: Following shows standard values in normal condition.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Insert T-adapter into connector FP1.
3. Set disconnect switch to ON.
4. Turn starting switch to ON position.
When
buzzer is Voltage 20 – 30 V
stopped
Between FP1 (18) and ground When
buzzer
Voltage Max. 3 V
operates
(sounds)

40-310 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DV00KB] Buzzer: Short circuit

Circuit diagram related to buzzer 40-31

GD555-5,GD655-5,GD675-5 40-311
(01)
Troubleshooting by failurecode
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit

Failure code [DW4BKA] Parking brake solenoid valve: Open circuit 40-312
Action code Failure code Parking brake solenoid valve: Open circuit
Failure
(Transmission controller system)
E03 DW4BKA
q Parking brake is not applied or released properly due to open circuit or hot short in parking brake
solenoid valve circuit.
Detail of failure
(No current flows when controller attempts to flow current to parking brake solenoid valve, or
current flows to parking brake solenoid valve from somewhere.)
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on
q Parking brake is not released or it is kept released.
machine
q Method of reproducing failure code: Start engine and operate gearshift lever (Position other than
P or P position).
Related infor-
q Parking brake can be released only when parking brake solenoid valve is actuated.
mation
q Output condition (ON/OFF) to parking brake solenoid valve can be checked by using monitoring
function (Code: TRANSMISSION1-40949 D-OUT-0).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective parking brake solenoid 2. Disconnect connector R11 and connect T-adapter to male side.
1
(Internal open circuit)
Between R11 (male) (1) and (2) Resistance 2 – 100 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (7) and ground Resistance 2 – 100 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness 2. Disconnect connectors TM41 and R11, and connect T-adapter to each
3 (Wire breakage or defective con- female side.
tact of connector) Between TM41 (female) (7) and R11 (female) (1) Resistance Max. 1 z
Between R11 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector R11 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between R11 (female) (1) and ground Voltage Max. 1 V
If no abnormality is found by above diagnoses, transmission controller may be
5 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-312 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW4BKA] Parking brake solenoid valve: Open circuit

Circuit diagram related to parking brake solenoid 40-313

GD555-5,GD655-5,GD675-5 40-313
(01)
Troubleshooting by failurecode
Failure code [DW4BKB] Parking brake solenoid valve: Short circuit

Failure code [DW4BKB] Parking brake solenoid valve: Short circuit 40-314
Action code Failure code Parking brake solenoid valve: Short circuit
Failure
(Transmission controller system)
E03 DW4BKB
q Parking brake is not released due to short circuit in parking brake solenoid circuit.
Detail of failure
(Abnormal current flows when controller attempts to flow current to parking brake solenoid valve.)
Action of con-
q Blinks centralized warning lamp and sounds alarm buzzer.
troller
Problem on
q Parking brake is not released.
machine
q Method of reproducing failure code: Start engine and operate gear shift lever (Position other than
P).
Related infor-
q Parking brake can be released only when parking brake solenoid valve is actuated.
mation
q Output condition (ON/OFF) to parking brake solenoid valve can be checked by using monitoring
function (Code: TRANSMISSION1-40949 D-OUT-0).

Cause Procedure, measuring location, criteria and remarks

Defective parking brake solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector R11 and connect T-adapter to male side.
Between R11 (male) (1) and (2) Resistance 2 – 100 z
Between R11 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and R11, and connect T-adapter to female
Between ground and TM41 (female) (7) or R11
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and R11, and connect a T-adapter to the
female side of R11.
Between R11 (female) (1) and (2) Resistance Min. 1 Mz
If no abnormality is found by above diagnoses , transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to parking brake solenoid 40-314

40-314 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKA] Fan reverse solenoid: Open circuit

Failure code [DW7BKA] Fan reverse solenoid: Open circuit 40-315

Action code Failure code Fan reverse solenoid: Open circuit
Failure
(Transmission controller system)
E01 DW7BKA
q When current is output to fan reverse solenoid, no current flows because of open circuit in fan re-
Detail of failure
verse solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
Problem on
q Fan does not turn in reverse by operating fan reverse switch.
machine
q Output condition (ON/OFF) to fan reverse solenoid can be checked by using monitoring function
Related infor- (Code: TRANSMISSION 1-40949 D-OUT-4).
mation q Method of reproducing failure code: Turn starting switch to ON position and set fan reverse switch
to ON.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fan reverse solenoid 2. Disconnect connector RT6 and connect T-adapter to male side.
1
(Internal open circuit)
Between RT6 (male) (1) and (2) Resistance 35 – 45 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
2
ing harness is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (28) and (13) Resistance 35 – 45 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness 2. Disconnect connectors TM41 and RT6, and connect T-adapters to female
3 (Wire breakage or defective con- side of them.
tact of connector) Between TM41 (female) (28) and RT6 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and RT6 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse solenoid 40-315

GD555-5,GD655-5,GD675-5 40-315
(01)
Troubleshooting by failurecode
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

Failure code [DW7BKB] Fan reverse solenoid: Short circuit 40-316

Action code Failure code Fan reverse solenoid: Short circuit
Failure
(Transmission controller system)
E01 DW7BKB
q Abnormal current flows when current is output to fan reverse solenoid due to short circuit in fan
Detail of failure
reverse solenoid system.
q Stops output to fan reverse solenoid.
Action of con- q Disables fan reverse function.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q Fan does not turn in reverse by operating fan reverse switch.
machine
q Output (ON/OFF) to fan reverse solenoid can be checked by using monitoring function (Code:
Related infor-
TRANSMISSION1-40949 D-OUT-4).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fan reverse solenoid
1
(Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector RT6 and connect T-adapter to male side.
Between RT6 (male) (1) and (2) Resistance 35 – 45 z
Between RT6 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
Between TM41 (female) (18) and RT6 (female) (1) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
side of one of them.
Between TM41 (female) (28) and (13) or between
Resistance Min. 1 Mz
RT6 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan reverse solenoid 40-316

40-316 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-317
(01)
Troubleshooting by failurecode
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line

Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power

supply line 40-318
Action code Failure code Fan reverse solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E01 DW7BKY
q When current is not output to fan reverse switch, abnormal voltage appears because of hot short
Detail of failure
in fan reverse solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.

Problem on q Fan does not rotate in normal direction.

machine q Machine may overheat.

q Output condition (ON/OFF) to fan reverse solenoid can be checked by using monitoring function
Related infor-
(Code: TRANSMISSION 1-40949 D-OUT-4).
mation
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector RT6 and connect T-adapter to male side.
Defective fan reverse solenoid
1
(Internal open circuit) Between RT6 (male) (1) and (2) Resistance 35 – 45 z
Between RT6 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit of wiring harness 2. Disconnect connector RT6 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT6 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT6, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (28) and each pin other No continuity (no sound
than (28) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM 39 through TM41 and RT6, and connect
T-adapters to female side of connectors TM 39 through TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (28) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (28) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-318 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DW7BKY] Fan reverse solenoid: Short circuit to power supply line

Circuit diagram related to fan reverse solenoid 40-319

GD555-5,GD655-5,GD675-5 40-319
(01)
Troubleshooting by failurecode
Failure code [DX16KA] Fan motor EPC solenoid: Open circuit

Failure code [DX16KA] Fan motor EPC solenoid: Open circuit 40-320
Action code Failure code Fan motor EPC solenoid: Open circuit
Failure
(Transmission controller system)
E01 DX16KA
q No current flows when controller attempts to flow current to fan motor EPC solenoid circuit due to
Detail of failure
open circuit in fan motor EPC solenoid system.
q Disables fan reverse function.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
Problem on
q The fan speed is set to the maximum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION1-41400 FAN EPC DIR and
mation TRANSMISSION1-41401 FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fan motor EPC solenoid 2. Disconnect connector RT7 and connect T-adapter to male side.
1
(Internal open circuit)
Between RT7 (male) (1) and (2) Resistance 2 – 12 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is 1 Mz or above, wiring harness has disconnection. If resis-
2
ing harness tance is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (37) and (13) Resistance 2 – 12 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
3 (Wire breakage or defective con- side of them.
tact of connector) Between TM41 (female) (37) and RT7 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and RT7 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan motor EPC solenoid 40-320

40-320 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DX16KB] Fan motor EPC solenoid: Short circuit

Failure code [DX16KB] Fan motor EPC solenoid: Short circuit 40-321
Action code Failure code Fan motor EPC solenoid: Short circuit
Failure
(Transmission controller system)
E01 DX16KB
q Abnormal current flows when controller attempts to flow current to fan motor EPC solenoid circuit
Detail of failure
due to ground fault in fan motor EPC solenoid system.
q Stops outputting current to fan motor EPC solenoid.
Action of con- q Disables fan reverse function.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on
q The fan speed is set to the maximum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION 1-41400 FAN EPC DIR, 41401
mation FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

Defective fan motor EPC solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of either one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector RT7 and connect T-adapter to male side.
Between RT7 (male) (1) and (2) Resistance 2 – 12 z
Between RT7 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
Between TM41 (female) (37) or RT7 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
side of either one of them.
Between TM41 (female) (37) and (13) or between
Resistance Min. 1 Mz
RT7 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to fan motor EPC solenoid 40-321

GD555-5,GD655-5,GD675-5 40-321
(01)
Troubleshooting by failurecode
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line

Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power
supply line 40-32
Action code Failure code Fan motor EPC solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E01 DW16KY
q When current is not output to fan motor EPC solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in fan motor EPC solenoid system.
q Stops outputting current to fan motor EPC solenoid.
Action of con-
q Disables fan reverse function.
troller
q If failure disappears, system resets itself.
Problem on
q The fan speed is set to the minimum.
machine
q Command current value output to fan motor EPC solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION 1-41400 FAN EPC DIR, 41401
mation FAN EPC).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector RT7 and connect T-adapter to male side.
Defective fan motor EPC solenoid
1
(Internal open circuit) Between RT7 (male) (1) and (2) Resistance 2 – 12 z
Between RT7 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit of wiring harness 2. Disconnect connector RT7 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between RT7 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and RT7, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (37) and each pin other No continuity (no sound
than (37) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM 39 through TM41 and RT6, and connect
T-adapters to female side of connectors TM 39 through TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (37) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (37) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-322 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DX16KY] Fan motor EPC solenoid: Short circuit to power supply line

Circuit diagram related to fan motor EPC solenoid 40-323

GD555-5,GD655-5,GD675-5 40-323
(01)
Troubleshooting by failurecode
Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit

Failure code [DXH1KA] Lockup ECMV solenoid: Open circuit 40-324

Action code Failure code Lockup solenoid: Open circuit
Failure
E03 DXH1KA (Transmission controller system)
Detail of failure q When current is output to lockup clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con-
q Keeps stopping output to lockup clutch ECMV solenoid.
troller
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF power.
q Machine remains in torque converter drive auto mode even if direct drive mode is selected by using
Problem on
transmission mode selector switch.
machine
q Lockup clutch is disengaged.
q Command current value output to lockup clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation q Method of reproducing failure code:
Turn starting switch to ON position and operate transmission mode selector switch (select direct
drive mode).
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup solenoid
1 2. Disconnect connector T31 and connect T-adapter to male side.
(Internal disconnection)
Between T31 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit or short circuit in wir- 2. Disconnect connector TM41 and connect T-adapter to female side.
2
ing harness a If resistance is 1 Mz or above, wiring harness has open circuit. If resistance
is 1 z or below, wiring harness has short circuit.
Between TM41 (female) (38) and (13) Resistance 5 – 15 z
a If cause 2 is not the cause for the failure, this diagnosis is not required.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
3 (Wire breakage or defective con- 2. Disconnect connectors TM41 and T31, and connect T-adapter to each
tact of connector) female side.
Between TM41 (female) (38) and T31 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and T31 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission may be defective.
4 Defective transmission controller
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to lockup solenoid 40-324

40-324 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit

Failure code [DXH1KB] Lockup ECMV solenoid: Short circuit 40-325

Action code Failure code Lockup solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH1KB
Detail of failure q When current is output to lockup clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to lockup clutch ECMV solenoid.
troller q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
tion.
Problem on q Torque converter mode (Mode 2) is kept on even when direct drive mode (Mode 1) is selected by
machine using transmission mode selector switch.
q Command current value output to lockup clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31609-ECMV L/U DIR, TRANSMISSION1-31642-ECMV L/U)
mation q Method of reproducing failure code:
Turn starting switch to ON position and operate transmission mode selector switch (select direct
drive mode).

Cause Procedure, measuring location, criteria and remarks

Defective lockup solenoid
1
(Internal open circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
1. Turn starting switch to OFF position.
2. Disconnect connector T31 and connect T-adapter to male side.
Between T31 (male) (1) and (2) Resistance 5 – 15 z
Between T31 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
Between ground and TM41 (female) (38) or T31
Resistance Min. 1 Mz
(female) (1)
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
side of one of them.
Between TM41 (female) (38) and (13), or between
Resistance Min. 1 Mz
T31 (female) (1) and (2)
If no abnormality is not found by above diagnoses, transmission controller
formed.)

Circuit diagram related to lockup solenoid 40-325

GD555-5,GD655-5,GD675-5 40-325
(01)
Troubleshooting by failurecode
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line

Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power

supply line 40-326
Action code Failure code Lockup ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH1KY
q When current is not output to lockup ECMV solenoid, abnomal voltage appears because of hot
Detail of failure
short circuit in lockup ECMV solenoid system.
q Lights up the centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if failure disappears, system does not reset itself until starting switch is turned to OFF posi-
troller
tion.
q The lock up clutch is always engaged.
Problem on
q Engine may stall.
machine
q Solenoid may burn up.
q Command current value output to lockup ECMV solenoid and detected value can be checked by
Related infor- using monitoring function (Code: TRANSMISSION1-31609 ECMV L/U DIR and
mation TRANSMISSION1-31642-ECMV L/U)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T31 and connect T-adapter to male side.
Defective lockup solenoid
1
(Internal short circuit) Between T31 (male) (1) and (2) Resistance 5 – 15 z
Between T31 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T31 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T31 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T31, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (38) and each pin other No continuity (no sound
than (38) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T31, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (38) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (38) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is not found by above diagnoses, transmission controller
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-326 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH1KY] Lockup ECMV solenoid: Short circuit to power supply line

Circuit diagram related to lockup solenoid 40-327

GD555-5,GD655-5,GD675-5 40-327
(01)
Troubleshooting by failurecode
Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit

Failure code [DXH2KA] FH clutch ECMV solenoid: Open circuit 40-328

Action code Failure code FH clutch ECMV solenoid: Open circuit
Failure
(Tramsmission controller system)
E03 DXH2KA
Detail of failure q No current flows when current is output to FH clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FH clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FH clutch is not engaged.
machine
q Output (current value) to FH clutch ECMV solenoid can be checked by using monitoring function.
Related infor- (Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F2, F4, F6
or F8).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FH clutch ECMV sole- 2. Disconnect connector T25 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T25 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T25 (male) (36) and (3) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T25, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (36) and T25 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T25 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FH clutch ECMV solenoid 40-328

40-328 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit

Failure code [DXH2KB] FH clutch ECMV solenoid: Short circuit 40-329

Action code Failure code FH clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH2KB
Detail of failure q Abnormal current flows when current is output to FH clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to H clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FH clutch is not engaged.
machine
q Command current value output to FH clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31600-ECMV H DIR, TRANSMISSION1-31610-ECMV H)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F2, F4, F6,
and F8).

Cause Procedure, measuring location, criteria and remarks

Defective FH clutch ECMV sole-
1
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T25 and connect T-adapter to male side.
Between T25 (male) (1) and (2) Resistance 5 – 15 z
Between T25 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
Between TM41 (female) (36) or T25 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
side of one of them.
Between TM41 (female) (36) and (3), or between
Resistance Min. 1 Mz
T25 (female) (1) and (2)
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FH clutch ECMV solenoid 40-329

GD555-5,GD655-5,GD675-5 40-329
(01)
Troubleshooting by failurecode
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power

supply line 40-3 0
Action code Failure code FH clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH2KY
q Abnormal voltage appears when no current is output to FH clutch ECMV solenoid due to hot short
Detail of failure
circuit in FH clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q FH clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to FH clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31600 ECMV H DIR and
mation TRANSMISSION1-31610-ECMV H)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FH clutch ECMV sole- 2. Disconnect connector T25 and connect T-adapter to male side.
1 noid Between T25 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T25 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T25 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T25 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnected switch to OFF.
2. Disconnect connectors TM41 and T25, and connect T-adapter to female
side of TM41.
a Check by using mulltimeter in continuity mode.
Between TM41 (female) (36) and each pin other No continuity (no sound
than (36) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnected switch to OFF.
2. Disconnect connectors TM39 to TM41 and T25, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (36) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (36) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-330 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH2KY] FH clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to FH clutch ECMV solenoid 40-3 1

GD555-5,GD655-5,GD675-5 40-331
(01)
Troubleshooting by failurecode
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit

Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit 40-3 2

Action code Failure code FL clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH3KA
Detail of failure q No current flows when current is output to FL clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FL clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FL clutch is not engaged.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV L DIR, TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FL clutch ECMV sole- 2. Disconnect connector T24 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T24 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T24 (male) (26) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T24, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (26) and T24 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T24 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-332 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KA] FL clutch ECMV solenoid: Open circuit

Circuit diagram related to FL clutch ECMV solenoid 40-3 3

GD555-5,GD655-5,GD675-5 40-333
(01)
Troubleshooting by failurecode
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit

Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit 40-3 4

Action code Failure code FL clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH3KB
Detail of failure q Abnormal current flows when current is output to FL clutch ECMV solenoid.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Maintains no output of power to FL clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q FL clutch is not engaged.
machine
q Command current value of output to FL clutch ECMV solenoid and sensed current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31601-ECMV L DIR and TRANSMISSION1-31611-ECMV L)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F3, F5,
and F7)

Cause Procedure, measuring location, criteria and remarks

Defective FL clutch ECMV sole-
1 Between T24 (male) (1) and (2)
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T24 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T24 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
Between TM41 (female) (26) or T24 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
side of one of them.
Between TM41 (female) (26) and (23), or between
Resistance Min. 1 Mz
T24 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to FL clutch ECMV solenoid 40-3 4

40-334 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KB] FL clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-335
(01)
Troubleshooting by failurecode
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power

supply line 40-3 6
Action code Failure code FL clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH3KY
q Abnormal voltage appears when no current is output to FL clutch ECMV solenoid due to hot short
Detail of failure
circuit in FL clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q FL clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to FL clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31601 ECMV L DIR and
mation TRANSMISSION1-31611-ECMV L)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective FL clutch ECMV sole- 2. Disconnect connector T24 and connect T-adapter to male side.
1 noid Between T24 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T24 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T24 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T24 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T24, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (26) and each pin other No continuity (no sound
than (26) is heard)
a Since T- adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T24, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (26) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (26) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality cause is found by above diagnoses, transmission controller
4 Defective transmission controller may be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-336 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH3KY] FL clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to FL clutch ECMV solenoid 40-3 7

GD555-5,GD655-5,GD675-5 40-337
(01)
Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit

Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit 40-3 8
Action code Failure code 1st clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH4KA
Detail of failure q When current is output to 1st clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stooping output to 1st clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 1st clutch is not engaged.
machine
q Command current value output to 1st clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 1st clutch ECMV sole- 2. Disconnect connector T27 and connect T-adapter to male side.
1
noid (internal short circuit)
Between T27 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (female) (5) and (13) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T27, and connect T-adapter to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (5) and T27 (female) (1) Resistance Max. 1 z
Between TM41 (female) (13) and T27 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-338 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KA] 1st clutch ECMV solenoid: Open circuit

Circuit diagram related to 1st clutch ECMV solenoid 40-3 9

GD555-5,GD655-5,GD675-5 40-339
(01)
Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit

Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit 40-340
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH4KB
Detail of failure q When current is output to 1st clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of8 con- q Keeps stopping output of power to 1st clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 1st clutch is not engaged.
machine
q Command current value output to 1st clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31602-ECMV 1 DIR, TRANSMISSION1-31612-ECMV 1)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F1, F2, and
R1)

Cause Procedure, measuring location, criteria and remarks

Defective 1st clutch ECMV sole-
1
noid (internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T27 and connect T-adapter to male side.
Between T27 (male) (1) and (2) Resistance 5 – 15 z
Between T27 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
Between TM41 (female) (5) or T27 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
side of one of them.
Between TM41 (female) (5) and (13), or between
Resistance Min. 1 Mz
T27 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 1st clutch ECMV solenoid 40-340

40-340 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KB] 1st clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-341
(01)
Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power
supply line 40-342
Action code Failure code 1st clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH4KY
q When current is not output to 1st clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 1st clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 1st clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 1st clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31602-ECMV 1 DIR and
mation TRANSMISSION1-31612-ECMV 1)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T27 and connect T-adapter to male side.
Defective 1st clutch solenoid
1
(Internal short circuit) Between T27 (male) (1) and (2) Resistance 5 – 15 z
Between T27 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T27 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T27 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T27, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (5) and each pin other than No continuity (no sound
(5) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T27, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (5) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (5) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-342 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH4KY] 1st clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 1st clutch ECMV solenoid 40-343

GD555-5,GD655-5,GD675-5 40-343
(01)
Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit

Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit 40-34
Action code Failure code 2nd clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH5KA
Detail of failure q When current is output to 2nd clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 2nd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 2nd clutch is not engaged.
machine
q Command current value output to 2nd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31603-ECMV 2 DIR and TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F3, F4, and
R2)

Cause Procedure, measuring location, criteria and remarks

Defective 2nd clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T28 and connect T-adapter to male side.
(Internal short circuit) Between T28 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (male) (15) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T28, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (15) and T28 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T28 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-344 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KA] 2nd clutch ECMV solenoid: Open circuit

Circuit diagram related to 2nd clutch ECMV solenoid 40-345

GD555-5,GD655-5,GD675-5 40-345
(01)
Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit

Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit 40-346
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Failure
(Transmission train controller system)
E03 DXH5KB
Detail of failure q When current is output to 2nd clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 2nd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 2nd clutch is not engaged.
machine
q Command current value output to 2nd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31603-ECMV 2 DIR and TRANSMISSION1-31613-ECMV 2)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F3, F4, and
R2)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective 2nd clutch ECMV sole- 2. Disconnect connector T28 and connect T-adapter to male side.
1 noid
Between T28 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T28 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Ground fault in wiring harness 2. Disconnect connectors TM41 and T28, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between TM41 (female) (15) or T28 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T28, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between TM41 (female) (15) and (23), or between
Resistance Min. 1 Mz
T28 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 2nd clutch ECMV solenoid 40-346

40-346 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KB] 2nd clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-347
(01)
Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power
supply line 40-348
Action code Failure code 2nd clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission train controller system)
E03 DXH5KY
q Abnormal voltage appears when no current is output to 2nd clutch ECMV solenoid due to hot short
Detail of failure
circuit in 2nd clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 2nd clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 2nd clutch ECMV solenoid and detected value can be checked
Related infor- by using monitoring function (Code: TRANSMISSION1-31603-ECMV 2 DIR and
mation TRANSMISSION1-31613-ECMV 2)
q Method of reproducing failure code: Turn starting switch to ON position.
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector T28 and connect T-adapter to male side.
Defective 2nd clutch solenoid
1
(Internal short circuit) Between T28 (male) (1) and (2) Resistance 5 – 15 z
Between T28 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T28 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T28 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T28, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (15) and each pin other No continuity (no sound
than (15) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T28, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (15) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (15) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-348 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH5KY] 2nd clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 2nd clutch ECMV solenoid 40-349

GD555-5,GD655-5,GD675-5 40-349
(01)
Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit

Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit 40-350
Action code Failure code 3rd clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH6KA
Detail of failure q When current is output to 3rd clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 3rd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 3rd clutch is not engaged.
machine
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR and TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F5, F6, and
R3)

Cause Procedure, measuring location, criteria and remarks

Defective 3rd clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T29 and connect T-adapter to male side.
(Internal short circuit) Between T29 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41 (female) (25) and (3) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T29, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (25) and T29 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T29 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-350 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KA] 3rd clutch ECMV solenoid: Open circuit

Circuit diagram related to 3rd clutch ECMV solenoid 40-351

GD555-5,GD655-5,GD675-5 40-351
(01)
Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit

Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit 40-352
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH6KB
Detail of failure q When current is output to 3rd clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 3rd clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 3rd clutch is not engaged.
machine
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31604-ECMV 3 DIR and TRANSMISSION1-31614-ECMV 3)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F5, F6, and
R3)
Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd clutch ECMV sole- 2. Disconnect connector T29 and connect T-adapter to male side.
1 noid
Between T29 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T29 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Ground fault in wiring harness 2. Disconnect connectors TM41 and T29, and connect T-adapter to female
2 side of one of them.
(Contact with ground circuit)
Between TM41 (female) (25) or T29 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T29, and connect T-adapter to female
3 Short circuit in wiring harness side of one of them.
Between TM41 (female) (25) and (3), or between
Resistance Min. 1 Mz
T29 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 3rd clutch ECMV solenoid 40-352

40-352 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KB] 3rd clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-353
(01)
Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power
supply line 40-354
Action code Failure code 3rd clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXH6KY
q When current is not output to 3rd clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 3rd clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 3rd clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 3rd clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function (Code: TRANSMISSION1-31604 ECMV 3 DIR and
mation TRANSMISSION1-31614-ECMV 3).
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T29 and connect T-adapter to male side.
Defective 3rd clutch solenoid
1
(Internal short circuit) Between T29 (male) (1) and (2) Resistance 5 – 15 z
Between T29 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T29 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T29 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T29, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (25) and each pin other No continuity (no sound
than (25) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T29, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (25) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (25) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-354 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH6KY] 3rd clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 3rd clutch ECMV solenoid 40-35

GD555-5,GD655-5,GD675-5 40-355
(01)
Troubleshooting by failurecode
Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit

Failure code [DXH7KA] R clutch ECMV solenoid: Open circuit 40-356

Action code Failure code R clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXH7KA
Detail of failure q When power is output to R clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to R clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q R clutch is not engaged.
machine
q Command current value output to R clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective R clutch ECMV solenoid 2. Disconnect connector T26 and connect T-adapter to male side.
1
(Internal short circuit)
Between T26 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between T26 (male) (16) and (3) Resistance 5 – 15 z
a If no abromality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T26, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (16) and T26 (female) (1) Resistance Max. 1 z
Between TM41 (female) (3) and T26 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to R clutch ECMV solenoid 40-356

40-356 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit

Failure code [DXH7KB] R clutch ECMV solenoid: Short circuit 40-357

Action code Failure code R clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXH7KB
Detail of failure q When current is output to R clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to R clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q R clutch is not engaged.
machine
q Command current value output to R clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of R1 to R4)

Cause Procedure, measuring location, criteria and remarks

Defective R clutch ECMV solenoid
1 Between T26 (male) (1) and (2)
(Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T26 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T26 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
Between TM41 (female) (16) or T26 (female) (1)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
side of one of them.
Between TM41 (female) (16) and (3), or between
Resistance Min. 1 Mz
T26 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to R clutch ECMV solenoid 40-357

GD555-5,GD655-5,GD675-5 40-357
(01)
Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power

supply line 40-358
Action code Failure code R clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission train controller system)
E03 DXH7KY
q When current is not output to R clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in R clutch ECMV solenoid system.
q Lights up centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q R clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to R clutch ECMV solenoid and sensed current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31606-ECMV R DIR and TRANSMISSION1-31616-ECMV R)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T26 and connect T-adapter to male side.
Defective R clutch solenoid
1 Between T26 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T26 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T26 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T26 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T26, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (16) and each pin other No continuity (no sound
than (16) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T26, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (16) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (16) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-358 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXH7KY] R clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to R clutch ECMV solenoid 40-359

GD555-5,GD655-5,GD675-5 40-359
(01)
Troubleshooting by failurecode
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit

Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit 40-360
Action code Failure code 4th clutch ECMV solenoid: Open circuit
Failure
(Transmission controller system)
E03 DXHHKA
Detail of failure q When current is output to 4th clutch ECMV solenoid, no current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 4th clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 4th clutch is not engaged.
machine
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code: TRANSMISSION1-31605-ECMV 4 DIR and TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, and
R4)

Cause Procedure, measuring location, criteria and remarks

Defective 4th clutch ECMV sole- 1. Turn starting switch to OFF position.
1 noid 2. Disconnect connector T30 and connect T-adapter to male side.
(Internal short circuit) Between T30 (male) (1) and (2) Resistance 5 – 15 z
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connector TM41 and connect T-adapter to female side.
Open circuit or short circuit in wir- a If resistance is above 1 Mz, wiring harness has open cirucit. If resistance
2
ing harness is below 1 z, wiring harness has short circuit.
Between TM41(female)(35) and (23) Resistance 5 – 15 z
a If no abnormality is found by diagnosis on cause 2, this diagnosis is not re-
quired.
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
Open circuit in wiring harness
2. Disconnect connectors TM41 and T30, and connect T-adapters to each
3 (Wire breakage or defective con-
female side.
tact of connector)
Between TM41 (female) (35) and T30 (female) (1) Resistance Max. 1 z
Between TM41 (female) (23) and T30 (female) (2) Resistance Max. 1 z
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-360 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKA] 4th clutch ECMV solenoid: Open circuit

Circuit diagram related to 4th clutch ECMV solenoid 40-361

GD555-5,GD655-5,GD675-5 40-361
(01)
Troubleshooting by failurecode
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit

Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit 40-362
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Failure
(Transmission controller system)
E03 DXHHKB
Detail of failure q When current is output to 4th clutch ECMV solenoid, abnormal current flows.
q Blinks centralized warning lamp and sounds alarm buzzer.
Action of con- q Keeps stopping output to 4th clutch ECMV solenoid.
troller q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
OFF position.
Problem on
q 4th clutch is not engaged.
machine
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
checked by using monitoring function.
Related infor-
(Code:TRANSMISSION1-31605-ECMV 4 DIR and TRANSMISSION1-31615-ECMV 4)
mation
q Method of reproducing failure code: Start engine and operate gearshift lever (to any of F7, F8, and
R4).

Cause Procedure, measuring location, criteria and remarks

Defective 4th clutch ECMV sole-
1 Between T30 (male) (1) and (2)
noid (Internal short circuit)
Ground fault in wiring harness
2 side of one of them.
(Contact with ground circuit)
3 Short circuit in wiring harness
4 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector T30 and connect T-adapter to male side.
Resistance 5 – 15 z
Between T30 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
Between TM41 (female) (35) and ground, or
Resistance Min. 1 Mz
between T30 (female) (1) and ground
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
side of one of them.
Between TM41 (female) (35) and (23), or between
Resistance Min. 1 Mz
T30 (female) (1) and (2)
If no abnormality is found by above diagnoses, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to 4th clutch ECMV solenoid 40-362

40-362 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKB] 4th clutch ECMV solenoid: Short circuit

GD555-5,GD655-5,GD675-5 40-363
(01)
Troubleshooting by failurecode
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line

Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power
supply line 40-364
Action code Failure code 4th clutch ECMV solenoid: Short circuit to power supply line
Failure
(Transmission controller system)
E03 DXHHKY
q When current is not output to 4th clutch ECMV solenoid, abnormal voltage appears because of hot
Detail of failure
short circuit in 4th clutch ECMV solenoid system.
q Lights up the centralized warning lamp and sounds alarm buzzer.
Action of con-
q Even if cause of failure disappears, system does not reset itself until starting switch is turned to
troller
OFF position.
Problem on q 4th clutch is kept engaged.
machine q When failure code [1500L0] is indicated, transmission gear is set to NEUTRAL.
q Command current value output to 4th clutch ECMV solenoid and detected current value can be
Related infor- checked by using monitoring function.
mation (Code: TRANSMISSION1-31605-ECMV 4 DIR, TRANSMISSION1-31615-ECMV 4)
q Method of reproducing failure code: Turn starting switch to ON position.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector T30 and connect T-adapter to male side.
Defective 4th clutch solenoid
1 Between T30 (male) (1) and (2) Resistance 5 – 15 z
(Internal short circuit)
Between T30 (female) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector T30 and connect T-adapter to female side.
2 3. Turn starting switch to ON position.
(Contact with 24 V circuit)
Between T30 (female) (1) and ground Voltage Max. 1 V
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM41 and T30, and connect T-adapter to female
side of TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (35) and each pin other No continuity (no sound
than (35) is heard)
a Since T-adapter is not available for connector R1, diagnose it for short cir-
cuit according to following procedure.
3 Short circuit in wiring harness
1. Turn starting switch to OFF position, and set disconnect switch to OFF.
2. Disconnect connectors TM39 to TM41 and T30, and connect T-adapters to
female side of TM39 to TM41.
a Check by using multimeter in continuity mode.
Between TM41 (female) (35) and each pin of TM39 No continuity (no sound
(female) is heard)
Between TM41 (female) (35) and each pin of TM40 No continuity (no sound
(female) is heard)
If no abnormality is found by above diagnoses, transmission controller may be
4 Defective transmission controller
defective. (Since this is internal failure, troubleshooting cannot be performed.)

40-364 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting by failurecode
Failure code [DXHHKY] 4th clutch ECMV solenoid: Short circuit to power supply line

Circuit diagram related to 4th clutch ECMV solenoid 40-365

GD555-5,GD655-5,GD675-5 40-365
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Troubleshooting of electrical system (E-mode) 40-36

E-1 Engine does not start (starting motor does not turn) 40-36
Failure q Starting motor does not turn and accordingly engine does not start.
q Engine start circuit has safety function that allows engine to star only when gearshift lever is set in
P position.
q If starting switch is turned to START position with either right or left blade lift lever set in FLOAT
position, blade may drop, so engine is not allowed to start.
q Before performing troubleshooting, check that no related failure code is displayed.
(If failure code [DDB6L4], [DF10KA] or [DF10L4] is displayed, perform troubleshooting for it first.)
q In the case of "Battery relay does not make operating sound" when starting switch is turned to ON
position, perform troubleshooting for E-1 also.
q Operation of safety circuit that is activated depending on blade lift lever position (detecting lever in
FLOAT position)
Float ENG cancel switches: Output from FP14 and FP15 (lever in FLOAT: 0 V, lever in a position
other than FLOAT: 24 V)
---> Circuit between (3) for ACC input and (6) for 24 V output of float lamp relay SP39:
Closed (lever in FLOAT), Open (lever in a position other than FLOAT)
---> Circuit between (3) for 24 V input and (6) for 24 V output of FLOAT ENG cancel relay SP38:
Open (lever in FLOAT), Closed (lever in a position other than FLOAT)
q Operation of safety circuit that is activated depending on gearshift lever position (detecting lever in
Related infor-
PARK)
mation
Output from gearshift lever “P” (lever in PARK: 24 V, lever in a position other than PARK: 0 V)
---> Diode SP35
---> Circuit between (5) for C signal input and (3) for 24 V output of safety relay SP17:
Closed (lever in PARK), Open (lever in a position other than PARK)
q Flow of starting switch C signal:
C signal (from ST8 terminal) ---> Safety relay: to SP17 (5) for input and from (3) for output--->*
Float ENG cancel relay: to SP38 (3) for input and from (6) for output --->
Engine cut relay: to W60 (3) for input and from (6) for output--->
---> Diode R28 or R29
---> Safety relay: Connector E01
---> E20 terminal for input is connected to E19 terminal for output.
---> Electricity from slow-blow fuse E32 terminal flows to starting motor C terminal (E21 terminal)
*: Safety relay SP17 holding circuit: SP17 (3) for output ---> S. holding relay SP33 (5) for input and
from (3) for output ---> Diode SP34 ---> SP17 (1)
a Before checking proximity switches for blade lift lever position (detecting lever in FLOAT), check
float lamp relay SP39 and float ENG cancel switch SP38.
a Before checking gearshift lever, check diode.

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuses (two
If slow-blow fuse is open, circuit probably has ground fault. In this case, per-
1 120 A fuses in holder 2, and 30 A
form troubleshooting for cause 19 first.
fuse in holder 1)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuses (2) and (11) in FB1
shooting for cause 19 first.
1. Turn starting switch to OFF position.
Loose terminal or open circuit at
3 Check terminals of battery relay, alternator, starting motor and GNDs (FT10,
terminal
FT 11, FT13 and ET40B).
Battery voltage Min. 24 V
4 Low charge level of battery
Electrolyte specific gravity Min. 1.26

40-366 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective float ENG cancel relay 2. Replace float ENG cancel relay (connector SP38) with another relay (stop
5 SP38 (internal open circuit or short lamp relay connected to connector SP16).
circuit) 3. Turn starting switch to ON position.
If starting motor rotates, original float ENG cancel relay is defective.
1. Turn starting switch to OFF position.
Defective float lamp relay SP39 2. Replace float lamp relay (connector SP39) with another relay (stop lamp
6 (Internal open or short circuit in relay connected to connector SP16).
wiring) 3. Turn starting switch to ON position.
If starting motor rotates, original float lamp relay is defective.
1. Turn starting switch to OFF position.
2. Remove float lamp relay (connector SP39).
Defective safety circuit that is acti- 3. Set right and left blade lift levers to a position other than FLOAT.
vated depending on blade lift lever 4. Set gearshift lever in the "P" position.
7
position (detecting lever in FLOAT) 5. Start engine.
(circuit up to float lamp relay SP39) If starting motor rotates, safety circuit (up to float lamp relay SP39) that is acti-
vated depending on blade lift lever position (detecting lever in FLOAT) is
defective.
1. Turn starting switch to OFF position.
2. Replace safety relay (SP17) with another relay (stop lamp relay connected
to connector SP16).
8 Defective safety relay SP17
3. Start engine.
If engine starts, original safety relay (SP17) is defective.

1. Turn starting switch to OFF position.

9 Defective engine cut relay W40
10 Defective S. hold relay (SP33)
Defective diode SP34, SP35, R28,
R29, R18 or R19
11
(Internal open or short circuit in
wiring)
Defective gearshift lever
12 (internal defect or defective adjust-
ment)
2. Replace engine cut relay (W60) with another relay (stop lamp relay
connected to connector SP16).
3. Start engine.
If engine starts, original engine cut relay (W60) is defective.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Replace safety relay (SP33) with another relay (stop lamp relay connected
to connector SP16).
4. Set disconnect switch to ON.
5. Start engine.
If engine starts, original S. hold relay (SP33) is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP34, SP35, R28, R29, R18 and R19, and connect
T-adapter to each diode.
a Measure by using multimeter in diode range.
Between each diode (male) (1) (+) and (2) (-) No continuity
Between each diode (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to ON position.
2. Operate gearshift lever to perform troubleshooting.
Lever at position other Other than “P” is dis-
Gear position display on than PARK played.
machine monitor
Lever at PARK “P” is displayed.

GD555-5,GD655-5,GD675-5 40-367
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

Defective blade lift lever proximity 1. Turn starting switch to ON position.
switch (float ENG cancel switch) 2. Move each blade lift lever to perform troubleshooting.
13 FP 14 or FP15 Display of “blade FLOAT” Lever at FLOAT Pilot lamp lights up.
(internal defect or defective adjust- pilot lamp on machine mon- Lever at position other
Pilot lamp goes off.
ment) itor that FLOAT
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect wires from ST6 to ST9 terminals (put tags to show their destina-
tion).
4. Turn starting switch to ON, OFF and START positions to perform trouble-
shooting.
Switch: Resis-
Min. 1 Mz
OFF tance
Defective starting switch Between terminals ST6 and ST7
14 Resis-
(internal open circuit) Switch: ON Max. 1 z
tance
Switch: Resis-
Min. 1 Mz
OFF tance
Between terminals ST6 and ST9
Resis-
Switch: ON Max. 1 z
tance
Switch: Resis-
Min. 1 Mz
OFF tance
Between terminals ST6 and ST8
Switch: Resis-
Max. 1 z
START tance
Defective alternator 1. Turn starting switch to ON position.
15
(internal short circuit) R terminal – ground Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector E01.
3. Turn starting switch to ON and START positions to perform troubleshooting.
Power supply circuit: between E30 (B)
Switch: ON Voltage 20 – 30 V
terminal and ground
Detective starting motor(internal
16 Power supply circuit: between E01 (2)
defect) Switch: ON Voltage Max. 1 V
(R) terminal and ground
Power supply circuit: between E21 (C) Switch:
Voltage 20 – 30 V
terminal and ground START
When voltages of power supply, charging and starting circuits are normal but
starting motor does not rotate, starting motor is defective.
q Battery relay
1. Turn starting switch to OFF position.
Resis-
Between ET76 terminal and ground Max. 1 z
tance
q Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
17 Open circuit in wiring harness a Check to where 24 V power is supplied to isolate open section.
Between ST7 terminal and ground Voltage 20 – 30 V
Between ET75 terminal and ground Voltage 20 – 30 V
Between input terminal for battery relay secondary
Voltage 20 – 30 V
circuit and ground
Between output terminal for battery relay secondary
Voltage 20 – 30 V
circuit and ground

40-368 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Cause Procedure, measuring location, criteria and remarks

q Alternator and starting motor
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapters into connectors SP17, SP38, SP33, SP34, W60, E01 and
R28.
4. Set disconnect switch to ON.
5. Check that gearshift lever is positioned at a position other than PARK and
right and left blade lift levers are positioned at other than FLOAT.
6. Turn starting switch to START position and troubleshoot.
a Check to where 24 V power is supplied in order to isolate open section.
Between ST8 and ground Voltage 20 – 30V
Between ST17 (5) and ground Voltage 20 – 30 V
Between ST17 (1) and ground Voltage 20 – 30 V
Between SP38 (3) and ground Voltage 20 – 30 V
Between SP33 (1) and ground Voltage 20 – 30 V
Between SP34 (2) and ground Voltage 20 – 30 V
Between W60 (3) and ground Voltage 20 – 30 V
Between R28 (2) and ground Voltage 20 – 30 V
Between E01 (1) and ground Voltage 20 – 30 V
Between alternator B terminal and ground Voltage 20 – 30 V
Between E30 terminal and ground Voltage 20 – 30 V
q Primary circuits of relays SP17 and SP33
1. Turn starting switch to OFF position.
17 Open circuit in wiring harness 2. Insert T-adapter into connector SP17.
a Check ground terminals FT10 and FT11 for looseness and rust.
Resis-
Between SP17 (2) and ground Max. 1 z
tance
Between SP17 (2) and ground (to measure coil Resis-
200 - 400 z
resistance of S. holding relay SP33) tance
q Safety circuit by detecting blade lift lever position (detecting lever in FLOAT
position)
1. Turn starting switch to OFF position.
2. Disconnect connectors FP15 and FP14, and connect T-adapters to female
side of them.
a Check ground terminals ET89, FT10 and FT11 for looseness and rust.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector FP15 and FP14.
3. Turn starting switch to ON position.
Resis-
Between FP14 (female) (C) and ground Max. 1 z
tance
Resis-
Between FP15 (female) (C) and ground Max. 1 z
tance
Between FP14 (female) (A) and ground (to measure Resis-
200 - 400 z
coil resistance of float lamp relay SP39) tance
Between FP15 (female) (A) and ground (to measure Resis-
200 - 400 z
coil resistance of float lamp relay SP39) tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector FP15 and FP14.
3. Turn starting switch to ON position.
Between FP14 (B) and (C) Voltage 20 – 30 V
Between FP15 (B) and (C) Voltage 20 – 30 V

GD555-5,GD655-5,GD675-5 40-369
(01)
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)
Cause
Defective battery relay
18
(not activated)
Ground fault in wiring harness
19
(Contact with ground circuit)
Hot short circuit in wiring harness
20
(contact with 24 V circuit)
21 Defective transmission controller
40-370
Procedure, measuring location, criteria and remarks
If only voltages measured at output terminals to battery relay secondary circuit
are incorrect in checks on cause 17, battery relay is defective.
a If slow-blow fuse or fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF and disconnect wiring harnesses from battery
relay terminal ET75 and output terminal to battery relay secondary circuit.
3. Disconnect connector SP33 and connect T-adapter to female side.
Resis-
Between ST7 and ground Min. 1 Mz
tance
Resis-
Between ST8 and ground Min. 1 Mz
tance
Resis-
Between ET75 (wiring harness side) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect wiring harness from alternator R terminal.
3. Insert T-adapter into connector SP38.
4. Turn starting switch to ON position.
Between alternator R terminal (on harness) and
Voltage Max. 1 V
ground
Between SP38 (1) and (2) Voltage Max. 1 V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector TM41.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
If starting motor rotates, transmission controller is defective.
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (starting motor does not turn)

Circuit diagram related to engine start circuit 40-371

GD555-5,GD655-5,GD675-5 40-371
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

E-2 Preheating does not work 40-372

Failure 1) Manual preheating does not work.
a This troubleshooting describes troubleshooting procedures to be followed when automatic and
manual preheating does not function to heat electrical intake air heater mounting section.
q Machine is equipped with "Automatic preheating" and "Manual preheating" functions. When either
function works, preheating monitor lights up.
(When only preheating monitor does not light up, perform troubleshooting for Failure "3) While
Related infor-
preheating is working, preheating monitor does not light up").
mation
q If "machine monitor displays nothing" or " battery relay does not make operating sound" when turn-
ing starting switch to ON position, main electric power supply system may be defective. So, per-
form troubleshooting for E-3 and E-1.
q Before carrying out troubleshooting, check that no related failure code is displayed.
(If failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, troubleshoot it first.)

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (holder 2, If slow-blow fuse (holder 2, 120 A) is open, circuit probably has ground fault. In
1
120 A) this case, perform troubleshooting for cause 7 first.

Loose terminal or open circuit at 1. Turn starting switch to OFF position.

2
terminal Check terminals of heater relay, battery relay, ground ET77, etc.
1. Turn starting switch to OFF position.
2. Remove connector R31 and connect T-adapter to diode.
Defective diode (R31)
a Measure by using multimeter in diode range.
3 (Internal open circuit or short cir-
cuit) Between R31 (male) (1) (+) and (2) (-) No continuity
Between R31 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
Defective electrical intake air
4 heater 2. Disconnect terminal E07.
(Internal open circuit) Between terminal E07 (on electrical intake air
Continuity
heater) and ground
1. Turn starting switch to OFF position.
2. Set disconnect to switch OFF.
5 Defective starting switch 3. Turn starting switch to OFF and HEAT position to perform troubleshooting.
Between terminals ST6 and ST10 OFF Resistance Min. 1 Mz
(both on switch) HEAT Resistance Max. 1 z
1. Turn starting switch to OFF position.
Between terminal ST10 and ground There is continuity
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Open circuit or ground fault in wir- Between heater relay terminal A and ground Voltage 20 – 30V
6
ing harness 1. Turn starting switch to OFF position.
2. Disconnect terminal ET54.
a To prevent current from flowing through heater when troubleshooting
with starting switch at HEAT position.
3. Turn starting switch to HEAT position (Connect R1).
Between terminal ET82 and ground Voltage 20 – 30V
a If no abnormality is found by check on cause 6, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors TM39 and R31 and terminals ET82 and E31.
7
(contact with ground circuit) Between heater relay terminal A and ground Resistance Min. 1 Mz
Between terminal ET82 (on wiring harness) and
Resistance Min. 1 Mz
ground
Defective heater relay If no abnormality is found by check on cause 6 and heater relay operation
8
(not activated) sound is not heard, heater relay is defective.

40-372 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Circuit diagram related to preheating of engine 40-373

GD555-5,GD655-5,GD675-5 40-373
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Failure 2) Automatic preheating does not work.

q Automatic preheating starts when boost temperature is below -4 °C.
q Boost temperature can be checked by using monitoring function. (Code: ENGING 18500 CHG
Related infor- TEMP)
mation q If automatic preheating does not work, check if manual preheating works.
q Engine controller checks primary (coil) circuit of preheat relay (connector SP40) and displays fail-
ure code [CA2555] or [CA2556] if abnormality is detected.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse FB1 (7)
Defective preheater relay
2 (Internal open circuit or short cir-
cuit)
Open circuit or ground fault in wir- a If resistance is above 1 Mz, wiring harness has open circuit. If resistance
3
ing harness
Open circuit in wiring harness
4 (wire breakage or defective con- 3. Remove fuse FB1 (7).
tact)
Ground fault in wiring harness
5
(contact with ground circuit)
If fuse FB1 (7) is blown, circuit may have ground fault. Troubleshoot for cause
5 first.
1. Turn starting switch to OFF position.
2. Replace preheater relay (connector: SP40) with stop lamp relay
(connector: SP16).
3. Turn starting switch ON.
If automatic preheating starts with boost temperature below -4 °C, original pre-
heat relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EC2 and connect T-adapter to female side.
is below 1 z, wiring harness has short circuit.
a Preheater relay coil resistance
Resis-
Between EC2 (female) (40) and ground 200 - 400 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors SP40 and TM39, and connect T-adapter to female
side of SP40.
Between SP40 (female) (5) and ground There is continuity
Resis-
Between SP40 (female) (3) and FB1 (7) Max. 1 z
tance
If fuse is not blown, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector SP40 and connect T-adapter to female side.
3. Remove fuse FB1 (7).
Resis-
Between SP40 (female) (3) and ground Min. 1 Mz
tance

40-374 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Circuit diagram related to preheating of engine 40-375

GD555-5,GD655-5,GD675-5 40-375
(01)
Troubleshooting of electrical system (E-mode)
E-2 Preheating does not work

Failure 3) While preheating is working, preheating monitor does not light up.
q Machine is equipped with "Automatic preheating" and "Manual preheating" functions. When either
Related infor- function is working, preheating monitor lights up.
mation q Preheating information is sent from transmission controller to machine monitor through CAN.
q For related circuit diagram, see previous page.

Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring harness
1 (wire breakage or defective con-
tact)
Ground fault in wiring harness
2 female side of TM39.
(contact with ground circuit)
3 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors SP40 and TM39, and connect T-adapters to female
side of them.
Between SP40 (female) (5) and TM39 (female) (24) Resistance Max. 1 z
Between terminal ST10 and TM39 (female) (24) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector TM39 and terminal ET82, and connect T-adapter to
Between TM39 (female) (24) and ground Resistance Min. 1 Mz
If no abnormality is found by above checks, transmission controller is defec-
tive.
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Disconnect terminal ET54.
a To prevent current from flowing through heater when troubleshooting
with starting switch at HEAT position.
4. Turn starting switch to HEAT position.
Between TM39 (24) and (4) Resistance 20 – 30V

40-376 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

E-3 When starting switch is turned to ON position, machine monitor

displays nothing 40-37
Failure q When starting switch turned to ON position, machine monitor displays nothing
q If "the battery relay does not make operating sound" when starting switch is turned to ON position,
perform troubleshooting E-1.
q When starting switch is turned to ON position, machine monitor displays as follows.
1) Centralized warning lamp lights up for 2 seconds, and then goes out.
2) Monitor lamp lights up for 2 seconds, goes out for one second, and then starts normal display.
Related infor- 3) Speedometer displays "88" for 2 seconds, goes out for one second, and then starts normal
mation display.
4) After 2 seconds of system check, meter section switches to normal display.
5) Character display section displays "KOMATSU" for 3 seconds, and then switches to normal
display.
q When starting switch is turned to ON position, machine monitor sounds alarm buzzer for 2 sec-
onds, and then stops sounding.

Cause Procedure, measuring location, criteria and remarks

Defective slow-blow fuse (30 A If slow-blow fuse is open, circuit probably has ground fault. In this case, per-
1
fuse in holder 1) form troubleshooting for cause 8 first.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuses (1) and (2) in FB1 shooting for cause 8 first.

Loose terminal or open circuit at 1. Turn starting switch to OFF position.

3
terminal Check terminals of battery, battery relay, etc.
1. Turn starting switch to OFF position.
4 Low charge level of battery Battery voltage (2 pieces) Min.24 V
Electrolyte specific gravity Min. 1.26
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect connector FP1, and connect T-adapter to female side.
4. Set disconnect switch to ON.
a If voltage is 0 V, wiring harness has open circuit or ground fault.
Open circuit or ground fault in wir- Between FP1 (5) (female) and (3) Voltage 20 – 30V
5 ing harness or defective starting
switch Between FP1 (6) (female) and (4) Voltage 20 – 30V
Steps 1 to 4 are same as above.
5.Turn starting switch to ON position (connect ACC).
Between FP1 (1) (female) and (3) Voltage 20 – 30V
Between FP1 (2) (female) and (4) Voltage 20 – 30V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Disconnect wiring harness from terminals ST6 and ST9.
4. Turn starting switch to ON and OFF positions to perform troubleshooting.
6 Defective starting switch Starting
switch at Resistance Min. 1 Mz
Between terminals ST6 and ST9 OFF
(On starting switch) Starting
switch at Resistance Max. 1 z
ON

GD555-5,GD655-5,GD675-5 40-377
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Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing
Cause
Open circuit in wiring harness
7 (wire breakage or defective con-
tact)
Ground fault in wiring harness
8 4. Disconnect connector FP1 and connect T-adapter to female side.
(contact with ground circuit)
9 Defective machine monitor
40-378
Procedure, measuring location, criteria and remarks
a If no abnormality is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. If fuse is blown, replace it with new one.
4. Disconnect connector FP1 and connect T-adapter to female side.
Between each of FP1 (female) (3) and (4) and
ground Resistance Max. 1 z
a Check ET89 terminal for looseness and rust.
Between each of FP1 (female) (5) and (6) and bat-
Resistance Max. 1 z
tery (+)
Steps 1 to 4 are same as above.
5. Turn starting switch to ON position (ACC connection with disconnect switch
at OFF).
Between each of FP1 (female) (1) and (2) and bat-
Resistance Max. 1 z
tery (+)
a If no abnormality is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. If fuse is blown, replace it with new one.
5. Turn starting switch to ON and OFF positions to perform troubleshooting
(with disconnect switch at OFF).
Between FA1 (female) (1) and ground Resistance Min. 1 Mz
If no abnormality is found by above check, machine monitor is defective.
GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-3 When starting switch is turned to ON position, machine monitor displays nothing

Circuit diagram related to machine monitor 40-379

GD555-5,GD655-5,GD675-5 40-379
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Troubleshooting of electrical system (E-mode)
E-4 When starting switch is turned to ON position, machine monitor does not reach standard screen

E-4 When starting switch is turned to ON position, machine monitor does

not reach standard screen 40-380
q When starting switch is turned to ON position, display of machine monitor does not display stan-
Failure
dard screen
q When starting switch is turned to ON position, display of machine monitor changes as follows.
1) Centralized warning lamp lights up for 2 seconds, and then goes out.
2) Monitor lamp lights up for 2 seconds, goes out for one second, and then is in normal display
condition.
3) Speedometer displays "88" for 2 seconds, goes out for one second, and then is in normal
Related infor-
display condition.
mation
4) After 2 seconds of system check, meter section switches to normal display.
5) Character display section displays "KOMATSU" for 3 seconds, and then switches to normal
display.
q When starting switch is turned to ON position, machine monitor sounds alarm buzzer for 2 sec-
onds, and then stops sounding.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)

E-5 When starting switch is turned to ON position, caution monitor

flashes or lights up, or machine monitor does not display correct screen40-380
Failure 1) Only parking brake pilot lamp is not indicated correctly (parking brake works normally).
q When parking brake is applied: Pilot lamp lights up
When parking brake is released: Pilot lamp goes off
Related infor-
q Operation information of parking brake pilot lamp is sent from transmission controller through CAN.
mation
q When parking brake cannot be applied or cannot be released, see troubleshooting for failure codes
[DW4BKA] and [DW4BKB].

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
1 Defective machine monitor
ing cannot be performed.)
Transmission controller may be defective. (Since this is internal failure, trou-
2 Defective transmission controller
bleshooting cannot be performed.)

Failure 2) Maintenance caution monitor blinks or lights up.

q Maintenance caution lamp blinks when remaining time to next replacement is 30 hours for maint-
Related infor-
erance item and lights up when replacement time is reached (for 30 seconds after starting switch
mation
is turned to ON position).

Cause Procedure, measuring location, criteria and remarks

Maintenance item is due for maint-
1 erance.
(when system is normal)
2 Defective machine monitor
Check display of character display section and perform maintenance of item
that needs maintenance.
If no item is found to be due for mainterance by check on cause 1, machine
monitor may be defective. (Since this is internal failure, troubleshooting cannot
be performed.)

40-380 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

E-6 Emergency stop monitor lights up while engine is running 40-381

Failure 1) Battery charge caution lamp lights up while engine is running.
q Battery charge caution lamp lights up and alarm buzzer sounds if abnormality is detected in battery
Related infor- charging circuit while engine is running.
mation q Input voltage from alternator can be checked by using monitoring function.
(Code: 04302-ALTERNATOR R)

Cause Procedure, measuring location, criteria and remarks

1 Defective alternator system Perform troubleshooting for failure code [AB00MA].
If no abnormality is found by check on cause 1, machine monitor may be
2 Defective machine monitor
defective. (Since this is internal failure, troubleshooting cannot be performed.)

2) Engine coolant temperature caution lamp lights up (engine coolant temperature is 102°C and
Failure
above).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then the data
Related infor- is transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: 04104-ENGINE COOLANT TEMPERATURE)

Cause Procedure, measuring location, criteria and remarks

Maintenance item is due for maint-
Check display on character display section and perform maintenance of item
1 erance.
that needs maintenance.
(when system is normal)
If no abnormality is found by check on cause 1, engine coolant temperature
Defective engine coolant tempera-
2 sensor system may be defective. Perform troubleshooting for failure codes
ture sensor system
[CA144] and [CA145].
If no abnormality is found by check on causes 1 and 2, machine monitor may
3 Defective machine monitor be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Failure 3) Engine oil pressure caution lamp lights up in red.

q Signal of engine oil pressure switch is input to engine controller. If engine oil pressure switch is
Related infor-
turned ON while engine is running, failure code [B@BAZG] is transmitted from engine controller to
mation
machine monitor through CAN.

Cause Procedure, measuring location, criteria and remarks

Dropped engine oil pressure
1
(when system is normal)
Defective engine oil pressure
2
switch system
Since engine oil pressure may be low, check it. If it is low, perform trouble-
shooting for "S-12 Oil pressure decreases".
If no abnormality is found by check on cause 1, engine oil pressure switch sys-
tem may be defective. Perform troubleshooting for failure codes [CA435].

GD555-5,GD655-5,GD675-5 40-381
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Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

Failure 4) Brake pressure caution lamp lights up (brake pressure is 4.4 MPa or below).
q When wiring harness has short circuit or ground fault, caution lamp does not light up even if brake
Related infor- pressure drops.
mation q Brake pressure can be checked by using monitoring function.
q (Code: 40921 D_IN_4 Brake ACC HYD P SW F, D_IN_5 Brake ACC HYD P SW R)

Cause Procedure, measuring location, criteria and remarks

Dropped brake oil pressure
1 For details, see Testing and adjusting “Testing and adjusting brake oil
(when system is normal)
2 Defective brake pressure switch
Open circuit in wiring harness
3 (Wire breakage or defective con-
tact of connector)
Short circuit or ground fault in wir-
4
ing harness
5 Defective machine monitor
Drop in brake pressure is detected. Check brake pressure.
pressure”.
1. Turn starting switch to OFF position.
2. Disconnect connector R15 and connect T-adapter to male side.
3. Start engine and perform troubleshooting
4. Turn starting switch to OFF position.
5. Disconnect connector R16 and connect T-adapter to male side.
6. Start engine.
Between R15 (male) (1) and (2) Resistance Max. 1 z
Between R16 (male) (1) and (2) Resistance Max. 1 z
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Disconnect connectors FP1, R15 and R16, and connect T-adapters to
female side of them.
Between R15 (female) (2) and ground
a Check ground terminal FT13 for looseness and Resistance Max. 1 z
rust.
Between R16 (female) (2) and ground
a Check ground terminal FT13 for looseness and Resistance Max. 1 z
rust.
Between FP1 (female) (11) and R15 (female) (1) Resistance Max. 1 z
Between FP1 (female) (12) and R16 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Disconnect connectors FP1, R15 and R16, and connect T-adapters to
female side of R15 and R16.
Between R15 (female) (1) and (2) Resistance Min. 1 Mz
Between R16 (female) (1) and (2) Resistance Min. 1 Mz
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position and set disconnect switch to OFF.
2. Loosen hydraulic tank cap gradually to release pressure.
3. Insert T-adapter into connector FP1.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between FP1 (11) and (3) Voltage Min. 5 V
Between FP1 (12) and (3) Voltage Min. 5 V
Steps 1 to 4 are same as above.
5. Close hydraulic tank cap.
6. Start engine.
Between FP1 (11) and (3) Voltage Max. 1 V
Between FP1 (12) and (3) Voltage Max. 1 V

40-382 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

Circuit diagram related to brake pressure switch 40-383

GD555-5,GD655-5,GD675-5 40-383
(01)
Troubleshooting of electrical system (E-mode)
E-6 Emergency stop monitor lights up while engine is running

5) Torque converter oil temperature caution lamp lights up (torque converter oil temperature is 120°
Failure
C and above).
q Torque converter oil temperature caution lamp lights up and alarm buzzer sounds if abnormal
torque converter oil temperature is detected while engine is running.
q Torque converter oil temperature caution lamp lights up and goes off in accordance with indication
Related infor- of torque converter oil temperature gauge.
mation q Signal voltage from torque converter oil temperature sensor is sent from transmission controller
through CAN.
q Torque converter oil temperature can be checked by using monitoring function.
(Code: TRANSMISSION1-30100-T/C OIL TEMP)

Cause Procedure, measuring location, criteria and remarks

Overheat of torque converter oil
1
(When system is normal.)
Defective torque converter oil tem-
2
perature gauge
3 Defective machine monitor
Overheat of torque converter oil is detected. Check torque converter oil for
overheat.
When torque converter oil temperature gauge indicates red range, perform
troubleshooting for failure code [DGT1KX].
See drawing shown below.
Oil temperature gauge: Green range
Oil temperature caution lamp: goes off
(G)
Oil temperature gauge: Red range (R) Oil temperature caution lamp: lights up
If no abnormality is found by check on causes 1 and 2, machine monitor may
be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

Torque converter oil temperature gauge 40-384

6) Differential oil temperature caution lamp lights up (differential oil temperature is 120°C and
Failure
above).
q Differential oil temperature caution lamp lights up and alarm buzzer sounds if differential oil tem-
perature rises above 120°C while engine is running.
Related infor- q Differential oil temperature can be checked by using monitoring function.
mation (Code: MONITOR 31909 DIFF TEMP)
q Signal voltage from differential oil temperature sensor is sent from transmission controller through
CAN.

Cause Procedure, measuring location, criteria and remarks

Overheat of differential oil
1 Overheat of differential oil is detected. Check differential oil for overheat.
(when system is normal)
Defective differential oil tempera- If no abnormality is found by check on cause 1, perform troubleshooting for
2
ture sensor system failure code [B@CKNS].
If no abnormality is found by checks on causes 1 and 2, machine monitor may
3 Defective machine monitor be defective. (Since this is internal failure, troubleshooting cannot be per-
formed.)

40-384 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-7 Speedometer or engine tachometer does not indicate correctly

E-7 Speedometer or engine tachometer does not indicate correctly 40-385

Failure 1) Speedometer does not indicate correctly.
Related infor- q Source information for speedometer (signal of transmission output shaft speed sensor) is sent from
mation transmission controller through CAN.

Cause Procedure, measuring location, criteria and remarks

Defective transmission output
1
shaft speed sensor
2 Slip of clutch
3 Defective machine monitor
4 Defective transmission controller
Check whether failure code [DLT3KA] is displayed. If it is displayed, perform
troubleshooting for it.
Check whether any of failure codes [15K0MW], [15L0MW], [15M0MW] or
[15N0MW] is displayed. If it is displayed, perform troubleshooting for it.
If no abnormality is found by check on cause 1, machine monitor may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no abnormality is found by check on cause 1, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

Failure 2) Speedometer display pilot lamp is not displayed correctly.

q Signals of speedometer display pilot lamp are processed by machine monitor.
Related infor-
a When “km/h” is selected for display unit, speedometer pilot lamp lights up. When “MPH” is se-
mation
lected, selected gear speed is displayed.

Cause Procedure, measuring location, criteria and remarks

Machine monitor may be defective. (Since this is internal failure, troubleshoot-
3 Defective machine monitor
ing cannot be performed.)

Failure 3) Engine tachometer is not displayed correctly.

q Information on engine speed (engine Ne speed sensor signal) is sent from engine controller to ma-
Related infor- chine monitor through CAN.
mation q Engine speed can be checked by using monitoring function.
(Code:: ENGINE 01002 - ENG SPEED)

Cause Procedure, measuring location, criteria and remarks

Defective engine Ne speed sen-
1
sor system
2 Defective machine monitor
3 Defective engine controller
Check whether failure code [CA238] is displayed. If it is displayed, perform
troubleshooting for it.
If no abnormality is found by check on cause 1, machine monitor may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
If no abnormality is found by check on cause 1, engine controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-385
(01)
Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

E-8 Engine coolant temperature gauge does not indicate correctly 40-386
1) While engine coolant temperature is rising normally, temperature gauge does not indicate above
white range (W).
Failure
2) While engine coolant temperature is stabilized in normal range, temperature gauge indicates red
range (R).
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: MONITOR PANEL 04104-COOLANT TEMP)

Cause Procedure, measuring location, criteria and remarks

Defective engine coolant
1
temperature sensor system
2 Defective machine monitor
Engine coolant temperature sensor system may be defective. Perform troubleshoot-
ing for failure codes [CA144] and [CA145].
If no abnormality is found by check on cause 1, machine monitor may be defective.
(Since this is internal failure, troubleshooting cannot be performed.)

3) Display of coolant temperature gauge does not correspond to actual engine coolant temperature.
Failure 4) Display of engine coolant temperature gauge does not correspond to display of engine coolant
temperature monitor.
q Signal voltage of engine coolant temperature sensor is input to engine controller and then data is
Related infor- transmitted to machine monitor through CAN.
mation q Engine coolant temperature can be checked by using monitoring function.
(Code: Code: MONITOR PANEL 04104-COOLANT TEMP)

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine, and then perform trouble-
shooting.
Engine coolant tempera- Coolant temperature Color of coolant tempera-
ture gange level ture gauge
Segments 9 and below
105°C and above
light up
Red (R)
Segments 8 and below
102 – 105°C
light up
Segments 7 and below
100 – 102°C
light up
1 Defective machine monitor Segments 6 and below
95 – 98°C
light up
Segments 5 and below
80 – 90°C
light up
Green (G)
Segments 4 and below
75 – 80°C
light up
Segments 3 and below
65 – 70°C
light up
Segments 2 and below
55 – 60°C
light up
50°C or below Segment 1 alone lights up White (W)

40-386 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-8 Engine coolant temperature gauge does not indicate correctly

Engine coolant temperature gauge and coolant temperature monitor 40-387

GD555-5,GD655-5,GD675-5 40-387
(01)
Troubleshooting of electrical system (E-mode)
E-9 Articulation angle indicator does not indicate correctly

E-9 Articulation angle indicator does not indicate correctly 40-38

Failure 1) Articulation angle indicator does not indicate correctly when machine is articulated.
q If articulation angle sensor system has abnormality, failure code [DKD0KX] may be displayed and
logged.
Related infor- q Data for articulation angle indicator (signal from articulation angle sensor) is sent from transmis-
mation sion controller through CAN.
q Input voltage from articulation angle sensor can be checked by using monitoring function. (Code:
TRANSMISSION1-43902-ARTICULATE)

Cause Procedure, measuring location, criteria and remarks

Defective articulation angle
1 Perform troubleshooting for failure code [DKD0KX].
sensor system
If no abnormality is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)

Circuit diagram related to articulation angle sensor 40-38

40-388 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-9 Articulation angle indicator does not indicate correctly

Failure 2) Indication of articulation angle indicator does not correspond to actual articulation angle.
Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Perform zero point adjustment for articulation angle indicator. For details, see
1 Improper zero point adjustment*
“Tuning” in “Special functions of machine monitor (EMS)”.
Start engine, and change articulation angle of machine to perform trouble-
shooting.
Articulation angle
Example of articulation
Articulation level (between front and rear
sensor output voltage
frames)
-25° or below
Segments 9 flash Min. approx. 3.75 V
(abnormal)
Segments 9 light up Approx. 3.6 – 3.75 V -22 to -25°
Segments 8 light up Approx. 3.25 – 3.4 V -16 to -19°
Segments 7 light up Approx. 2.8 – 3.0 V -8 to -12°
2 Defective machine monitor
Segments 6 light up Approx. 2.45 – 2.65 V -2 to -5°
Segments 5 light up Approx. 2.25 – 2.45 V * ± 2°
Segments 4 light up Approx. 2.1 – 2.25 V 2 to 5°
Segments 3 light up Approx. 1.7 – 1.9 V 8 to 12°
Segments 2 light up Approx. 1.4 –1.6V 16 to 19°
Segments 1 light up Approx. 0.95 – 1.15 V 22 – 25°
25° or higher
Segments 1 flash Max. approx. 0.95 V
(abnormal)
*: The "zero point adjustment" means to adjust the articulation sensor so that it has an output voltage of 2.5 V and
the segments 5 light up when the front and rear frames are set straight (0°).

Articulation angle indicator 40-389

GD555-5,GD655-5,GD675-5 40-389
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Troubleshooting of electrical system (E-mode)
E-10 Torque converter oil temperature gauge does not indicate correctly

E-10 Torque converter oil temperature gauge does not indicate correctly40-390
1) While torque converter oil temperature is rising normally, temperature gauge does not indicate
above white range (W).
Failure
2) While torque converter oil temperature is stabilized in normal range, temperature gauge indicates
red range (R).
q If abnormality occurs in torque converter oil temperature sensor system, failure code [DGT1KX]
may be displayed and recorded.
q Information for torque converter oil temperature gauge (torque converter oil temperature sensor
Related infor-
signal) is sent from transmission controller to machine monitor through CAN.
mation
q Input voltage from torque converter oil temperature sensor can be checked by using monitoring
function.
(Code: TRANSMISSION1-30101-T/C OIL TEMP)

Cause Procedure, measuring location, criteria and remarks

Defective torque converter
1 oil temperature sensor sys- Perform troubleshooting for failure code [DGT1KX].
tem
If no abnormality is found by check on cause 1, machine monitor may be defective.
2 Defective machine monitor
(Since this is internal failure, troubleshooting cannot be performed.)
Defective transmission con- If no abnormality is found by check on cause 1 transmission controller may be
3
troller defective. (Since this is internal failure, troubleshooting cannot be performed.)

3) Torque converter oil temperature gauge does not indicate correct torque converter oil tempera-
ture.
Failure
4) Indication of torque converter oil temperature gauge does not correspond to indication of torque
converter oil temperature caution lamp.
Related informa- q Torque converter oil temperature caution lamp lights up when torque converter oil temperature is
tion above 120°C.

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine, and then perform trouble-
shooting.
Color of torque converter Torque converter oil tem- Torque converter oil tem-
oil temperature gauge perature gauge lever perature
Segments 9 and below
120°C and above
light up
Red (R)
Segments 8 and below
110–120°C
light up
Segments 7 and below
100 –1 10°C
light up
1 Defective machine monitor Segments 6 and below
95 – 100°C
light up
Segments 5 and below
85 – 90°C
light up
Green (G)
Segments 4 and below
75 – 80°C
light up
Segments 3 and below
65 – 70°C
light up
Segments 2 and below
55 – 60°C
light up
White (W) Segment 1 alone lights up 50°C or below

40-390 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-10 Torque converter oil temperature gauge does not indicate correctly

Torque converter oil temperature gauge and torque converter oil temperature monitor 40-391

GD555-5,GD655-5,GD675-5 40-391
(01)
Troubleshooting of electrical system (E-mode)
E-11 Fuel level gauge does not indicate correctly

E-11 Fuel level gauge does not indicate correctly 40-392

Failure 1) Fuel gauge does not indicate correctly.
q If an abnormality occurs in fuel level sensor system, failure code [DJF1KA] may be displayed and
Related infor- recorded.
mation q Resistance and voltage values from fuel level sensor can be checked by using monitoring function.
(Code: MONITOR PANEL-04201-FUEL SENSOR, MONITOR PANEL-04200-FUEL SENSOR)

Cause Procedure, measuring location, criteria and remarks

Defective fuel level sensor
1 Perform troubleshooting for failure codes [DJF1KA].
system
1. Turn starting switch to OFF position.
Ground fault in wiring har- 2. Disconnect connectors FP2 and ET39 and connect T-adapter to female side of
2 ness either of them.
(contact with ground circuit) Between FP 2 (female) (10) or ET39 (female) (1) and
Resistance Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors FP2 and ET39 and connect T-adapter to female side of
Short circuit in wiring har- FP2.
3
ness a Check by using multimeter in continuity mode.
Between FP2 (female) (10) and each pin other than No continuity
(10) (No sound is heard)
4 Defective machine monitor If no abnormality is found by above checks, machine monitor is defective.

Circuit diagram related to fuel level sensor 40-392

40-392 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-11 Fuel level gauge does not indicate correctly

Failure 2) Display of fuel level gauge does not correspond to actual fuel level.
Related informa- q Resistance of fuel level sensor can be measured between machine monitor connectors FP2 (fe-
tion male) (10) and FP1 (female) (3).

Cause Procedure, measuring location, criteria and remarks

a Turn starting switch to ON position or start engine. and then perform trouble-
shooting.
Reading of fuel Color of fuel
Fuel level Resistance
level gauge level gauge
Segments 5
FULL 295 – 400 l and below light Max. 7 z
up
Segments 4
3/4 240 – 295 l and below light 7 - 10 z
1 Defective machine monitor
up
Green (G)
Segments 3
1/2 143 – 240 l and below light Approx. 32 z
up
Segments 2
1/4 89 – 143 l and below light Approx. 50 z
up
Segment 1
min. Max. 89 l Min. 85 z Red (R)
alone lights up

Fuel level gauge and fuel level monitor 40-393

GD555-5,GD655-5,GD675-5 40-393
(01)
Troubleshooting of electrical system (E-mode)
E-12 Character display does not display correctly

E-12 Character display does not display correctly 40-394

1) Service meter reading stays unchanged while engine is running.
Failure 2) Odometer reading stays unchanged while machine is traveling.
3) Character display section displays nothing.
Related infor- q Service meter uses signals from engine Ne speed sensor to read operating hours.
mation q Odometer calculates distance referring to signals from transmission output shaft speed sensor.

Cause Procedure, measuring location, criteria and remarks

Display panel of machine monitor may be defective. (Since this is internal fail-
1 Defective machine monitor
ure, troubleshooting cannot be performed.)

40-394 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-12 Character display does not display correctly

GD555-5,GD655-5,GD675-5 40-395
(01)
Troubleshooting of electrical system (E-mode)
E-13 Centralized warning lamp does not light up or does not go off

E-13 Centralized warning lamp does not light up or does not go off 40-396
Failure q Centralized warning lamp does not light up or does not go out.
qCentralized warning lamp lights up in following cases.
1) When any abnormality is found in emergency stop item
Related infor- 2) When action code [E02] or [E03] is displayed on character display section
mation 3) For 2 seconds after starting switch is turned to ON position
q When centralized warning lamp lights up, alarm buzzer is sounded intermittently at the same time.
a When machine overruns, only alarm buzzer sounds.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (15) in fuse box
1 If fuse is blown, circuit may have ground fault. (See cause 5.)
FB1
2 Broken bulb
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
3
defect)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
5 side of them.
(contact with ground circuit)
6 Defective machine monitor
Bulb of centralized warning lamp may be broken or may have defective con-
tact. Check it directly.
it directly.
1. Turn starting switch to OFF position.
2. Remove fuse (15) from fuse box FB1.
3. Disconnect connectors FP1 and FP3, and connect T-adapters to female
side of them.
Between terminal ST9 and FP3 (female) (1) Resistance Max. 1 z
Between FP3 (female) (11) and FP1 (female) (19) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse (15) from fuse box FB1.
3. Disconnect connectors FP1 and FP3, and connect T-adapters to female
Between FP3 (female) (1) and ground Resistance Max. 1 z
Between FP3 (female) (11) or FP1 (female) (19)
Resistance Max. 1 z
and ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
For 2 seconds after start-
ing switch is turned to Voltage Max. 1 V
Between FP1 (19) and ON position
ground When 2 seconds elapsed
since starting switch is Voltage 20 – 30V
turned to ON position.

40-396 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-13 Centralized warning lamp does not light up or does not go off

Circuit diagram related to machine monitor 40-397

GD555-5,GD655-5,GD675-5 40-397
(01)
Troubleshooting of electrical system (E-mode)
E-14 Alarm buzzer does not sound or does not stop sounding

E-14 Alarm buzzer does not sound or does not stop sounding 40-398
Failure q Alarm buzzer does not sound or does not stop sounding.
q When abnormality occurs in alarm buzzer system, failure code [DV00KB] may be displayed and
Related infor-
recorded.
mation
q When machine overruns, only alarm buzzer sounds.

Cause Procedure, measuring location, criteria and remarks

1 Defective alarm buzzer system
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of them.
(contact with ground circuit)
Defective alarm buzzer
4 ing switch is turned to
(internal defect)
5 Defective machine monitor
Perform troubleshooting for failure code [DV00KB] .
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP4, and connect T-adapters to female
side of them.
Between terminal ST9 and FP4 (female) (1) Resistance Max. 1 z
Between FP4 (female) (2) and FP1 (female) (18) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP4, and connect T-adapters to female
Between FP4 (female) (2) or FP1 (female) (18) and
Resistance Max. 1 z
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP4.
3. Turn starting switch to ON position to perform troubleshooting.
For 2 seconds after start-
Voltage Max. 3 V
ON position
Between FP4 (1) and (2)
When 2 seconds elapsed
since starting switch is Voltage 20–30V
turned to ON position.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position to perform troubleshooting.
For 2 seconds after start-
ing switch is turned to Voltage Max. 3 V
Between FP1 (18) and ON position
ground When 2 seconds elapsed
since starting switch is Voltage 20–30V
turned to ON position.

40-398 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-14 Alarm buzzer does not sound or does not stop sounding

Circuit diagram related to alarm buzzer 40-39

GD555-5,GD655-5,GD675-5 40-399
(01)
Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

E-15 Machine monitor mode selector switch does not work 40-40
Failure 1) Machine monitor mode selector switch 1 does not work.
Related infor- q U (upper): To select (enter) desired mode and operation item
mation q t (lower): To cancel selected mode and operation item

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (1) in fuse box FB1 If fuse is blown, circuit may have ground fault. (See cause 5.)

1. Turn starting switch to OFF position.

2. Disconnect connector FP6 and connect T-adapter to male side.
Defective machine monitor mode
Between FP6 (male) (5) Switch 1: Neutral Resistance Min. 1 Mz
selector switch 1
2 and (6) Switch 1: U (upper) Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Between FP6 (male) (4) Switch 1: Neutral Resistance Min. 1 Mz
and (5) Switch 1: t (lower) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP6, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (Wire breakage or defective con- Between FP1 (female) (16) and FP6 (female) (6) Resistance Max. 1 z
tact of connector) Between FP1 (female) (17) and FP6 (female) (4) Resistance Max. 1 z
Between FP1 (female) (5) or (6) and FP6 (female)
Resistance Max. 1 z
(5)
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP6, and connect T-adapter to female side
Ground fault in wiring harness of FP1.
4
(contact with ground circuit) Between FP1 (female) (16) and (3) Resistance Min. 1 Mz
Between FP1 (female) (17) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP6 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
5
(contact with 24 V circuit) Between FP6 (female) (4) and ground Voltage Max. 1 V
Between FP6 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
6 Defective machine monitor 4. Operate machine monitor mode selector switch 1 to perform trouble-
shooting.
Between FP1 (17) and Switch 1: Neutral Voltage Max. 1 V
(3) Switch 1: U (upper) Voltage 20 – 30V

Between FP1 (16) and Switch 1: Neutral Voltage Max. 1 V

(4) Switch 1: t (lower) Voltage 20 – 30V

40-400 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Circuit diagram related to machine monitor mode selector switches 1 and 2 40-401

GD555-5,GD655-5,GD675-5 40-401
(01)
Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Failure 2) Machine monitor mode selector switch 2 does not work.

q > (upper)
Related infor- To move to next screen, move cursor forward, increase number for inputting numeral, etc.
mation q < (lower)
To move to previous screen, move cursor backward, decrease number for inputting numeral, etc.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector PF5 and connect T-adapter to male side.
Defective machine monitor mode
Between FP5 (male) (4) Switch 2: Neutral Resistance Min. 1 Mz
selector switch 2
1 and (5) Switch 2: < (lower) Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Between FP5 (male) (5) Switch 2: Neutral Resistance Min. 1 Mz
and (6) Switch 2: > (upper) Resistance Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors FP1 and FP5, and connect T-adapters to female
2 (Wire breakage or defective con- side of them.
tact of connector) Between FP1 (female) (15) and FP5 (female) (6) Resistance Max. 1 z
Between FP1 (female) (14) and FP5 (female) (4) Resistance Max. 1 z
Between FP5 (female) (5) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP1 and FP5, and connect T-adapter to female side
Ground fault in wiring harness of FP1.
3
(contact with ground circuit) Between FP1 (female) (14) and (3) Resistance Min. 1 Mz
Between FP1 (female) (15) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP5 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
4
(contact with 24 V circuit) Between FP5 (female) (4) and (5) Voltage Max. 1 V
Between FP5 (female) (6) and (5) Voltage Max. 1 V
If no abnormality is found by above checks, machine monitor may be defec-
tive. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
5 Defective machine monitor 4. Operate machine monitor mode selector switch 2 to perform trouble-
shooting.
Between FP1 (14) and Switch 2: Neutral Voltage 20 – 30V
(3) Switch 2: < (lower) Voltage Max. 1 V

Between FP1 (15) and Switch 2: Neutral Voltage 20 – 30V

(4) Switch 2: > (upper) Voltage Max. 1 V

40-402 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-15 Machine monitor mode selector switch does not work

Circuit diagram related to machine monitor mode selector switches 1 and 2 40-403

GD555-5,GD655-5,GD675-5 40-403
(01)
Troubleshooting of electrical system (E-mode)
E-16 Transmission mode does not switch

E-16 Transmission mode does not switch 40-404

Failure q Transmission mode does not switch.
q Manual mode: Direct drive and power shift (HYDROSHIFT) mode
Related infor- Auto mode: Torque converter drive mode
mation q Input signal (ON/OFF) from transmission mode selector switch can be checked by using monitor-
ing function. (Code: TRANSMISSION-1-41700-SHIFT MODE SW)

Cause Procedure, measuring location, criteria and remarks

Defective transmission mode
selector switch
1 Resistance Max. 1 z
(Internal open circuit or short cir-
cuit)
Open circuit in wiring harness
2 (Wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of either of them.
(contact with ground circuit)
Hot short circuit in wiring harness
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector TM30 and connect T-adapter to male side.
Switch: ON (Manual
Between TM30 (male) mode)
(5) and (6)
Switch: OFF (Auto mode) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM30 and TM39, and connect T-adapters to female
side of them.
3. Remove fuse (11) in fuse box FB1.
Between TM39 (female) (18) and TM30 (female) (6) Resistance Max. 1 z
Between FB1 (11) and TM30 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM30 and TM39, and connect T-adapter to female
Between TM39 (female) (18) or TM30 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM30 and connect T-adapter to female side.
Between TM30 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
4. Operate transmission mode selector switch to make diagnosis.
Switch: ON (Manual
Between TM39 (18) and mode) Voltage 20 – 30V
(4)
Switch: OFF (Auto mode) Voltage Max. 1 V

40-404 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-16 Transmission mode does not switch

Circuit diagram related to transmission mode selector switch 40-405

GD555-5,GD655-5,GD675-5 40-405
(01)
Troubleshooting of electrical system (E-mode)
E-17 Engine mode does not switch

E-17 Engine mode does not switch 40-406

Failure q Engine mode does not swtich.
q P-mode (Power mode): Switch at ON.
Related infor- E-mode (Economy mode): Switch at OFF
mation q Input (ON/OFF) from engine mode selector switch can be checked by using monitoring function.
(Code: TRANSMISSION1-40905 D-IN-7).

Cause Procedure, measuring location, criteria and remarks

Defective engine mode selector
switch
1 Switch: ON (P-mode)
(internal open circuit or short cir-
cuit)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
3 side of either of them.
(contact with ground circuit)
Hot short circuit in wiring harness
4 3. Turn starting switch ON.
(contact with 24 V circuit)
5 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connector TM45 and connect T-adapter to male side.
Resistance Max. 1 z
Between TM45 (male)
(5) and (6) Switch: OFF (E-mode) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM45 and TM39, and connect T-adapters to female
side of them.
3. Remove fuse (11) from fuse box FB1.
Between TM39 (female) (6) and TM45 (female) (6) Resistance Max. 1 z
Between FB1 (11) and TM45 (female) (5) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors TM45 and TM39, and connect T-adapter to female
Between TM39 (female) (6) or TM45 (female) (6)
Resistance Min. 1 Mz
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector TM45 and connect T-adapter to female side.
Between TM45 (female) (6) and ground Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM39.
3. Turn starting switch to ON position.
4. Operate engine mode selector switch to perform troubleshooting.
Between TM39 (6) and Switch: ON (P-mode) Voltage 20 – 30 V
(4) Switch: OFF (E-mode) Voltage Max. 1 V

40-406 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-17 Engine mode does not switch

Circuit diagram related to engine mode selector switch 40-407

GD555-5,GD655-5,GD675-5 40-407
(01)
Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

E-18 Differential lock function does not work or cannot be reset [for
machine with differential lock specification] 40-408
Failure Differential lock function does not work or is not reset.
q Transmission controller monitors coil circuit (primary circuit) of differential lock relay to check for
failure in circuit. If open circuit or short circuit is detected, failure code [D19KKZ] is displayed.
q Input signal status (ON/OFF) from differential lock switch can be checked by using monitoring func-
Related infor-
tion.
mation
(Code: TRANSMISSION1-31904-DIFF LOCK SW)
q Activation status (ON/OFF) of differential lock relay can be checked by using monitoring function.
(Code: TRANSMISSION1-31903-DIFF RELAY)

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box 1
Defective differential lock switch
2 (Internal open or short circuit in
wiring)
Defective primary circuit of differ-
3 Perform troubleshooting for failure code [D19KKZ].
ential lock relay (TM43)
Defective differential lock solenoid 2. Disconnect connector R9 and connect T-adapter to male side.
4 valve (internal open circuit or short
circuit)
Open circuit in wiring harness
5 (Wire breakage or defective con-
tact of connector)
If fuse is blown, circuit may have ground fault. (See, description for causes 4
and 6.)
1. Turn starting switch to OFF position.
2. Disconnect connector FP12 and connect T-adapter to male side.
Switch: OFF Resistance Min. 1 Mz
Between FP12 (male) (5)
and (6) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Approx.
Between R9 (male) (1) and (2) Resistance
25 z
Between R9 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40 and TM43, and connect T-adapters to female
side of them.
3. Remove fuse (7) in fuse box FB1.
4. Set differential lock switch to ON.
Between TM40 (female) (28) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.
Between TM43 (female) (6) and ground
(to measure coil resistance of differential lock sole-
Approx.
noid valve) Resistance
25 z
a Check ground terminal ET77 for looseness and
rust.
Between FB1 (7) and TM43 (female) (3) Resistance Max. 1 z
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM40, TM43, FP12 and R9, and connect
T-adapters to female side of them.
Between TM40 (female) (28) and FP12 (female) (6) Resistance Max. 1 z
Between FP12 (female) (5) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.
Between TM43 (female) (6) and R9 (female) (1) Resistance Max. 1 z
Between R9 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.

40-408 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

1. Turn starting switch to OFF position.

2. Disconnect connectors TM40, TM43, FP12 and R9, and connect
T-adapters to female side of them.
Ground fault or short circuit in wir- 3. Remove fuse (7) in fuse box FB1.
6 ing harness 4. Set differential lock switch to ON.
(contact with ground circuit) Between FP12 (female) (5) and (6) Resistance Min. 1 Mz
Between R9 (female) (1) and (2) Resistance Min. 1 Mz
Between TM43 (female) (3) and (2) Resistance Min. 1 Mz

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector TM43 and connect T-adapter to female side.
7 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between TM43 (female) (6) and (2) Voltage Max. 1 V
If no abnormality is found by above checks, transmission controller may be
defective. (Since this is internal failure, troubleshooting cannot be performed.)
q Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM40.
8 Defective transmission controller
3. Turn starting switch to ON position.
4. Operate differential lock switch to make diagnosis.
Between TM40 (28) and Switch: OFF Voltage 7–12V
ground Switch: ON Voltage Max. 1 V

2) Differential lock pilot lamp does not work correctly. (Differential lock is activated and reset nor-
Failure
mally.)
q When differential lock is activated: Pilot lamp lights up
Related infor-
When differential lock is canceled: Pilot lamp goes off
mation
q Operation signal of differential lock pilot lamp is sent from transmission controller through CAN.

Cause Procedure, measuring location, criteria and remarks

1 Defective machine monitor
2 Defective transmission controller
Machine monitor may be defective. (Since trouble is in system, troubleshoot-
ing cannot be performed.)
Transmission controller may be defective. (Since trouble is in system, trouble-
shooting cannot be performed.)

GD555-5,GD655-5,GD675-5 40-409
(01)
Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

Circuit diagram related to differential lock switch and differential lock solenoid valve 40-410

40-410 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-18 Differential lock function does not work or cannot be reset [for machine with differential lock specification]

GD555-5,GD655-5,GD675-5 40-411
(01)
Troubleshooting of electrical system (E-mode)
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]

E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for
machine with lift arm specification] 40-412

Failure 1) Lift arm lock pin cannot lock or unlock lift arm
Related infor- q Lift arm lock switch is activated (pin unlocks lift arm) when it is pushed in, and is not activated (pin
mation locks lift arm) when it is popped up.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box FB1 When fuse is blown, ground fault may be in circuit. (See causes 3 and 5.)

1. Turn starting switch to OFF position.

2. Disconnect connector SP28 and connect T-adapter to male side.
Defective lift arm lock switch (inter-
2
nal open circuit or short circuit) Between SP28 (male) (1) Switch: OFF Resistance Min. 1 Mz
and (2) Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
Defective lock solenoid valve for 2. Disconnect connector R10 and connect T-adapter to male side.
3 lift arm (internal open circuit or
Between R10 (male) (1) and (2) Resistance 2 – 100 z
short circuit)
Between R10 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP28 and R10, and connect T-adapters to female
side of them.
Open circuit in wiring harness 3. Remove fuse (7) from fuse box FB1.
4 (wire breakage or defective con- Between R10 (female) (1) and SP28 (2) Resistance Max. 1 z
tact of connector) Between R10 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.
Between FB1 (7) and SP28 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors FP11 and R10, and connect T-adapter to female
Ground fault or short circuit in wir- side of R10.
5 ing harness 3. Remove fuse (7) from fuse box FB1.
(contact with ground circuit)
4. Set lift arm lock switch to ON.
Between R10 (female) (1) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short in wiring harness 2. Disconnect connector R10 and connect T-adapter to female side.
6 3. Set starting switch to ON position.
(contact with 24 V circuit)
Between R10 (female) (1) and (2) Voltage Max. 1 V

40-412 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-19 Lift arm lock pin does not lock lift arm or does not unlock it [for machine with lift arm specification]

Failure 2) Only pilot lamp for lift arm lock pin is not indicated correctly (lift arm lock works normally).

q When lift arm is locked: Pilot lamp lights up

Related infor-
q When lift arm is unlocked: Pilot lamp goes off
mation
q If wiring harness has ground fault or hot short circuit, lift arm lock does not work normally.

Cause Procedure, measuring location, criteria and remarks

Bulb of pilot lamp for lift arm lock pin may be broken or may have defective
1 Broken bulb
contact. Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
2
defect) it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP28, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (wire breakage or defective con- Between FP3 (female) (9) and SP28 (2) Resistance Max. 1 z
tact of connector) Between FP3 (female) (12) and ground
a Check ground terminal ET89 for looseness and Resistance Max. 1 z
rust.

Circuit diagram related to lift arm lock switch and lock solenoid valve for lift arm 40-413

GD555-5,GD655-5,GD675-5 40-413
(01)
Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

E-20 Blade accumulator function does not work or is not reset [for
machine with blade accumulator specification] 40-414

Failure Blade accumulator function does not work or is not reset.

q If either of blade accumulator solenoid valves operates, related relay, diode, and switch are not de-
fective and ground fault and hot short circuit are not in wiring harnesses. Accordingly, check oper-
Related infor-
ation of blade accumulator solenoid valves.
mation
q Diode FL15 is a protection circuit to eliminate back electromotive force generated by solenoid
valve.

Cause Procedure, measuring location, criteria and remarks

1 Defective fuse (7) in fuse box FB1
Defective accumulator relay
2 (SP31) (internal open circuit or
short circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 8 first.
1. Turn starting switch to OFF position.
2. Replace accumulator relay (connected to connector SP31) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Start engine.
4. Set blade accumulator switch to ON.
5. Operate machine to check operation of blade accumulator function.

If blade accumulator functions properly, original accumulator relay is defective.

1. Turn starting switch to OFF position.

2. Disconnect connector FL15 and connect T-adapter to male side.
a Measure by using multimeter in diode range.
3 Defective diode (FL15)
Between FL15 (male) (1) (+) and (2) (-) No continuity
Between FL15 (male) (1) (-) and (2) (+) Continuity
1. Turn starting switch to OFF position.
Defective blade accumulator 2. Disconnect connector TM45 and connect T-adapter to male side.
4 switch (internal open circuit or
Between TM45 (male) Switch: ON Resistance Max. 1 z
short circuit)
(5) and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Defective right blade accumulator 2. Disconnect connector FL13 and connect T-adapter to male side.
5 solenoid valve (internal open cir- Approx.
Between FL13 (male) (1) and (2) Resistance
cuit or short circuit) 25 z
Between FL13 (male) (1) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Defective left blade accumulator 2. Disconnect connector FL14 and connect T-adapter to male side.
6 solenoid valve (internal open cir- Approx.
Between FL14 (male) (1) and (2) Resistance
cuit or short circuit) 25 z
Between FL14 (male) (1) and ground Resistance Min. 1 Mz

40-414 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector SP31 and connect T-adapter to female side.
3. Disconnect connector FP11 (to separate pilot lamp circuit).
4. Remove fuse (7) in fuse box FB1.
5. Set blade accumulator switch to ON (to connect TM45 (5) and (6)).
Between FB1 (7) and SP31 (female) (3) Resistance Max. 1 z
Between FB1 (7) and SP31 (female) (1) Resistance Max. 1 z
Between SP31 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP31 (female) (5) and ground
(to measure resistance of coils of left and right
blade accumulator solenoid valves connected in Approx.
Resistance
parallel: Resistance is half of one coil resistance) 13 z
a Check ground terminal FLG2 for looseness and
Open circuit in wiring harness rust.
7 (Wire breakage or defective con- a If no abnormality is found by above checks, this check is not required.
tact of connector) 1. Turn starting switch to OFF position.
2. Disconnect connectors FL13, FL14, SP31 and TM45, and connect
T-adapters to female side of them.
3. Disconnect connector FP11 (to separate pilot lamp circuit).
4. Remove fuse (7) from fuse box FB1.
Between FB1 (7) and TM45 (female) (5) Resistance Max. 1 z
Between TM45 (female) (6) and SP31 (female) (1) Resistance Max. 1 z
Between SP31 (female) (5) and FL13 (female) (1) Resistance Max. 1 z
Between FL13 (female) (1) and FL14 (female) (1) Resistance Max. 1 z
Between FL13 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
Between FL14 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors FL13 to F15 and SP31, and connect T-adapter to
female side of connector SP31
3. Disconnect connector FP11 (to separate pilot lamp circuit).
Ground fault or short circuit in wir- 4. Disconnect connector TM43 (to separate differential lock circuit).
8 ing harness
5. Remove fuse (7) in fuse box FB1.
(contact with ground circuit)
Between SP31 (female) (1) and (2) Resistance Min. 1 Mz
Between SP31 (female) (3) and (2) Resistance Min. 1 Mz
Between SP31 (female) (5) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP31 and connect T-adapter to female side.
Hot short circuit in wiring harness 3. Turn starting switch to ON position.
9
(contact with 24 V circuit) Between SP31 (female) (1) and (2) Voltage Max. 1 V
Between SP31 (female) (5) and (2) Voltage Max. 1 V

GD555-5,GD655-5,GD675-5 40-415
(01)
Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

2) Blade accumulator pilot lamp does not work correctly. (Blade accumulator function works or is reset
Failure
normally.)
q When blade accumulator is activated: Pilot lamp lights up
Related infor-
q When blade accumulator is canceled: Pilot lamp goes off
mation
q If wiring harness has ground fault or hot short circuit, blade accumulator does not work normally.

Cause Procedure, measuring location, criteria and remarks

Blade accumulator pilot lamp bulb may be broken or have poor contact. Check
1 Broken bulb
it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (open circuit or short circuit). Check
2
defect) it directly.
1. Turn starting switch to OFF position.
2. Disconnect connector FP3 and connect T-adapter to female side.
Open circuit in wiring harness Between FP3 (female) (7) and ground
Resis- Approx.
3 (Wire breakage or defective con- a To measure resistance of right and left blade accumu-
tance 13 z
tact of connector) lator solenoid valves connected in parallel
Between FP3 (female) (12) and ground Resis-
Max. 1 z
a Check ground terminal ET89 for looseness and rust. tance

40-416 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-20 Blade accumulator function does not work or is not reset [for machine with blade accumulator specification]

Circuit diagram related to blade accumulator 40-417

GD555-5,GD655-5,GD675-5 40-417
(01)
Troubleshooting of electrical system (E-mode)
E-21 Horn does not sound or does not stop sounding

E-21 Horn does not sound or does not stop sounding 40-418

Failure 1) Horn does not sound.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective fuse (14) in fuse box
1
FB1
Defective horn relay (SP27) (inter-
2 3. Turn starting switch to ON position.
nal open circuit or short circuit)
3 Defective horn RH (FL7)
4 Defective horn LH (FL8)
Defective horn switch (internal
5
open circuit or short circuit)
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
Short circuit or ground fault in wir-
7 ing harness
(contact with ground circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 7 first.
1. Turn starting switch to OFF position.
2. Replace horn relay (connected to connector SP27) with another relay
(head lamp relay or connector SP13, etc.)
4. Press horn switch to sound horn.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FL7 and connect T-adapter to male side.
Between FL7 (male) (1) and (2) Continuity
Between FL7 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FL8 and connect T-adapter to male side.
Between FL8 (male) (1) and (2) Continuity
Between FL8 (male) (2) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector FP9 and connect T-adapter to male side.
Between FP9 (male) (1) Switch: ON Resistance Max. 1 z
and ground Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP27, FP9, FL7 and FL8, and connect T-adapters
to female side of them.
3. Remove fuse (14) in fuse box FB1.
Between FP9 (female) (1) and SP27 (female) (6) Resistance Max. 1 z
Between FB1 (14) and SP27 (female) (5) Resistance Max. 1 z
Between SP27 (female) (2) and FL7 (female) (2) Resistance Max. 1 z
Between SP27 (female) (2) and FL8 (female) (2) Resistance Max. 1 z
Between FL7 (female) (1) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
Between FL8 (female) (1) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors FL7, FL8, and SP27 and connect T-adapters to
female side of them.
3. Remove fuse (14) in fuse box FB1.
Between FL7 (female) (1) and (2) Resistance Min. 1 Mz
Between SP27 (female) (1) and ground Resistance Min. 1 Mz

40-418 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-21 Horn does not sound or does not stop sounding

Failure 2) Horn does not stop sounding.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn relay (SP27) (inter- 2. Remove horn relay (connected to connector SP27).
1 3. Turn starting switch to ON position.
nal open circuit or short circuit)
If horn stops sounding, original horn relay is defective.
1. Turn starting switch to OFF position.
Defective horn switch (internal 2. Disconnect connector FP9.
2 3. Turn starting switch to ON position.
open circuit or short circuit)
If horn stops sounding, horn switch is defective.

Short circuit or ground fault in wir- 1. Turn starting switch to OFF position.
3 ing harness 2. Disconnect connector SP27 and connect T-adapter to female side.
(contact with ground circuit) Between SP27 (female)(6) and ground Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in wiring harness 2. Disconnect connector SP27 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Between SP27 (female) (2) and ground Voltage Max. 1 V

Circuit diagram related to horn 40-419

GD555-5,GD655-5,GD675-5 40-419
(01)
Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

E-22 Backup alarm does not sound or does not stop sounding 40-420

Failure 1) Backup alarm does not sound.

q If backup lamp lights up when gearshift lever is set to “R” position, related fuses and relays are
not defective and wiring harnesses have not ground fault or hot short circuit. Check whether back-
Related infor- up lamp lights up or not.
mation q If fuse is blown, stop lamp does not light up either.
q Whether backup lamp relay is activated by transmission controller can be checked by using mon-
itoring function (code: TRANSMISSION1 40951 D-OUT-19).

Cause Procedure, measuring location, criteria and remarks

Defective fuse (13) in fuse box
1
FB1
Defective backup lamp relay
2 (TM42) (internal open circuit or
short circuit)
3 Defective backup alarm
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Replace backup lamp relay (connected to connector TM42) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
If backup alarm sounds, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector BZ and connect T-adapter to male side.
Between BZ (male) (1) and (2)
a Check backup alarm terminal for looseness and Continuity
rust.
Between BZ (male) (1) and ground Resistance Min. 1 Mz
q Primary circuit of backup lamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector TM41 and connect T-adapter to female side.
Between TM41 (female) (18) and ground
(to measure coil resistance of backup lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
q Secondary circuit of backup lamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Disconnect connector RL1(to disconnect backup lamp circuit).
4. Remove fuse (13) in fuse box FB1.
Between TM42 (female) (3) and FB1 (13) Resistance Max. 1 z
Between TM42 (female) (5) and ground
a Check ground terminal ET77 for looseness and Continuity
rust.
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42 and BZ, and connect T-adapters to
female side of them.
3. Disconnect connector RL1 (to separate backup lamp circuit).
4. Remove fuse (13) in fuse box FB1.
Between TM41 (female) (18) and TM42 (female) (1) Resistance Max. 1 z
Between TM42 (female) (2) and ground Resistance Max. 1 z
Between TM42 (female) (5) and BZ (female) (1) Resistance Max. 1 z
Between BZ (female) (2) and ground Resistance Max. 1 z

40-420 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

Cause Procedure, measuring location, criteria and remarks

Short circuit or ground fault in wir- 3. Remove fuse (14) in fuse box FB1.
5 ing harness
(contact with ground circuit)
6 Defective transmission controller
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42 and BZ, and connect T-adapter to
female side of TM42.
Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
Between TM42 (female) (3) and (2) Resistance Min. 1 Mz
Between TM42 (female) (5) and (2) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector TM41.
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
a If input voltage to "Shift lever R" is correct but output voltage from "Back
lamp relay" is incorrect, transmission controller is defective.
Between TM41 (female) (16) and (21)
Voltage 20 – 30 V
(input voltage to "Shift lever R")
Between TM41 (female) (18) and (21)
Voltage 20 – 30 V
(to measure output voltage from "Back lamp relay")

Failure 2) Backup alarm does not stop sounding

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective backup lamp relay
1 (TM42) (internal open circuit or
short circuit)
Hot short circuit in wiring harness
2
(Contact with 24 V circuit)
1. Turn starting switch to OFF position.
2. Remove backup lamp relay (connector TM42).
3. Turn starting switch to ON position.
If backup alarm stops sounding, original backup lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between TM42 (female) (1) and (2) Voltage Max. 1 V
Between TM42 (female) (5) and (2) Voltage Max. 1 V

3 Defective transmission controller See Failure 1).

GD555-5,GD655-5,GD675-5 40-421
(01)
Troubleshooting of electrical system (E-mode)
E-22 Backup alarm does not sound or does not stop sounding

Circuit diagram related to backup alarm 40-42

40-422 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go
off 40-423

Failure 1) None of headlamp, clearance lamp, and tail lamp light up or go off.
q If fuse (12) of FB1 is blown, none of headlamp, clearance lamp and tail lamp light up.
Related infor-
q If small lamp relay is defective or fuse (9) in FB2 is blown, headlamp lights up, but none of the clear-
mation
ance lamp, tail lamp, and night light of machine monitor light up.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (12) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
1
FB1 shooting for cause 4 first.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Switch: Clearance lamp
Between SP22 (male) (5) ON Resistance Max. 1 z
Defective headlamp switch (Inter- and (6)
2 Switch: OFF Resistance Min. 1 Mz
nal disconnection or short circuit)
Switch: Clearance lamp
Between SP22 (male) (4) ON Resistance Max. 1 z
and (5)
Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP22 and SP13, and connect T-adapters to female
side.
3. Remove fuse (12) in fuse box FB1.
Open circuit in wiring harness Between SP13 (female) (6) and ground
3 (Wire breakage or defective con- a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
tact of connector) looseness and rust.
Between FB1 (12) and SP22 (female) (5) Resistance Max. 1 z
Between FB1 (12) and SP13 (female) (1) Resistance Max. 1 z
Between FB1 (12) and SP13 (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP22 and SP13, and connect T-adapter to female
side of SP13.
Ground fault or short circuit in wir-
4 3. Remove fuse (12) in fuse box FB1.
ing harness
Between SP13 (female) (1) and (2) Resistance Min. 1 Mz
Between SP13 (female) (1) and (6) Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-423
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 2) Headlamp does not light up or does not go off

q If headlamp and clearance lamp do not light up, check turn signal lamp and hazard lamp. If none
Related infor-
of their front lamps light up, ground circuit (FLG1) may be defective (Tail lamp lights up).
mation
q Dimmer relay (SP11) switches between the high and low beam.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective headlamp relay (SP13)
2 (internal open circuit or short cir-
cuit)
Defective dimmer relay (SP11)
3 (internal open circuit or short cir-
cuit)
Defective headlamp switch (inter-
4 Max. 1 z
nal open circuit or short circuit) Between SP22 (male) (5) Switch: Head ON
and (6)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If specific working lamp does not light up, its bulb may be broken or may have
defective contact. Check it directly.
1. Turn starting switch to OFF position.
2. Replace headlamp relay (connector SP13) with another relay (horn relay
connected to connector SP27, etc.)
3. Turn starting switch to ON position.
4. Set headlamp switch to Head ON.
If headlamp lights up, original headlamp relay is defective.
1. Turn starting switch to OFF position.
2. Replace dimmer relay (connector SP11) with another relay (stop lamp relay
connected to connector SP16, etc.)
3. Turn starting switch to ON position.
4. Set headlamp switch to Head ON.
If headlamp lights up, original dimmer relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Resistance
Switch: OFF Resistance Min. 1 Mz
q Primary circuit of headlamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to female side.
Between SP22 (female) (6) and ground
(headlamp relay coil resistance)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
q Secondary circuit of headlamp relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP13 and connect T-adapter to female side.
a Check that dimmer (high beam) switch is at OFF position.
Between SP13 (female) (2) and (6)
a Check ground terminal FLG1 for looseness and
rust. Resistance Approx. 4 z
a Parallel resistance of lamps having resistance of
approx. 8 z each (8/2)
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, SP22, FL1, and FL2, and connect
T-adapters to female side of them.
Between SP22 (female) (6) and SP13 (female) (5) Resistance Max. 1 z
Between SP13 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (6) and FL1 (female) (A) Resistance Max. 1 z
Between SP11 (female) (6) and FL2 (female) (A) Resistance Max. 1 z
Between FL1 (female) (B) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.
Between FL2 (female) (B) and ground
a Check ground terminal FLG1 for looseness and Resistance Max. 1 z
rust.

40-424 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, SP22, FL1, and FL2, and connect
T-adapter to female side of SP13.
3. Remove fuse (12) in fuse box FB1.
Ground fault or short circuit in wir- Between SP13 (female) (2) and (6) Resistance Min. 1 Mz
6
ing harness
Between SP13 (female) (5) and (6) Resistance Min. 1 Mz
Between SP13 (female) (1) and (2) Resistance Min. 1 Mz
Between SP13 (female) (1) and (5) Resistance Min. 1 Mz

Circuit diagram related to headlamp, clearance lamp, tail lamp, and front working lamp 40-425

GD555-5,GD655-5,GD675-5 40-425
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 3) Headlamp beam direction cannot switch between high beam and low beam.
Related infor-
q Dimmer relay (SP11) switches between the high and low beam.
mation

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective dimmer relay (SP11)
2 (internal open circuit or short cir-
cuit)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
1. Turn starting switch to OFF position.
2. Replace dimmer relay (connector SP11) with another relay (stop lamp relay
connected to connector SP16, etc.)
3. Turn starting switch to ON position.
4. Turn on headlamp and turn dimmer switch to ON and OFF position.

If beam switches between high and low, original dimmer relay is defective.

1. Turn starting switch to OFF position.

Defective dimmer switch (internal
3
open circuit or short circuit)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir- Between SP11 (female) (1) and (2)
5
ing harness
2. Disconnect connector FP7 and connect T-adapter to male side.
Between FP7 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
q Primary circuit of dimmer relay
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11 and SP13, and connect T-adapters to female
side of them.
3. Set dimmer (high beam) switch to ON.
Between SP13 (female) (2) and SP11 (female) (1) Resistance Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
q Secondary circuit of dimmer relay
1. Turn starting switch to OFF position.
2. Disconnect connector SP11 and connect T-adapter to female side.
a Parallel resistance of lamps having resistance of approx. 8 z each (8/2)
a Check ground terminal FLG1 for looseness and rust.
Between SP11 (female) (5) and (2) Resistance Approx. 4 z
Between SP11 (female) (6) and (2) Resistance Approx. 4 z
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, FP7, FL1 and FL2, and connect
T-adapter to each female side.
Between SP13 (female) (2) and FP7 (female) (6) Resistance Max. 1 z
Between SP11 (female) (1) and FP7 (female) (5) Resistance Max. 1 z
Between SP13 (female) (2) and SP11 (female) (3) Resistance Max. 1 z
Between SP11 (female) (5) and FL1 (female) (C) Resistance Max. 1 z
Between SP11 (female) (5) and FL2 (female) (C) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP11, SP13, FL1 and FL2, and connect T-adapter
to female side of SP11.
a Check that dimmer (high beam) switch is set to OFF.
Resistance Min. 1 Mz
Between SP11 (female) (1) and (5) Resistance Min. 1 Mz
Between SP11 (female) (2) and (5) Resistance Min. 1 Mz
Between SP11 (female) (3) and (5) Resistance Min. 1 Mz

40-426 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Failure 4) High beam pilot lamp for headlamp does not light up or does not go off.
Related infor- q Headlamp cannot switch between high beam and low beam if ground fault or open circuit is in its
mation circuit.

Cause Procedure, measuring location, criteria and remarks

High beam pilot lamp bulb for headlamp may be broken or have defective con-
1 Broken bulb
tact. Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP11, and connect T-adapters to female
Breaking of harness
side of them.
3 (Wire breakage or defective con-
tact of connector) Between FP3 (female) (3) and SP11 (female) (1) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

Failure 5) Clearance lamp, tail lamp, and night light for machine monitor do not light up or do not go off
q If small lamp relay is defective or fuse (9) in FB2 is blown, headlamp lights up, but none of the clear-
ance lamp, tail lamp, and night light for machine monitor light up.
q If clearance lamp does not light up while tail lamp lights up, check headlamp, turn signal lamp, and
Related infor-
hazard lamp. If none of their front lamps light up, ground circuit (FLG1) may be defective.
mation
q If clearance lamp lights up but tail lamp does not light up, check headlamp, turn signal lamp, hazard
lamp, stop lamp, and backup lamp. If none of their rear lamps light up, ground circuit (ET77) may
be defective.

Cause Procedure, measuring location, criteria and remarks

If a specific working lamp does not light up, its bulb may be broken or may
1 Broken bulb
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse (9) in fuse box FB2
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Disconnect connector SP22 and connect T-adapter to male side.
Defective headlamp switch (inter-
3
nal open circuit or short circuit) Between SP22 (male) (4) Switch: Head ON Resistance Max. 1 z
and (5) Switch: OFF Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-427
(01)
Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors SP22, SP12, SP13, and FP1, and connect
T-adapters to female side of them.
3. Remove fuse (9) in fuse box FB2.
Between SP12 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB2 (9) and SP12 (female) (3) Resistance Max. 1 z
Between SP12 (1) and SP13 (female) (4) Resistance Max. 1 z
Between SP12 (1) and SP2 (female) (4) Resistance Max. 1 z
Between SP12 (5) and FP1 (female) (8) Resistance Max. 1 z
Between SP12 (5) and (2)
Open circuit in wiring harness a Parallel resistance of 4 lamps having resistance
4 (wire breakage or defective con- Approx.
of approx. 125 z each (125/4) Resistance
tact of connector) 30 z
a Check ground terminals FLG1 and ET77 for
looseness snd rust.
a If no abnormality is found by above checks, this
check is not required.
1. Turn starting switch to OFF position.
Resistance Max. 1 z
2. Disconnect connectors SP12, FL3, FL4, RL2,
and RL3, and connect T-adapters to female side
of them.
Between SP12 (5) and FL3 (female) (A) Resistance Max. 1 z
Between SP12 (5) and FL4 (female) (A) Resistance Max. 1 z
Between SP12 (5) and RL2 (female) (6) Resistance Max. 1 z
Between SP12 (5) and RL3 (female) (6) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP12, SP13, FL3, FL4, RL2, and RL3, and connect
T-adapter to female side of SP12.
3. Disconnect connector FP1 (to separate circuit of night light for machine
monitor).
Ground fault or short circuit in wir- 4. Remove fuse (9) in fuse box FB2.
5
ing harness Between SP12 (female) (1) and (2) Resistance Min. 1 Mz
Between SP12 (female) (1) and (3) Resistance Min. 1 Mz
Between SP12 (female) (2) and (5) Resistance Min. 1 Mz
Between SP12 (female) (3) and (5) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FP1.
3. Turn starting switch to ON position.
6 Defective machine monitor 4. Set clearance lamp switch to ON and OFF to perform troubleshooting.
Switch: ON Resistance 20 – 30 V
Between FP1 (8) and (3)
Switch: OFF Resistance Max. 1 V

40-428 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-23 Headlamp, clearance lamp and tail lamp do not light up or do not go off

Circuit diagram related to headlamp, clearance lamp, tail lamp, and front working lamp 40-429

GD555-5,GD655-5,GD675-5 40-429
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

E-24 Working lamp does not light up or does not go off 40-430

Failure 1) Front working lamp and cab (MID) working lamp do not light up or do not go off.
Related infor- q Circuit for front working lamp and cab (MID) working lamp is completely independent from that for
mation headlamp, clearance lamp and tail lamp, having its own fuse and ground circuit.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective fuse (10) in fuse box
2
FB1
Defective front working lamp relay
3 (SP14) (internal open circuit or
short circuit)
Defective front working lamp
4 switch (internal open circuit or
short circuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace front working lamp relay (connected to connector SP14) with
another relay (horn relay connected to connector SP27, etc.).
3. Turn starting switch to ON position.
4. Set front working lamp switch to ON.
If front working lamp lights up, original front working lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP23 and connect T-adapter to male side.
Between SP23 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP14 and connect T-adapter to female side.
3. Remove fuse (10) in fuse box FB1.
4. Set front working lamp switch to ON.
Between SP14 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (10) and SP14 (female) (1) Resistance Max. 1 z
Between SP14 (female) (1) and (5)
Resistance Max. 1 z
a Front working lamp switch circuit
Between SP14 (female) (2) and (6)
a Check ground terminal FLG2 for looseness and
Approx. 8 z
rust.
Resistance (Approx.
a Resistance of one lamp is approx. 8 z. Total re-
4 z)
sistance is approx. 4 z if cab working lamp is in-
stalled in parallel.
Between SP14 (female) (4) and (6)
a Check ground terminal FLG2 for looseness and
Approx. 8 z
rust.
Resistance (Approx.
a Resistance of one lamp is approx. 8 z. Total re-
4 z)
sistance is approx. 4 z if cab working lamp is in-
stalled in parallel.

40-430 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

a If no abnormality is found by above checks, this
check is not required.
1. Turn starting switch to OFF position.
Resistance Max. 1 z
2. Disconnect connectors SP23, SP14, FP9, FL10,
FL11 and FL12, and connect T-adapter to each
female side.
Between SP23 (female) (5) and SP14 (female) (3) Resistance Max. 1 z
Between SP23 (female) (6) and SP14 (female) (5) Resistance Max. 1 z
Between SP14 (female) (1) and (3) Resistance Max. 1 z
Between SP14 (female) (2) and FL9 (female) (1) Resistance Max. 1 z
Between SP14 (female) (4) and FL10 (female) (1) Resistance Max. 1 z
Open circuit in wiring harness Between FL9 (female) (2) and ground
5 (Wire breakage or defective con- a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
tact of connector) rust.
Between FL10 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.

Between SP14 (female) (2) and FL11 (female) (1) Resistance Max. 1 z

Between SP14 (female) (4) and FL12 (female) (1) Resistance Max. 1 z

Between FL11 (female) (2) and ground

a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
Between FL12 (female) (2) and ground
a Check ground terminal FLG2 for looseness and Resistance Max. 1 z
rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP14, FP3, FL9 and FL10, and connect T-adapter
to female side of SP14.
a Disconnect connectors FL11 and FL12 too if cab working lamp is in-
stalled.
3. Remove fuse (10) in fuse box FB1.
Between SP14 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
6 Between SP14 (female) (1) and (4) Resistance Min. 1 Mz
ing harness
Between SP14 (female) (1) and (5) Resistance Min. 1 Mz
Between SP14 (female) (1) and (6) Resistance Min. 1 Mz
Between SP14 (female) (6) and (2) Resistance Min. 1 Mz
Between SP14 (female) (6) and (4) Resistance Min. 1 Mz
Between SP14 (female) (6) and (5) Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-431
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Failure 2) Pilot lamp for working lamp does not lights up or does not go off
Related infor- q Front working lamp does not light up or does not go off normally if ground fault or open circuit is in
mation its circuit.

Cause Procedure, measuring location, criteria and remarks

Pilot lamp for working lamp may have broken bulb or have defective contact.
1 Broken bulb
Check it directly.
Defective lamp assembly (internal Lamp assembly may have internal defect (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and SP14, and connect T-adapters to female
Breaking of harness
side of them.
3 (Wire breakage or defective con-
tact of connector) Between FP3 (female) (5) and SP14 (female) (5) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

40-432 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Circuit diagram related to headlamp, clearance lamp, tail lamp, front working lamp and cab (MID)
working lamp 40-43

GD555-5,GD655-5,GD675-5 40-433
(01)
Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Failure 3) Rear working lamp does not light up or does not go off.
q Rear working lamp relay shares power supply (fuse) in its primary circuit with front working lamp.
Related infor- Check whether front working lamp lights up and goes off normally.
mation q If tail lamp does not light up, grounding may be defective. In this case, see “E-23 Headlamp, clear-
ance lamp and tail lamp do not light up or do not go off”

Cause Procedure, measuring location, criteria and remarks

If a specific lamp does not light up, its bulb may be broken or may have defec-
1 Broken bulb
tive contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2 Defective fuse (9) in fuse box FB1
shooting for cause 6 first.
1. Turn starting switch to OFF position.
Defective rear working lamp relay 2. Replace rear working lamp relay (SP15) with another relay (stop lamp relay
3 (SP15) (internal open circuit or connected to connector SP16, etc.).
short circuit) 3. Turn on rear working lamp switch.
If rear working lamp lights up, original rear working lamp relay is defective.
1. Turn starting switch to OFF position.
Defective rear working lamp switch 2. Disconnect connector SP24 and connect T-adapter to male side.
4 (internal open circuit or short cir-
Between SP24 (male) (5) Switch: ON Resistance Max. 1 z
cuit)
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector SP15 and connect T-adapter to female side.
3. Remove fuses (9) and (10) in fuse box FB1.
4. Turn on rear working lamp switch.
Between SP15 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (10) and SP15 (female) (1) Resistance Max. 1 z
Between FB1 (9) and SP15 (female) (3) Resistance Max. 1 z
Between SP15 (female) (5) and ground
a Parallel resistance of lamps having resistance of Resistance Approx. 4 z
approx. 8 z each
Open circuit in wiring harness a If no abnormality is found by above checks, this check is not required.
5 (Wire breakage or defective con- 1. Turn starting switch to OFF position.
tact of connector) 2. Disconnect connectors SP15, SP24, SP14, RL4 and RL5, and connect
T-adapters to each female side of them.
3. Remove fuse (10) in fuse box FB1.
Between FB1 (10) and SP14 (female) (1) Resistance Max. 1 z
Between SP14 (female) (3) and SP24 (female) (5) Resistance Max. 1 z
Between SP15 (female) (1) and SP24 (female) (6) Resistance Max. 1 z
Between SP15 (female) (5) and RL5 (female) (1) Resistance Max. 1 z
Between SP15 (female) (5) and RL4 (female) (1) Resistance Max. 1 z
Between RL4 (female) (2) and ground Resistance Max. 1 z
Between RL5 (female) (2) and ground Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP15, SP24, RL4 and RL5, and connect T-adapter
to female side of SP15.
Ground fault or short circuit in wir- 3. Remove fuse (9) in fuse box FB1.
6
ing harness Between SP15 (female) (2) and (1) Resistance Min. 1 Mz
Between SP15 (female) (2) and (3) Resistance Min. 1 Mz
Between SP15 (female) (2) and (5) Resistance Min. 1 Mz

40-434 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-24 Working lamp does not light up or does not go off

Circuit diagram related to rear working lamp 40-435

GD555-5,GD655-5,GD675-5 40-435
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

E-25 Turn signal lamp and hazard lamp do not flash. 40-436

Failure 1) Neither of turn signal lamp and hazard lamp flash.

q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
(Turn signal lamp and hazard lamp have their respective fuses.)
q Circuit common to both turn signal lamp and hazard lamp is "flasher (connected connector SP26)"
that generates flashing.
Related infor- q When flasher is defective, every turn signal lamp may not flash but lights up even if right or left turn
mation signal lamp is turned on or hazard lamp is turned on.

q Troubleshoot flasher after troubleshooting of wiring harness.

q When front or rear lamps do not flash, ground circuit may be defective. In this case, see "E-23
Headlamp, clearance lamp, and tail lamp do not light up or do not go off".

Cause Procedure, measuring location, criteria and remarks

Defective hazard lamp relay 2
1 (SP19) (internal open circuit or
short circuit)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir-
3 Between SP26 (female) (1) and (3)
ing harness
4 Defective flasher (internal defect)
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 2 (connected to connector SP19) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 2 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP26, SP18 and SP19, and connect T-adapters to
female side of them.
Between SP26 (female) (1) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP26 (female) (3) and SP19 (female) (3) Resistance Max. 1 z
Between SP26 (female) (4) and SP18 (female) (3) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector SP26 and connect T-adapter to female side.
3. Remove fuse (6) in fuse box FB1.
Resistance Min. 1 Mz
Between SP26 (female) (1) and (4) Resistance Min. 1 Mz
Between SP26 (female) (3) and (4) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector SP26.
3. Turn starting switch to ON position.
Between SP26 (3) and Power sup-
Voltage 20 – 30V
(1) ply
Between SP26 (4) and Pulse voltage of 20 to 30
Output Voltage
(1) V and 1 V or below

40-436 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Circuit diagram related to turn signal lamp and hazard lamp 40-437

GD555-5,GD655-5,GD675-5 40-437
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Failure 2) Turn signal lamp does not flash.

q Check that hazard lamp operates normally.
q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
Related infor-
q When right or left turn signal lamps do not flash, wiring harness is defective.
mation
q When front or rear lamps do not flash, ground circuit may be defective. In this case, see "E-23
Headlamp, clearance lamp, and tail lamp do not light up or do not go off".

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
2 Defective fuse (6) in fuse box FB1
Defective turn signal lever (internal
3 and (B)
open circuit or short circuit)
Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir- 3. Remove fuse (6) in fuse box FB1.
5
ing harness
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Disconnect connector FP8 and connect T-adapter to male side.
Lever: Left turn position
Between FP8 (male) (A) (upper position) Resistance Max. 1 z
Lever: Neutral position Resistance Min. 1 Mz
Lever: Right turn posi-
Between FP8 (male) (A) tion (lower position) Resistance Max. 1 z
and (C)
Lever: Neutral position Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, FP8, FL3, FL4, RL2 and RL3, and
connect T-adapters to female side of them.
3. Remove fuse (6) in fuse box FB1.
Between FB1 (6) and SP19 (female) (6) Resistance Max. 1 z
Between SP18 (female) (1) and (3) Resistance Max. 1 z
Between SP18 (female) (1) and FP8 (female) (A) Resistance Max. 1 z
Between FP8 (female) (B) and FL4 (female) (C) Resistance Max. 1 z
Between FP8 (female) (B) and RL3 (female) (1) Resistance Max. 1 z
Between FP8 (female) (C) and FL3 (female) (C) Resistance Max. 1 z
Between FP8 (female) (C) and RL2 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, SP26, FP8, FL3, FL4, RL2 and RL3,
and connect T-adapters to female side of SP19 and FP8.
Between SP19 (female) (2) and (6) Resistance Min. 1 Mz
Between FP8 (female) (B) and ground Resistance Min. 1 Mz
Between FP8 (female) (C) and ground Resistance Min. 1 Mz

40-438 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Circuit diagram related to turn signal lamp and hazard lamp 40-439

GD555-5,GD655-5,GD675-5 40-439
(01)
Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Failure 3) Hazard lamp does not flash.

q Check that turn signal lamp operates normally.
q Hazard lamp relay 2 (SP19) switches power supply for flasher (connected to connector SP26).
Related infor-
q When starting switch is turned to ON position and hazard lamp fhases, hazard lamp relay 2 (SP19)
mation
is defective.
q For related circuit diagram, see Failure 1) or 2).

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
2 Defective fuse (4) in fuse box FB1
Defective hazard lamp relay 2
3 (SP19) (internal open circuit or
short circuit)
Defective hazard lamp relay 1
4 (SP18) (internal open circuit or
short circuit)
Defective hazard lamp switch
5 (internal open circuit or short cir-
cuit)
Open circuit in wiring harness
6 (wire breakage or defective con-
tact of connector)
If a specific working lamp does not light up, its bulb may be broken or may
have defective contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 7 first.
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 2 (connected to connector SP19) with another
relay (stop lamp relay connected to connector SP16, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 2 is defective.
1. Turn starting switch to OFF position.
2. Replace hazard lamp relay 1 (SP18) with another relay (horn relay
connected to connector SP27, etc.).
3. Set hazard lamp switch to ON.
If hazard lamp flashes, original hazard lamp relay 1 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector SP25 and connect T-adapter to male side.
Between SP25 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19, SP26, FL3, FL4, RL2 and RL3, and
connect T-adapters to female side of them.
3. Remove fuse (4) in fuse box FB1.
4. Set hazard lamp switch to ON.
Between SP19 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between FB1 (4) and SP19 (female) (5) Resistance Max. 1 z
Between FB1 (4) and SP19 (female) (1) Resistance Max. 1 z
Between SP18 (female) (1) and (3) Resistance Max. 1 z
Between SP18 (female) (2) and FL4 (female) (C) Resistance Max. 1 z
Between SP18 (female) (2) and RL3 (female) (1) Resistance Max. 1 z
Between SP18 (female) (4) and FL3 (female) (C) Resistance Max. 1 z
Between SP18 (female) (4) and RL2 (female) (1) Resistance Max. 1 z

40-440 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-25 Turn signal lamp and hazard lamp do not flash.

Cause Procedure, measuring location, criteria and remarks

a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18, SP19 and SP25, and connect T-adapters to
female side of them.
3. Remove fuse (4) in fuse box FB1.
Open circuit in wiring harness Between FB1 (4) and SP25 (female) (5) Resistance Max. 1 z
6 (wire breakage or defective con- Between SP25 (female) (6) and SP18 (female) (5) Resistance Max. 1 z
tact of connector)
Between SP18 (female) (5) and SP19 (female) (1) Resistance Max. 1 z
Between SP18 (female) (6) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between SP18 (female) (6) and SP19 (female) (2) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors SP18 and SP19, and connect T-adapter to female
side of SP18.
a Check that hazard lamp switch is in OFF position.
Between SP18 (female) (5) and (6) Resistance Min. 1 Mz
Between SP18 (female) (3) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
7
ing harness Between SP18 (female) (3) and (4) Resistance Min. 1 Mz
Between SP18 (female) (2) and (5) Resistance Min. 1 Mz
Between SP18 (female) (4) and (5) Resistance Min. 1 Mz
Between SP18 (female) (2) and (6) Resistance Min. 1 Mz
Between SP18 (female) (4) and (6) Resistance Min. 1 Mz

Failure 4) Turn signal pilot lamp does not flash.

Related infor-
q Turn signal lamp does not flash if ground fault or open circuit is in its circuit.
mation

Cause Procedure, measuring location, criteria and remarks

Bulb of turn signal pilot lamp that does not light up may be broken or have
1 Broken bulb
defective contact. Check it directly.
Defective lamp assembly (internal Lamp assembly may be internally defective (disconnection or short circuit).
2
defect) Check it directly.
1. Turn starting switch to OFF position.
2. Disconnect connectors FP3 and FP8, and connect T-adapters to female
Open circuit in wiring harness side of them.
3 (wire breakage or defective con- Between FP3 (female) (4) and FP8 (female) (B) Resistance Max. 1 z
tact of connector)
Between FP3 (female) (2) and FP8 (female) (C) Resistance Max. 1 z
Between FP3 (female) (12) and ground Resistance Max. 1 z

GD555-5,GD655-5,GD675-5 40-441
(01)
Troubleshooting of electrical system (E-mode)
E-26 Stop lamp does not light up or does not go off

E-26 Stop lamp does not light up or does not go off 40-4 2

Failure Stop lamp does not light up or does not go off.

Related infor- q If neither tail lamp nor backup lamp light up, ground terminal (ET77) or fuse (13) in fuse box FB1
mation may be defective.

Cause Procedure, measuring location, criteria and remarks

1 Broken bulb
Defective fuse (13) in fuse box
2
FB1
Defective stop lamp relay (SP16)
3 (internal open circuit or short cir-
cuit)
Defective brake lamp switch
4 (internal open circuit or short cir-
cuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
If a specific lamp does not light up, its bulb may be broken or may have defec-
tive contact. Check it directly.
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace stop lamp relay (connected to connector SP16) with another relay
(small lamp relay connected to connector SP12, etc.).
3. Turn starting switch to ON position.
4. Depress brake pedal.
If stop lamp lights up, original stop lamp relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapter to male side.
When brake pedal is
Resistance Max. 1 z
Between B13 (male) (1) depressed
and (2) When brake pedal is
Resistance Min. 1 Mz
released
1. Turn starting switch to OFF position.
2. Disconnect connector B13 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between B13 (female) (2) and ground
(to measure coil resistance of stop lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
loosenes and rust.
Between FB1 (13) and B13 (female) (1) Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector SP16 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between FB1 (13) and SP16 (female) (3) Resistance Max. 1 z
Between SP16 (female) (5) and (2)
a Check ground terminal ET77 for looseness and
Approx.
rust. Resistance
12 z
a To measure resistance of lamps connected in
parallel having resistance of approx. 24 z each
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapters
to female side of them.
Between B13 (female) (2) and SP16 (female) (1) Resistance Max. 1 z
Between SP16 (female) (5) and RL2 (female) (5) Resistance Max. 1 z
Between SP16 (female) (5) and RL3 (female) (5) Resistance Max. 1 z
Between SP16 (female) (2) and ground
a Check ground terminal ET77 for looseness and Resistance Max. 1 z
rust.

40-442 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-26 Stop lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors B13, SP16, RL2 and RL3, and connect T-adapter
to female side of SP16.
3. Remove fuse (13) in fuse box FB1.
Between SP16 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
6
ing harness Between SP16 (female) (2) and (3) Resistance Min. 1 Mz
Between SP16 (female) (2) and (5) Resistance Min. 1 Mz
Between SP16 (female) (1) and (3) Resistance Min. 1 Mz
Between SP16 (female) (3) and (5) Resistance Min. 1 Mz

Circuit diagram related to stop lamp 40-4 3

GD555-5,GD655-5,GD675-5 40-443
(01)
Troubleshooting of electrical system (E-mode)
E-27 Backup lamp does not light up or does not go off

E-27 Backup lamp does not light up or does not go off 40-4 4

Failure Backup lamp does not light up or does not go off

q If backup alarm sounds when gearshift lever is set to "R" position, related fuse and relay are not
defective and ground fault and hot short are not in wiring harness. Check whether backup alarm
sounds or not.
Related infor- q If fuse is blown, stop lamp does not light up too.
mation q If tail lamp and stop lamp do not light up too, ground circuit (ET77) may be defective.
q For troubleshooting of backup alarm, see E-22.
q Whether backup lamp relay is activated by transmission controller can be checked by using mon-
itoring function (code: TRANSMISSION1 40951 D-OUT-19).

Cause Procedure, measuring location, criteria and remarks

If a specific lamp does not light up, its bulb may be broken or may have defec-
1 Broken bulb
tive contact. Check it directly.
Defective fuse (13) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
2
FB1 shooting for cause 5 first.
1. Turn starting switch to OFF position.
2. Replace backup lamp relay with another relay (small lamp relay connected
Defective backup lamp relay to connector SP12, etc.).
3 (TM42) (internal open circuit or 3. Start engine.
short circuit) 4. While depressing brake pedal, set gearshift lever to "R" position.

If backup lamp lights up, original backup lamp relay is defective.

1. Turn starting switch to OFF position.

Open circuit in wiring harness
4 (wire breakage or defective con-
tact of connector)
2. Disconnect connector TM41 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between TM41 (female) (18) and ground
(to measure coil resistance of backup lamp relay)
Resistance 200 – 400 z
a Check ground terminals FT10 and FT11 for
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connector TM42 and connect T-adapter to female side.
3. Remove fuse (13) in fuse box FB1.
Between FB1 (13) and TM42 (female) (3) Resistance Max. 1 z
Between TM42 (female) (5) and (2)
a Check ground terminal ET77 for looseness and
Approx.
rust. Resistance
25 z
a To measure resistance of lamps connected in
parallel having resistance of approx. 50 z each
a If no abnormality is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42, RL2 and RL3, and connect
T-adapters to female side of them.
Between TM41 (female) (18) and TM42 (female) (1) Resistance Max. 1 z
Between TM42 (female) (2) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between TM42 (female) (5) and RL2 (female) (2) Resistance Max. 1 z
Between TM42 (female) (5) and RL3 (female) (2) Resistance Max. 1 z

40-444 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-27 Backup lamp does not light up or does not go off

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors TM41, TM42, RL2 and RL3, and connect T-adapter
to female side of TM42.
3. Remove fuse (13) in fuse box FB1.
Between TM42 (female) (1) and (2) Resistance Min. 1 Mz
Ground fault or short circuit in wir-
5
ing harness Between TM42 (female) (2) and (3) Resistance Min. 1 Mz
Between TM42 (female) (2) and (5) Resistance Min. 1 Mz
Between TM42 (female) (1) and (3) Resistance Min. 1 Mz
Between TM42 (female) (3) and (5) Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors TM40 and TM41.
3. Start engine.
4. While depressing brake pedal, set gearshift lever to "R" position.
a If input voltage to "Shift lever R" is correct but output voltage from "Back
6 Defective transmission controller lamp relay" is inccorect, transmission controller is defective.
Between TM40 (15) and TM41 (21)
Voltage 20 – 30 V
(to measure input voltage to "shift lever R")
Between TM40 (18) and (21)
Voltage 20 – 30 V
(to measure output voltage from "Back lamp relay)

Circuit diagram related to backup lamp 40-4 5

GD555-5,GD655-5,GD675-5 40-445
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

E-28 Windshield wiper does not operate 40-4 6

Failure 1) Front and rear windshield wipers do not operate.

Related infor- q If door wiper does not operate either, ground circuits (FT10 and FT11) may be defective.
mation q Power supply (fuse) for front and rear windshield wipers is separated from that for door wipers.

Cause Procedure, measuring location, criteria and remarks

Defective fuse (15) in fuse box If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
1
FB2 shooting for cause 4 first.
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
Open circuit or ground fault in wir-
2 3. Turn starting switch to ON position.
ing harness
Between C15 (female) (6) and (3) Voltage 20 – 30 V
Between C16 (female) (1) and (4) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
3. Remove fuse (15) in fuse box FB2.
Between FB2 (female) (15) and C15 (6) Resistance Max. 1 z
Open circuit in wiring harness
3 (wire breakage or defective con- Between FB2 (female) (15) and C16 (1) Resistance Max. 1 z
tact of connector) Between C15 (female) (3) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between C16 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors C15 and C16, and connect T-adapters to female
side of them.
Ground fault in wiring harness
4 3. Remove fuse (15) in fuse box FB2.
(contact with ground circuit)
Between C15 (female) (6) and ground Resistance Min. 1 Mz
Between C16 (female) (1) and ground Resistance Min. 1 Mz

40-446 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Circuit diagram related to wiper 40-4 7

GD555-5,GD655-5,GD675-5 40-447
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 2) Front windshield wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24V power is supplied to pin 4 of front wiper intermittent relay (C33), front windshield wiper op-
erates normally. If 24V power is supplied to pin 2, front windshield wiper operates intermittently.
Related infor- q Wiper relay (front wiper relay C14) switches destination of 24 V power for wiper intermittent relay
mation (front wiper intermittent relay C33) according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective front wiper motor 2. Disconnect connector C15 and connect T-adapter to male side.
1
(internal open circuit)
Between C15 (male) (2) and (3) Continuity
1. Turn starting switch to OFF position.
2. Replace front wiper relay (connected to connector C14) with rear wiper
Defective front wiper relay (C14) relay or door wiper relay.
2 (internal open circuit or short cir- 3. Turn starting switch to ON position.
cuit)
4. Set door wiper switch to ON.
If front windshield wiper operates, original front wiper relay is defective.
1. Turn starting switch to OFF position.
2. Replace front wiper intermittent relay (connected to connector C33) with
Defective front wiper intermittent rear wiper intermittent relay or door wiper intermittent relay.
3 relay (C33) (internal open circuit or 3. Turn starting switch to ON position.
short circuit) 4. Set door wiper switch to ON.
If front windshield wiper operates, original front wiper intermittent relay is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to male side.
Defective front wiper switch (inter-
4
nal open circuit) Between C17 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to female side.
Open circuit in wiring harness
5 (wire breakage or defective con- 3. Remove fuse (15) in fuse box FB2.
tact of connector) Between FB2 (15) and C17 (female) (3) Resistance Max. 1 z
q For power supply of wiper motor, see Failure 1).
1. Turn starting switch to OFF position.
2. Disconnect connectors C17, C15 and C33, and connect T-adapter to
female side of C17 and C15.
Ground fault or short circuit in wir-
6 Between C17 (female) (2) and ground Resistance Min. 1 Mz
ing harness
Between C15 (female) (2) and ground Resistance Min. 1 Mz
Between C15 (female) (5) and ground Resistance Min. 1 Mz

40-448 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Circuit diagram related to wiper 40-4 9

GD555-5,GD655-5,GD675-5 40-449
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 3) Rear windshield wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24V power is supplied to pin 4 of rear wiper intermittent relay (C34), rear windshield wiper oper-
ates normally. If 24V power is supplied to pin 2, rear windshield wiper operates intermittently.
Related infor- q Wiper relay (rear wiper relay C10) switches destination of 24 V power for wiper intermittent relay
mation (rear wiper intermittent relay C34) according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective rear wiper motor
1
(internal open circuit)
Defective rear wiper relay (C10)
2 (internal open circuit or short cir-
cuit)
Defective rear wiper intermittent
3 relay (C34) (internal open circuit or 3. Turn starting switch to ON position.
short circuit)
Defective rear wiper switch
4
(internal open circuit)
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault or short circuit in wir-
6 Between C8 (female) (2) and ground
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C16 and connect T-adapter to male side.
Between C16 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace rear wiper relay (connector C10) with front wiper relay or door
wiper relay.
3. Turn starting switch to ON position.
4. Set rear wiper switch to ON.
If rear windshield wiper operates, original rear wiper relay is defective.
1. Turn starting switch to OFF position.
2. Replace rear wiper intermittent relay (connector C34) with front wiper inter-
mittent relay or door wiper intermittent relay.
4. Set rear wiper switch to ON.
If rear windshield wiper operates, original rear wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to male side.
Between C8 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between FB2 (15) and C8 (female) (3) Resistance Max. 1 z
q For power supply of wiper motor, see Failure 1).
1. Turn starting switch to OFF position.
2. Disconnect connectors C8, C16 and C34, and then connect T-adapters to
female side of C8 and C16.
Resistance Min. 1 Mz
Between C16 (female) (2) and (4) Resistance Min. 1 Mz
Between C16 (female) (3) and (4) Resistance Min. 1 Mz

40-450 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 4) Right and left door windshield wipers do not operate.

q If front and rear windshield wipers do not operate either, ground circuits (FT10 and FT11) may be
Related infor- defective.
mation q Power supply (fuse) for door wiper is separated from that for front and rear wipers.
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective fuse (14) in fuse box
1
FB2
Defective door wiper relay (C12)
2 (internal open circuit or short cir-
cuit)
Defective door wiper switch (inter-
3
nal open circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
Open circuit or ground fault in wir-
4 3. Turn starting switch to ON position.
ing harness
Open circuit in wiring harness
5 (wire breakage or defective con-
tact of connector)
Ground fault in wiring harness
6 3. Remove fuse (14) in fuse box FB2.
(contact with ground circuit)
If fuse is blown, circuit probably has ground fault. In this case, perform trouble-
shooting for cause 6 first.
1. Turn starting switch to OFF position.
2. Replace door wiper relay (connected to connector C12) with front wiper
relay or rear wiper relay.
3. Turn starting switch to ON position.
4. Set door wiper switch to ON.
If door windshield wiper operates, original door wiper relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C9 and connect T-adapter to male side.
Between C9 (male) (2) Switch: ON Resistance Max. 1 z
and (3) Switch: OFF Resistance Min. 1 Mz
side of them.
Between C11 (female) (1) and (4) Voltage 20 – 30 V
Between C13 (female) (1) and (4) Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
side of them.
3. Remove fuse (14) in fuse box FB2.
Between FB2 (female) (14) and C11 (1) Resistance Max. 1 z
Between FB2 (female) (14) and C13 (1) Resistance Max. 1 z
Between C11 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
Between C13 (female) (4) and ground
a Check ground terminals FT10 and FT11 for Resistance Max. 1 z
looseness and rust.
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C13, and connect T-adapters to female
side of them.
Between C11 (female) (1) and ground Resistance Min. 1 Mz
Between C13 (female) (1) and ground Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-451
(01)
Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 5) Right door wiper does not operate.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24 V power is supplied to pin 4 of wiper intermittent relay, windshield wiper operates normally. If
24 V power is supplied to pin 2, windshield wiper operates intermittently.
Related infor- q Wiper relay (door wiper relay C12) switches destination of 24 V power for wiper intermittent relay
mation according to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective right door wiper motor
1
(internal open circuit)
Defective right door wiper intermit-
2 tent relay (C36) (internal open cir- 3. Turn starting switch to ON position.
cuit or short circuit)
Open circuit in wiring harness
3 (wire breakage or defective con- q For power supply of wiper motor, see Failure 4).
tact of connector)
Ground fault or short circuit in wir-
4
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C13 and connect T-adapter to male side.
Between C13 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace right door wiper intermittent relay (connector C36) with front wiper
intermittent relay or rear wiper intermittent relay.
4. Set right door wiper switch to ON.
If right door wiper operates, original right door wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connectors C13 and C36, and then connect T-adapter to
female side of C13.
Between C13 (female) (2) and (4) Resistance Min. 1 Mz
Between C13 (female) (3) and (4) Resistance Min. 1 Mz

Failure 6) Left door wiper does not operate.

Related infor-
mation

Cause Procedure, measuring location, criteria and remarks

Defective left door wiper motor
1
(internal open circuit)
Defective left door wiper intermit-
2 tent relay (C35) (internal open cir- 3. Turn starting switch to ON position.
cuit or short circuit)
Open circuit in wiring harness
3 (wire breakage or defective con- q For power supply of wiper motor, see Failure 4).
tact of connector)
Ground fault or short circuit in wir-
4
ing harness
1. Turn starting switch to OFF position.
2. Disconnect connector C11 and connect T-adapter to male side.
Between C11 (male) (2) and (4) Continuity
1. Turn starting switch to OFF position.
2. Replace left door wiper intermittent relay (connector C35) with front wiper
intermittent relay or rear wiper intermittent relay.
4. Set left door wiper switch to ON.
If left door wiper operates, original left door wiper intermittent relay is defec-
tive.
1. Turn starting switch to OFF position.
2. Disconnect connectors C11 and C35, and then connect T-adapter to
female side of C11.
Between C11 (female) (2) and (4) Resistance Min. 1 Mz
Between C11 (female) (3) and (4) Resistance Min. 1 Mz

40-452 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-28 Windshield wiper does not operate

Failure 7) None of wipers operate intermittently.

Related infor- q T-adapter is not available for each wiper intermittent relay.
mation q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective intermittent wiper switch
1 Max. 1 z
(internal disconnection)
Open circuit in wiring harness
2 (wire breakage or defective con-
tact of connector)
1. Turn starting switch to OFF position.
2. Disconnect connector C37 and connect T-adapter to male side.
Between C37 (male) (5) Switch: ON Resistance
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector C37 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between C37 (female) (6) and ground
(to measure resistance of three wiper relay coils Approx.
Resistance
connected in parallel) 100 z
a Resistance of coil unit: Approx. 290 z
Between FB2 (15) and C37 (female) (5) Resistance Max. 1 z

Failure 8) Some windshield wipers do not operate intermittently.

q T-adapter is not available for each wiper relay and for each wiper intermittent relay.
q For related circuit diagram, see Failure 1).
q If 24 V power is supplied to pin 4 of wiper intermittent relay, windshield wiper operates normally. If
24 V power is supplied to pin 2, windshield wiper operates intermittently.
Related infor- q Each wiper relay switches destination of 24 V power for related wiper intermittent relay according
mation to setting of intermittent wiper switch.

q "SW OFF" terminal is for output from wiper motor which indicates that windshield wiper is at stroke
end. Upon receiving this signal, wiper intermittent relay stops supplying 24V power to wiper motor
(24V power input for wiper motor: "ON" terminal).

Cause Procedure, measuring location, criteria and remarks

Defective wiper intermittent relay
1 (internal open circuit or short cir-
cuit)
Defective wiper relay (internal
2 relay.
open circuit or short circuit)
1. Turn starting switch to OFF position.
q Four wiper intermittent relays are installed for front window (C33), rear
window (C34), right door window (C35), and left door window(C36).
2. Replace wiper intermittent relay for wiper which does not operate with
another wiper intermittent relay.
3. Turn starting switch to ON position.
4. Set wiper switch for windshield wiper which does not operate to ON.
If windshield wiper operates, original wiper intermittent relay is defective.
1. Turn starting switch to OFF position.
q Three wiper relays are installed for front wiper (C12), rear wiper (C10),
and door wipers (C12).
2. Replace wiper relay for wiper which does not operate with another wiper
3. Turn starting switch to ON position.
4. Set wiper switch for windshield wiper which does not operate to ON.
If windshield wiper operates, original wiper relay is defective.

GD555-5,GD655-5,GD675-5 40-453
(01)
Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

E-29 Window washer does not operate 40-454

Failure 1) Front window washer does not operate.
q If windshield wiper does not operate either, see Failure 1) or 2) of E-28.
Related infor-
q T-adapter is not available for window washer motor connector (troubleshooting is performed with-
mation
out using T-adapter).

Cause Procedure, measuring location, criteria and remarks

Defective front window washer
1 motor (Internal defect)
(internal open circuit)
2 Defective front wiper switch
Open circuit in wiring harness
3 (wire breakage or defective con-
tact)
Ground fault in wiring harness
4 female side of C17.
(contact with ground circuit)
a Check that rear window washer sprays water normally.
1. Turn starting switch to OFF position.
2. Connect connector B16 to counterpart of B17 and connect connector B17
to that of B16.
3. Turn starting switch to ON position.
4. Set front window washer switch to ON.
If rear window washer sprays water, original front window washer motor is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to male side.
3. Set front wiper switch to ON and OFF to perform troubleshooting.
Switch:
Resistance Min. 1 Mz
Between C17 (male) (5) and (6) OFF
Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C17 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between fuse box FB2 (15) (on harness side) and
Resistance Max. 1 z
C17 (female) (5)
Between C17 (female) (6) and ground Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors C17 and B16, and then connect T-adapter to
Between C17 (female) (6) and ground Resistance Min. 1 Mz

40-454 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Wiring harness between L22 (female) (7) – fuse No. 9 of fuse box B and chassis ground 40-45

GD555-5,GD655-5,GD675-5 40-455
(01)
Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Failure 2) Rear window washer does not operate.

q If windshield wiper does not operate either, see Failure 1) or 2) of E-28.
Related infor- q T-adapter is not available for window washer motor connector (troubleshooting is performed with-
mation out using T-adapter).
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

Defective rear window washer
1 motor
(internal open circuit)
2 Defective rear wiper switch
Open circuit in wiring harness
3 (wire breakage or defective con-
tact)
Ground fault in wiring harness
4 side of C8.
(contact with ground circuit)
a Check that front window washer sprays water normally.
1. Turn starting switch to OFF position.
2. Connect connector B16 to counterpart of B17 and connect connector B17
to that of B16.
3. Turn starting switch to ON position.
4. Set rear window washer switch to ON.
If front window washer spouts water, original rear window washer motor is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to male side.
3. Set rear wiper switch to ON and OFF to perform troubleshooting.
Switch:
Resistance Min. 1 Mz
Between C8 (male) (5) and (6) OFF
Switch: ON Resistance Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector C8 and connect T-adapter to female side.
3. Remove fuse (15) in fuse box FB2.
Between fuse box FB2 (15) (on harness side) and
Resistance Max. 1 z
C8 (female) (5)
Between C8 (female) (6) and ground Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors B16 and C8, and then connect T-adapter to female
Between C8 (female) (6) and ground Resistance Min. 1 Mz

40-456 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of electrical system (E-mode)
E-29 Window washer does not operate

Failure 3) Door washer does not operate.

q If windshield wiper does not operate either, see Failure 4) to 6) of E-26.
Related infor-
q T-adapter is not available for washer motor connector.
mation
q For related circuit diagram, see Failure 1).

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector C9 and connect T-adapter to male side.
Defective door wiper switch (inter-
1
nal open circuit) Between C9 (male) (5) Switch: ON Resistance Max. 1 z
and (6) Switch: OFF Resistance Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector B15.
Between B15 (male) (1) and (2) Continuity
q If door washer motor does not operate while check results of "A" and "B"
below are normal, door washer motor is defective.
q If check result of A is abnormal, open circuit is in wiring harness.
Defective door washer motor 1. Turn starting switch to OFF position.
2 (internal open circuit), or open cir- 2. Disconnect connector C9 and connect T-adapter to female side.
cuit in wiring harness
Between C9 (female) (6) and ground A Continuity
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector C9.
3. Turn starting switch to ON position.
4. Set door washer switch to ON.
Between C9 (female) (6) and ground B Voltage 20 – 30 V
1. Turn starting switch to OFF position.
Ground fault or short circuit in wir- 2. Disconnect connectors C9 and B15, and connect T-adapter to female side
3 of C9.
ing harness
Between C9 (female) (6) and ground Resistance Min. 1 Mz

GD555-5,GD655-5,GD675-5 40-457
(01)
Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

E-30 KOMTRAX system does not operate correctly 40-458

q Standard specification
Failure q KOMTRAX system does not operate normally
q If KOMTRAX system administrator asks for checking whether system installed on machine has
Related infor-
trouble, perform following troubleshooting.
mation
q Even if KOMTRAX system has trouble, problem does not appear on machine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
1 Defective power supply 4. Set disconnect switch to ON.
Between L80 (39) and
Voltage 20 – 30 V
(37) Unswitched power sup-
Between L80 (40) and ply
Voltage 20 – 30 V
(38)
1. Start engine.
LED(1)* Normal condition ON
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
Defective starting switch ACC sig- 3. Insert T-adapter into connector L80.
2
nal or alternator R signal 4. Set disconnect switch to ON.
5. Start engine.
Between L80 (36) and
Starting switch ACC Voltage 20 – 30 V
(37)
Between L80 (28) and
Alternator R Voltage 20 – 30 V
(38)
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between L80 (27) and
Starting switch C Voltage Max. 1 V
(37)
3 Defective starting switch C signal
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector L80.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
Between L80 (27) and
Starting switch C Voltage 20 – 30 V
(37)
1. Turn starting switch ON.
LED(4)* Normal condition ON
1. Turn starting switch to OFF position.
4 Defective CAN connection
2. Set disconnect switch to OFF.
3. Disconnect connector L80 and connect T-adapter to female side.
Between L80 (female) (8)
CAN(KOMNET) Resistance 40 – 80 z
and (7)
1. Turn starting switch to ON position.
5 Number of unsent mails
7-segment LED (7)* Normal condition 0–9
1. Turn starting switch to ON position.
Dot LED (8)* Normal condition ON
6 Defective GPS positioning status
One or more minute may be taken until GPS positioning is completed after
starting switch is turned to ON position with machine in good reception area.
* For position of each LED, see next page.

40-458 GD555-5,GD655-5,GD675-5
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 Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

LED display section of KOMTRAX terminal 40-459 L80 connector 40-459

LED for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download-writing state)
6. LED-C6 (Download-writing state)
7-segment and dot LED for CPU
7. 7-segment LED (number of unsent mails)
8. Dot LED (GPS positioning state)

GD555-5,GD655-5,GD675-5 40-459
(03)
Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

q Chinese specification
Failure q KOMTRAX system does not operate normally
q If KOMTRAX system administrator asks for checking whether system installed on machine has
Related infor-
trouble, perform following troubleshooting.
mation
q Even if KOMTRAX system has trouble, problem does not appear on machine.

Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
1 Defective power supply 4. Set disconnect switch to ON.
Unswitched power sup-
Between V4 (6) and (2) Voltage 20 – 30 V
ply

1. Start engine.
LED(1)* Normal condition ON
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
Defective starting switch ACC sig-
2 3. Insert T-adapter into connector V4.
nal or alternator R signal
4. Set disconnect switch to ON.
5. Start engine.
Between V4 (3) and (2) Starting switch ACC Voltage 20 – 30 V
Between V4 (4) and (2) Alternator R Voltage 20 – 30 V
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
4. Set disconnect switch to ON.
5. Turn starting switch to ON position.
Between V4 (11) and (2) Starting switch C Voltage Max. 1 V
3 Defective starting switch C signal
1. Turn starting switch to OFF position.
2. Set disconnect switch to OFF.
3. Insert T-adapter into connector V4.
4. Set disconnect switch to ON.
5. Turn starting switch to START position.
Between V4 (11) and (2) Starting switch C Voltage 20 – 30 V
1. Turn starting switch ON.
LED(4)* Normal condition ON
1. Turn starting switch to OFF position.
4 Defective CAN connection
2. Set disconnect switch to OFF.
3. Disconnect connector V1 and connect T-adapter to female side.
Between V1 (female)
CAN(KOMNET) Resistance 40 – 80 z
(10) and (11)
1. Turn starting switch to ON position.
5 Number of unsent mails
7-segment LED (6)* Normal condition 0–9
1. Turn starting switch to ON position.
Dot LED (7)* Normal condition ON
6 Defective GPS positioning status
One or more minute may be taken until GPS positioning is completed after
starting switch is turned to ON position with machine in good reception area.
* For position of each LED, see next page.

40-459-1 GD555-5,GD655-5,GD675-5
(03)
 Troubleshooting of electrical system (E-mode)
E-30 KOMTRAX system does not operate correctly

LED display section of KOMTRAX terminal 40-459 connector 40-459

LED for CPU

1. LED-1 (State of R or ACC signal)
2. LED-2 (Starting output state)
3. LED-3 (State of S-NET or C signal)
4. LED-4 (CAN state)
5. LED-5 (Download-writing state)
7-segment and dot LED for CPU
6. 7-segment LED (Station opening or operating
state)
7. Dot LED (GPS positioning state or state of check
connector connection)

GD555-5,GD655-5,GD675-5 40-459-2
(03)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix
The simplified troubleshooting matrix is prepared to locate the failed portion from the given nature of machine
failure. Troubles are broadly classified based on the devices such as the steering system, hydraulic system
for work equipment, etc. Perform the following procedure to ensure correct and quick troubleshooting.
Step 1. Interview with operator
q The questions to be asked to the operator are
listed under the respective failure. If the answer
of the operator coincides with the listed failure,
the potential cause is the one written succeeding
to "o". Proceed to Steps 2 and 3 to locate the
true cause with the points of the operator's an-
swers and referencing the simplified trouble-
shooting matrix.
(Example) Machine does not turn
Ask the operator the following.
q Did the machine suddenly become unable to
steer?
oDamage on the steering related equipment
q Were there indications from before such as
steering wheel operating effort was felt heavy?
oInternal wear or defective seal on the steering
related equipment
Step 2. Check before troubleshooting
q Before starting an actual troubleshooting such
as measurement of oil pressure, check along the
check before starting items, check for oil leak-
age, and loosening of bolts, etc. must be per-
formed to avoid fruitless efforts. The items listed
in the checks before troubleshooting must be
checked with particular care prior to start of the
an actual troubleshooting of a given problem.
(Example) Check before troubleshooting
q Are the oil level in the hydraulic tank and the type
of oil used appropriate?
q Is the steering valve or demand valve free from
oil leakage?
q Is the steering cage correctly adjusted?
40-460
40-460
40-460
Step 3. How to read troubleshooting matrix
1. While operating the machine, perform the trou-
bleshooting along the items listed in the diag-
nosis column. If a failure is found in the
troubleshooting process, apply a checkmark to
the applicable diagnosis column.
a This diagnosis does not require to follow the
diagnosis number given in the column. Start
with the items easier to perform.
(Example)
Remedy
No.
Diagnosis
Machine does not turn in any of the left
1
and right direction.
2
Machine turns in either of the left or right
direction alone.
Steering wheel is felt heavy when turning
3
to any of the left and right side.
Steering wheel is heavy to operate and
4
not turnable to either left or right.
5 Work equipment works
2. Find the cause from the cause column.
The cause of the failure is indicated by Q situ-
ated at the intersection of the diagnosis column,
where the failure was identified, and cause
column. (The cause of diagnosis (2) shown in
the following figure is c or e)
[When the cause (marked with Q) identified in a
diagnosis is one]
Before proceeding to repair work, check whether
the same trouble was identified in other diag-
nosis (Q mark is indicated for the same cause).
[When two or more causes (marked with Q) are
identified in a diagnosis]
Go to 3 to narrow down the cause.
GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

3. Operate the machine to perform diagnosis of
other than (2) and if a failure is found, apply a
checkmark in the corresponding diagnosis
column. (In the following figure, the same trouble
is identified in diagnosis (5).)
4. Find the cause from the cause column.
The cause of the failure is indicated by Q situ-
ating at the intersection of the diagnosis column,
where the trouble was identified, and cause
column. (The cause of diagnosis (5) shown in
the following figure is b or e)
6. Repeat the procedures 3 - 5 until the causes are
narrowed down to a single item (a single
common cause).
a It sometimes cannot be narrow down the
cause to a single one. In such case, repeat
the above procedure until the causes are
minimized.
7. Remedy
When the common cause is singled out, take
appropriate action according to the remedy
column.
[Symbols used in remedy column and corrective
actions]
x: Replacement E: Correction A: Adjustment C:
Cleaning

5. Narrowing down the cause.

Among the causes located in (2) and (5), the one
that is commonly observed in the both diagnosis
items (marked with Q on both of the same
vertical lines) becomes the cause commonly
identifiable in the procedure 2 and 3, too.
a The items that are not common (Q are not
duplicated on the vertical line) should be dis-
carded since they are most probably not the
cause. (The cause of diagnosis (2) shown in
the following figure is c or e, and the cause of
diagnosis (5) is b or e. Therefore, cause e is
regarded as the common cause.

GD555-5,GD655-5,GD675-5 40-461
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

40-462 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

GD555-5,GD655-5,GD675-5 40-463
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

40-464 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
How to read troubleshooting matrix

GD555-5,GD655-5,GD675-5 40-465
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-1 Engine speed lowers significantly or engine stalls.

H-1 Engine speed lowers significantly or engine stalls. 40-46

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e

Malfunction of piston pump (servo piston)

Malfunction of piston pump (PC valve)
Clogging of piston pump (orifice plug)

Internal defect of piston pump

Defective engine
Remedy A
No. C x A *
Diagnosis x
1 Piston pump is internally clogged. Q
2 PC valve is abnormal. Q
3 Main pump assembly is abnormal. Q
4 Piston pump unit is abnormal. Q
5 Engine unit is defective. Q
* Perform troubleshooting of engine unit (S mode).

40-466 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-2 Machine does not start

H-2 Machine does not start 40-467

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropri- a b c d e f g h i
ate.
q Oil pressure must be checked while the torque converter oil tem-
perature gauge is within the operating range.

Malfunction of main relief valve of torque converter

Clogging of suction strainer in transmission case
Air inhaled in suction circuit of power train pump

Malfunction of main relief valve of power train

Defective power train pump (drive system)

Internal defect of power train pump

Internal defect of torque converter

Internal defect of transmission
Internal defect of PTO
Remedy E E E E E E E E E
No.
Diagnosis x x C x x x x x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q
2 The machine does not start at a specific gear speed. Q
Unusual noise comes out from the strainer or transmission filter when the transmis-
3 Q Q
sion oil temperature is low.
4 Main relief valve of the power train is not normal. Q
5 Inlet pressure of torque converter relief is low. Q
6 Outlet pressure of torque converter is not normal. Q
7 Transmission is not normal. Q

GD555-5,GD655-5,GD675-5 40-467
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-3 Gear is not shifted.

H-3Gear is not shifted. 40-468

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropriate. a b c
q Oil pressure must be checked while the torque converter oil temperature gauge
is within the operating range.
Operate the gear shift lever to each gear speed and, before starting trouble-
shooting, check that gear cannot be shifted for forward or reverse only.

Defective operation of transmission clutch valve (ECMV)

Wear or damage on clutch disc or plate of transmission

Defective sealing of transmission clutch piston
Remedy E E E
No.
Diagnosis x x x
1 Forward or reverse travel of machine is not available. Q Q Q
2 Shift up or down of gear is not available. Q Q Q
3 Sealing of transmission clutch piston is defective. Q
4 Cluch disc plate of transmission is worn or damaged. Q

40-468 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

H-4 Travel lacks speed or power. 40-469

Check before troubleshooting Cause
q Check whether the oil level in the transmission case is ap- a b c d e f g h i j
propriate.
q Oil pressure must be checked while the torque converter oil

Defective operation of the corresponding clutch valve (ECMV)

temperature gauge is within the operating range.
q Before performing troubleshooting, check that the wheel

Wear or damage on the corresponding clutch disc or plate

brake and parking brake do not drag.

Defective sealing of the corresponding clutch piston

Malfunction of main relief valve of torque converter
Clogging of suction strainer in transmission case
Internal defect of power train pump (pump unit)
Malfunction of main relief valve of power train

Internal defect of torque converter

Internal defect of transmission
Internal defect of final drive
Remedy C EEEEE
No. x * * *
Diagnosis x x x x x x
Metal particles (aluminum, copper, iron, etc.) are adhered to the transmission
1 filter or strainer. Q Q Q
(Aluminum, copper or iron, etc.) is sticking
Unusual noise comes out from the pump or transmission filter when the trans-
2 Q Q
mission oil temperature is low.
3 The torque converter oil temperature rises too high Q Q Q Q Q Q
4 The main relief pressure of power train is abnormal. Q Q
5 When measuring ECMV output oil pressure (clutch), the oil pressure is low. Q Q Q Q Q Q
6 Sealing of the lockup clutch piston of torque converter is defective. Q
7 The lockup clutch disc or plate of torque converter is worn or damaged. Q
8 Sealing of the transmission clutch piston is defective. Q
9 Clutch disc or plate of transmission is worn or damaged. Q
10 Main relief inlet pressure of torque converter is low. Q Q
11 The final drive is not normal. Q
* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

GD555-5,GD655-5,GD675-5 40-469
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
w w

Defective operation of the 2nd clutch ECMV (fill switch)

Defective operation of the 3rd clutch ECMV (fill switch)
F2

Defective operation of the 4th clutch ECMV (fill switch)

Defective operation of the FH clutch ECMV (fill switch)

Defective operation of the 1st clutch ECMV (fill switch)

Defective operation of the FL clutch ECMV (fill switch)

Defective operation of the R clutch ECMV (fill switch)

F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code displays 15SBL1 after troubleshooting, the failure code
3
is not displayed by disconnecting R fill switch connector (CN-T38). If the
(2) 15SBMA
failure code displays 15SBMA after troubleshooting, the failure code is
not displayed by replacing the ECMV other than R ECMV.
The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.

40-470 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-471
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of
machine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting

the engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RENGE
F1 w w

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
w w

Wear or seizing on R clutch disc, or wear on the piston seal

F2
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the
clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is
1
not displayed by disconnecting FL fill switch connector (CN-T36). If the
(2) 15SDMA Q
failure code is 15SDMA, the failure code is not displayed by replacing
the ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is
2
not displayed by disconnecting FH fill switch connector (CN-T37). If the
(2) 15SCMA Q
failure code is 15SCMA, the failure code is not displayed by replacing
the ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is
3
not displayed by disconnecting R fill switch connector (CN-T38). If the
(2) 15SBMA Q
failure code is 15SBMA, the failure code is not displayed by replacing
the ECMV other than R ECMV.

40-472 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-4 Travel lacks speed or power.

The failure code 15SEL1 is not displayed at F1 and F2, but it is dis-
(1) 15SEL1 Q
played at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is
4
not displayed by disconnecting 1st fill switch connector (CN-T39). If the
(2) 15SEMA Q
failure code is 15SEMA, the failure code is not displayed by replacing
the ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is dis-
(1) 15SFL1 Q
played at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the
(2) 15SFMA Q
failure code is 15SFMA, the failure code is not displayed by replacing
the ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is dis-
(1) 15SGL1 Q
played at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is
6
not displayed by disconnecting 3rd fill switch connector (CN-T41). If the
(2) 15SGMA Q
failure code is 15SGMA, the failure code is not displayed by replacing
the ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is dis-
(1) 15SHL1 Q
played at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is
7
not displayed by disconnecting 4th fill switch connector (CN-T42). If the
(2) 15SHMA Q
failure code is 15SHMA, the failure code is not displayed by replacing
the ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-473
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-5 Torque converter lockup does not work or is not released.

H-5 Torque converter lockup does not work or is not released. 40-474
Check before troubleshooting Cause
q Check whether the oil level in the transmission case is appropriate. a b c
q Oil pressure must be checked while the torque converter oil temperature gauge
is within the operating range.
q The torque converter lockup clutch operates only at the specific gear speed be-
ing selected by the transmission mode selector switch.

Wear or damage on lockup clutch disc or plate

Defective sealing of lockup clutch piston
Malfunction of lockup clutch ECMV
Remedy
No. x x x
Diagnosis
1 Lockup oil pressure is low or 0 Q Q
2 Clutch remains engaged even at 0 lockup oil pressure. Q

40-474 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

H-6 A large time lag results at start or in gear shift 40-475

Check before troubleshooting Cause
q Check whether the oil level of transmission case is appropriate. a b c

q Oil pressure must be checked while the torque converter oil temperature gauge

Wear or damage on the corresponding clutch disc or plate

is within the operating range.
q Before performing troubleshooting, operate the gear shift lever to each gear
speed to identify the gear speed or forward/reverse travel in which a large time

Defective sealing of the corresponding clutch piston

lag results.

Defective operation of the corresponding ECMV

q Before performing troubleshooting, check that the travel speed is normal.
(When not normal, perform troubleshooting of "H-4 Travel lacks speed or
power" before this troubleshooting.)

Remedy
No. * * *
Diagnosis
1 A large time lag results at a specific gear speed. Q Q
2 When measuring ECMV output oil pressure (clutch), the oil pressure is low at a specific gear speed. Q Q
3 Clutch disc or plate of transmission is worn or damaged. Q

* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

GD555-5,GD655-5,GD675-5 40-475
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
F2 w w
F3 w w

Defective operation of the 2nd clutch ECMV (fill switch)

w w

Defective operation of the 3rd clutch ECMV (fill switch)

Defective operation of the 4th clutch ECMV (fill switch)
Defective operation of the 1st clutch ECMV (fill switch)
Defective operation of the FH clutch ECMV (fill switch)
Defective operation of the FL clutch ECMV (fill switch)
F4

Defective operation of the R clutch ECMV (fill switch)

F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

40-476 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-477
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
w w

Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
F1

Wear or seizing on R clutch disc, or wear on the piston seal

F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Troubleshooting Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the fail-
(2) 15SDMA Q
ure code is 15SDMA, the failure code is not displayed by replacing the
ECMV other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA Q
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA Q
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

40-478 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-6 A large time lag results at start or in gear shift

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA Q
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA Q
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA Q
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA Q
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

GD555-5,GD655-5,GD675-5 40-479
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

H-7 Oil temperature of torque converter is high. 40-480

Check before troubleshooting Cause
q Check whether the oil level of transmission case is appropri- a b c d e f g h i j
ate.

q Oil pressure must be checked while the torque converter oil

Defective operation of lockup clutch valve of torque converter (ECMV)

temperature gauge is within the operating range.
Before performing troubleshooting, check that the wheel brake

Wear or damage on lockup clutch disc or plate of torque converter

and parking brake do not drag.

Defective sealing of lock up clutch piston of torque converter

Wear or damage on the corresponding clutch disc or plate

Defective sealing of the corresponding clutch piston
Defective operation of torque converter relief valve

Defective operation of the corresponding ECMV

Malfunction of main relief valve of power train

Internal defect of torque converter

Internal defect of transmission

Remedy E E EEE E
No. x * * *
Diagnosis x x x x x x
Necessary travel speed, counteracting force, and gradability are not available at
1 Q Q Q Q Q Q Q Q Q Q
any gear speed.
Necessary travel speed, counteracting force, and gradeability are not available at
2 Q
a specific gear speed.
An abnormal engine speed is indicated when measuring speed at low idle and full
3 Q Q
speed.
4 When measuring torque converter stall speed, it is too high. Q Q Q Q Q Q Q Q Q Q
When measuring ECMV output oil pressure (clutch), it is low at a specific gear
5 Q
speed.
6 Main relief inlet pressure of torque converter is low. Q Q
* Proceed to "How to identify a defective clutch and ECMV (Confirmation by failure code)".

40-480 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

* How to indentify a defective clutch (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.
a When replacing the ECMV for troubleshooting, clean dust around the
ECMV and tighten the mounting bolt to the specified torque.
a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
a b c d e f g

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE
F1 w w
F2 w w
F3 w w

Defective operation of the 2nd clutch ECMV (fill switch)

w w

Defective operation of the 3rd clutch ECMV (fill switch)

Defective operation of the 4th clutch ECMV (fill switch)
Defective operation of the 1st clutch ECMV (fill switch)
Defective operation of the FH clutch ECMV (fill switch)
Defective operation of the FL clutch ECMV (fill switch)
F4

Defective operation of the R clutch ECMV (fill switch)

F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the failure
(2) 15SDMA
code is 15SDMA, the failure code is not displayed by replacing the ECMV
other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed
(1) 15SBL1 Q
at F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

GD555-5,GD655-5,GD675-5 40-481
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

40-482 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

* How to identify a defective ECMV (Confirmation by failure code)

a For how to confirm the displayed failure code, see "Special functions of ma-
chine monitor (EMMS)" in Testing and adjusting.

a When replacing the ECMV for troubleshooting, clean dust around the ECMV
and tighten the mounting bolt to the specified torque.

a Perform the following troubleshooting in the manual mode after starting the
engine.
Cause
h i j k l m n

Table of ECMV operation

No.
SPEED FL FH R 1st 2nd 3rd 4th
RANGE

Wear or seizing on 2nd clutch disc, or wear on the piston seal

Wear or seizing on 3rd clutch disc, or wear on the piston seal
Wear or seizing on 4th clutch disc, or wear on the piston seal
w w

Wear or seizing on FH clutch disc, or wear on the piston seal

Wear or seizing on 1st clutch disc, or wear on the piston seal

Wear or seizing on FL clutch disc, or wear on the piston seal
F1

Wear or seizing on R clutch disc, or wear on the piston seal

F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
F7 w w
F8 w w
N
R1 w w
R2 w w
R3 w w
R4 w w
a When N is selected in the manual mode, the clutch of the gear speed to
which the gear shift lever is set (marked with Q) is engaged.
q As long as N is set, operating the gear shift lever does not switch the clutch.

Remedy Failure
No. x x x x x x x
Diagnosis Code
The failure code 15SDL1 is not displayed at F1, F3, F5 and F7, but it is
(1) 15SDL1 Q
displayed at R1 to R4, F2, F4, F6 and F8.
If the failure code is 15SDL1 after troubleshooting, the failure code is not
1
displayed by disconnecting FL fill switch connector (CN-T36). If the failure
(2) 15SDMA Q
code is 15SDMA, the failure code is not displayed by replacing the ECMV
other than F ECMV.
The failure code 15SCL1 is not displayed at F2, F4, F6 and F8, but it is
(1) 15SCL1 Q
displayed at R1 to R4, F1, F3, F5 and F7.
If the failure code is 15SCL1 after troubleshooting, the failure code is not
2
displayed by disconnecting FH fill switch connector (CN-T37). If the fail-
(2) 15SCMA Q
ure code is 15SCMA, the failure code is not displayed by replacing the
ECMV other than FH ECMV.
The failure code 15SBL1 is not displayed at R1 to R4, but it is displayed at
(1) 15SBL1 Q
F1 to F8.
If the failure code is 15SBL1 after troubleshooting, the failure code is not
3
displayed by disconnecting R fill switch connector (CN-T38). If the failure
(2) 15SBMA Q
code is 15SBMA, the failure code is not displayed by replacing the ECMV
other than R ECMV.

GD555-5,GD655-5,GD675-5 40-483
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-7 Oil temperature of torque converter is high.

The failure code 15SEL1 is not displayed at F1 and F2, but it is displayed
(1) 15SEL1 Q
at F3 to F8 and R1 to R4.
If the failure code is 15SEL1 after troubleshooting, the failure code is not
4
displayed by disconnecting 1st fill switch connector (CN-T39). If the fail-
(2) 15SEMA Q
ure code is 15SEMA, the failure code is not displayed by replacing the
ECMV other than 1st ECMV.
The failure code 15SFL1 is not displayed at F3 and F4, but it is displayed
(1) 15SFL1 Q
at F1, F2, F5 to F8 and R1 to R4.
If the failure code is 15SFL1 after troubleshooting, the failure code is not
5
displayed by disconnecting 2nd fill switch connector (CN-T40). If the fail-
(2) 15SFMA Q
ure code is 15SFMA, the failure code is not displayed by replacing the
ECMV other than 2nd ECMV.
The failure code 15SGL1 is not displayed at F5 and F6, but it is displayed
(1) 15SGL1 Q
at F1 to F4, F7, F8 and R1 to R4.
If the failure code is 15SGL1 after troubleshooting, the failure code is not
6
displayed by disconnecting 3rd fill switch connector (CN-T41). If the fail-
(2) 15SGMA Q
ure code is 15SGMA, the failure code is not displayed by replacing the
ECMV other than 3rd ECMV.
The failure code 15SHL1 is not displayed at F7 and F8, but it is displayed
(1) 15SHL1 Q
at F1 to F6 and R1 to R4.
If the failure code is 15SHL1 after troubleshooting, the failure code is not
7
displayed by disconnecting 4th fill switch connector (CN-T42). If the fail-
(2) 15SHMA Q
ure code is 15SHMA, the failure code is not displayed by replacing the
ECMV other than 4th ECMV.

40-484 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-8 Differential lock-up function does not work or is not released

H-8 Differential lock-up function does not work or is not released 40-485
Check before troubleshooting Cause
q Check whether the oil level in the final drive case is appropriate. a b c d e f g

Defective operation or defective adjustment of differential lock-up valve

q Check the oil pressure when the final drive case oil temperature is be-
tween 60 and 80°C.

Defective connection of differential lock-up pump (drive system)

Wear or damage on clutch disc or plate of differential lock-up

Air sucked in suction circuit of differential lock-up pump
Internal defect of differential lock-up pump (pump unit)

Defective sealing of differential lock-up clutch piston

Clogging of suction strainer on final drive case
Remedy E C EEE
No. E x
Diagnosis x x x x x
1 Differential lock-up pump does not rotate Q Q Q Q Q Q Q
2 Unusual noise comes out from the strainer when the final drive case oil temperature is low. Q Q Q
3 Oil pressure of differential lock-up (pump outlet and valve outlet) is not normal. Q

GD555-5,GD655-5,GD675-5 40-485
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-9 Steering lacks speed or power.

H-9 Steering lacks speed or power. 40-486

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.
q Before performing troubleshooting, check that work equipment operates nor-

Defective operation of priority valve (relief valve)

mally.
(When not normal, perform troubleshooting of "H-15 All work equipment is oper-
ation lacks speed or power" before this troubleshooting.)
q Since the variable ratio type is used for steering valve (orbit-roll), the steering

Defective sealing of steering cylinder

speed varies depending on the rotating speed of the steering wheel.

Malfunction of steering valve

Remedy E E E
No.
Diagnosis x x x
1 Response of the steering wheel is poor independent of the turning direction, left or right. Q Q Q
2 Steering wheel is heavy to operate when turning to any of the left and right side. Q
3 Work equipment works. Q Q Q
When measuring the steering relief pressure, the oil pressure is low on both sides or no oil pressure is
4 Q Q
generated.

40-486 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-10 Steering wheel does not move

H-10 Steering wheel does not move 40-487

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c
q Before performing troubleshooting, check that work equipment operates nor-
mally.

Defective connection of steering wheel and steering valve

(When not normal, conduct troubleshooting of "H-16 Work equipment does not
work at all" before this troubleshooting.)

Deformation of steering cylinder

Malfunction of steering valve
Remedy E E
No. x
Diagnosis x x
1 Steering wheel is turning idle Q Q
2 Steering wheel is heavy to operate when turning to any of the left and right side. Q Q

GD555-5,GD655-5,GD675-5 40-487
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-11 Wheel brake does not work at all or sufficiently

H-11 Wheel brake does not work at all or sufficiently 40-48

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f g h
q The oil pressure and cylinder oil leakage must be checked when hy-

Defective operation of charging valve of brake accumulator (pressure governor valve)

draulic oil temperature is between 45 and 55°C.
q Before performing troubleshooting, check that work equipment oper-

Defective operation of charging valve of brake accumulator (LS releasing valve)

ates normally.
(When not normal, conduct troubleshooting of "H-13 Speed or power
of all work equipment is low" or "H-16 Work equipment does not
work at all" prior to this troubleshooting.)

Low gas pressure of brake accumulator

Wear or damage on brake disc or plate

Insufficient air breeding of brake circuit
Defective seal of brake piston
Malfunction of slack adjuster
Malfunction of brake valve
Remedy E E E E E E E
No. E
Diagnosis x x x x x x x
1 Resistance resulting from depressing the brake pedal is low. Q Q Q Q Q Q
2 Brake pedal effort is heavy. Q
3 Unordinary depressing force is required to obtain the specified braking force. Q Q Q
4 When the brake is operated, unusual noise comes out from the axle brake. Q
5 Defective machine travel (insufficient traction force) Q
Outflow of air was observed in air bleeding of the brake circuit, but normal state was
6 Q
restored after air bleeding was over.
7 An abnormal quantity of brake oil leakage in the axle was found in the leak check. Q
Brake does not operate efficiently though no abnormality is found in depressing force of
8 Q
the brake pedal and stroke.
9 Frequency of effective braking applied is limited when the engine is stopped. Q Q Q Q Q
10 The buzzer sounds even when charging to the accumulator is not completed. Q Q Q
11 There is a time lag on the effective braking applied. Q

40-488 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-12 Wheel brake cannot be released or drags

H-12 Wheel brake cannot be released or drags 40-489

Check before troubleshooting Cause
q Is the brake pedal completely returned to the original position?
q Is the parking brake completely released?

Wheel brake
Check for abnormality

Brake valve
q Abnormal heat buildup on brake
q Is smooth coasting available on level ground?

a b c

Internal defect of brake valve (stuck piston)

Defective operation of brake piston in axle

Abnormality on brake lining in axle
Remedy E E E
No.
Diagnosis x x x
1 Brake is working after the brake pedal is released. Q Q Q
If oil is drained from the air bleeder after the brake pedal is released, the circuit pressure goes low and
2 Q
the brake is released.
If tires are rotated manually after the axle is placed on a bench when the engine is stopped and the park-
3 Q Q
ing is released, specific wheel is felt heavy.

GD555-5,GD655-5,GD675-5 40-489
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-13 Parking brake does not work at all or insufficiently

H-13 Parking brake does not work at all or insufficiently 40-490

Ask the operator the following points. Cause
q Did the brake stop working suddenly? oDamage on the related equip-
ment.
Did unusual noise come out then? Where on the brake did it come out?
q Did the brake lose braking force gradually? oWear or defective sealing
of the related equipment.

Parking brake
Check before troubleshooting

Solenoid
q Check whether the emergency release switch of parking brake is in the
ON position.

Valve
q Check whether the mechanical release operation is done for the parking
brake. a b c d e

Defective parking brake emergency release valve

Defective solenoid valve of parking brake

Malfunction of parking brake piston

Defective spring of parking brake

Wear of parking brake disc

Remedy E E
No. x x x
Diagnosis x x
1 The parking brake does not work after the engine is stopped. Q Q Q
2 When checking wear on the parking brake disc, the disc thickness is below the criteria. Q
the parking brake switch is in the ON position
3 Q Q
When measuring the inlet pressure of parking and no oil pressure is present (normal).
brake The parking brake switch is in the ON position
4 Q Q Q
and oil pressure is present.
the parking brake switch is in the ON position
5 Q Q
When measuring the parking brake solenoid and no oil pressure is present (normal).
valve The parking brake switch is in the ON position
6 Q
and oil pressure is present.

40-490 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-14 Parking brake (including emergency release system) cannot be released or drags.

H-14 Parking brake (including emergency release system) cannot be

released or drags. 40-491
Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e

Defective operation of bank valve (parking solenoid valve) of parking brake

q The oil pressure and cylinder oil leakage must be checked when hydraulic
oil temperature is between 45 and 55°C.
q Check that the wheel brake operates normally before starting trouble-
shooting.
(When not normal, perform troubleshooting of "H-11 Wheel brake does
not work at all or sufficiently" before this troubleshooting.)

Clogging of bank valve (filter) of parking brake

Defective adjustment of parking brake

Malfunction of parking brake caliper
Clogging of elbow filter
Remedy E E E
No.
Diagnosis x x x
1 The parking brake does not work after the engine is stopped. Q Q Q Q Q
When measuring output pressure of the solenoid valve of parking brake, the oil pressure is
2 Q
present at the parking brake switch being in the ON position.
3 Elbow filter is clogged Q
4 The parking brake caliper malfunctions. Q

GD555-5,GD655-5,GD675-5 40-491
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-15 All work equipment operation lacks speed or power.

H-15 All work equipment operation lacks speed or power. 40-492

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f g h i
q Oil pressure must be checked while the hydraulic oil temperature

Defective operation or adjustment of the control valve (main relief valve and LS relief valve)
is between 45 and 55°C.

Looseness of the piston pump suction pipe at the joint, or crack on the hose
Defective operation or adjustment of piston pump (PC valve)
Defective operation or adjustment of piston pump (LS valve)

Defective operation of the control valve (unload valve)

Defective operation of piston pump (servo piston)
Clogging of suction strainer in hydraulic tank

Internal defect of piston pump (pump unit)

Clogging of piston pump (orifice plug)

Remedy C E E E A E E A
No. x
Diagnosis x x x x x x x x
1 The hydraulic tank strainer is clogged. Q Q Q
Pipe joint between the hydraulic tank and pump is loosened or cracks are present on
2 Q
the hose.
3 Relief pressure of LS relief valve is not normal. Q Q Q
4 Large volumes of metal particles are attached on the discharge side filter of pump. Q Q
Oil does not appear when cranking after removing the pressure pickup plug of main
5 Q
pump.
6 Relief pressure of the main relief valve is not normal. Q

40-492 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-16 Work equipment does not work at all

H-16 Work equipment does not work at all 40-493

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q The oil pressure and cylinder oil leakage must be checked when hydraulic

Defective operation or adjustment of the control valve (main relief valve and LS relief valve)
oil temperature is between 45 and 55°C.

Defective operation of the control valve (unload valve)

Defective connection of piston pump (drive system)
Internal defect of piston pump (pump unit)
Internal defect of PTO
Remedy E E E
No. x A
Diagnosis x x x
1 Oil does not appear when cranking after removing the pressure pickup plug of main pump. Q Q
2 The piston pump does not rotate. Q
3 Measured unload pressure is abnormal Q
4 Adjustment of the unload valve does not restore the normal oil pressure. Q

GD555-5,GD655-5,GD675-5 40-493
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-17 Unusual noise comes out from around hydraulic pump

H-17 Unusual noise comes out from around hydraulic pump 40-494
Cause
q Low oil level of hydraulic tank
q Mixing of air in hydraulic oil
q Clogging of hydraulic tank cap
q Clogging of hydraulic tank strainer
q Internal defect of piston pump
q Low oil level in transmission case
q Mixing of air in transmission oil
q Clogging of transmission case strainer
q Internal defect of power train pump

When none of the above is the cause, run the system for a while to see whether characteristics of the trouble
changes.

40-494 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-18 Blade lift operation lacks speed or power

H-18 Blade lift operation lacks speed or power 40-495

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q The oil pressure and cylinder oil leakage must be checked when hydraulic
oil temperature is between 45 and 55°C.

Defective operation of blade lift control valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of blade lift control valve (spool)

Defective sealing of blade lift cylinder

Deformation of blade lift cylinder
A
Remedy EE
No. E x x
Diagnosis x x
x
1 Blade lift speed is low Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q

GD555-5,GD655-5,GD675-5 40-495
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-19 Hydraulic drift of blade lift cylinders is large.

H-19 Hydraulic drift of blade lift cylinders is large. 40-496

Check before troubleshooting
q Check whether the oil level in the hydraulic tank is appropriate.
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil temperature is between 45
and 55°C.

Cause
q Malfunction of pilot check valve (check valve)
q Malfunction of pilot check valve (relief valve)
q Defective sealing of blade lift cylinder

40-496 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-20 Drawbar side shift operation lacks speed or power

H-20 Drawbar side shift operation lacks speed or power 40-497

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil

Insufficient stroke of the control valve (spool) for the drawbar side sift operation
temperature is between 45 and 55°C.

Defective seal of the cylinder for the drawbar side sift operation
Deformation of the cylinder tfor the drawbar side sift operation
Defective operation of pilot check valve (check valve)
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of drawbar side sift operation is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

GD555-5,GD655-5,GD675-5 40-497
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-21 Blade side shift operation lacks speed or power

H-21 Blade side shift operation lacks speed or power 40-498

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d

Insufficient stroke of the control valve (spool) for the blade side shift operation
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Deformation of the cylinder for the blade side shift operation

Defective operation of pilot check valve (check valve)
Defective sealing of swivel joint
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of blade side shift operation is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

40-498 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-22 Power tilt operation lacks speed or power

H-22 Power tilt operation lacks speed or power 40-49

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e f
q The oil pressure and cylinder oil leakage must be checked when hydrau-
lic oil temperature is between 45 and 55°C.

Defective operation of pilot check valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of power tilt control valve (spool)

Defective sealing of power tilt cylinder

Deformation of blade lift cylinder
Defective sealing of swivel joint
A
Remedy EE
No. E x x x
Diagnosis x x
x
1 Speed of power tilt is low. Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q Q

GD555-5,GD655-5,GD675-5 40-499
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-23 Articulate operation lacks speed or power

H-23 Articulate operation lacks speed or power 40-50

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Insufficient stroke of the articulate control valve (spool)

Defective operation of pilot check valve
Defective sealing of articulate cylinder
Deformation of articulate cylinder
A
Remedy E
No. E x x
Diagnosis x
x
1 Speed of articulate is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

40-500 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-24 Leaning operation lacks speed or power

H-24 Leaning operation lacks speed or power 40-501

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil
temperature is between 45 and 55°C.

Insufficient stroke of leaning control valve (spool)

Defective operation of pilot check valve
Defective sealing of leaning cylinder
Deformation of leaning cylinder
A
Remedy E
No. E x x
Diagnosis x
x
1 Leaning speed is low. Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q

GD555-5,GD655-5,GD675-5 40-501
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-25 Hydraulic drift of leaning cylinders (leaning) is large

H-25 Hydraulic drift of leaning cylinders (leaning) is large 40-502

Check before troubleshooting
q Check the oil level in the hydraulic tank is appropriate.
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil temperature is between 45
and 55°C.

Cause
q Malfunction of pilot check valve
q Defective sealing of leaning cylinder

40-502 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-26 Blade does not rotate

H-26 Blade does not rotate 40-503

Check before troubleshooting Cause
q Check whether the oil level in the hydraulic tank is appropriate. a b c d e
q Make sure that oil level is appropriate in the circle reverse gear case.

Defective operation of pilot check valve (check valve)

Defective operation of pilot check valve (relief valve)
Insufficient stroke of blade lift control valve (spool)

Defective sealing of blade lift cylinder

Deformation of blade lift cylinder
A
Remedy EE
No. E x x
Diagnosis x x
x
1 Blade does not rotate. Q Q
2 The check valve malfunctions. Q
3 The release pressure of relief valve of work equipment is low. Q Q Q

GD555-5,GD655-5,GD675-5 40-503
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for machine with lift arm specification)

H-27 Lift arm lock pin does not lock lift arm or does not unlock it (for
machine with lift arm specification) 40-504
Check before troubleshooting Cause
q The oil pressure and cylinder oil leakage must be checked when hydraulic oil a b c d
temperature is between 45 and 55°C.

Defective operation of bank valve (bank solenoid valve) of parking brake

Defective operation of internal defect of lift arm lock cylinder
Clogging of bank valve (filter) of parking brake
Improper positioning of lift arm and lock pin
A
Remedy EE
No. E x
Diagnosis x x
x
1 Lift arm lock pin does not lock lift arm. Q Q Q Q
2 Lift arm and lock pin are misaligned. Q
3 Filter of parking brake valve is clogged. Q
4 Cylinder head or bottom pressure of bank solenoid valve is normal. Q

40-504 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-28 Blade accumulator function does not work or cannot be released (for machine with blade accumulator float

H-28 Blade accumulator function does not work or cannot be released

(for machine with blade accumulator float specification) 40-505
Check before troubleshooting
q Check that both solenoid valves for blade accumulator (locating at left and right sides) work normally.

Cause
q Malfunction or internal defect of solenoid valves for blade accumulator
q Low gas pressure of blade accumulator

GD555-5,GD655-5,GD675-5 40-505
(01)
Troubleshooting of hydraulic and mechanical system (H-mode)
H-29 Blade float function does not work or cannot be released

H-29 Blade float function does not work or cannot be released 40-506
Check before troubleshooting
q Check that lever is shifted to the blade float position correctly and the function works normally.

Cause
q Malfunction or internal defect of control valve
q Defective adjustment of lever link

40-506 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of hydraulic and mechanical system (H-mode)
H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)

H-30 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats) 40-507
Check the following with the operator. Cause
q Did the fan start making the abnormal sound sudden- Tank to Charge
Fan motor Others
ly? Pump valve
oDamage of the devices related to the fan and fan a b c d e f g h i j k
motor
q Did the engine overheat after the fan had started mak-
ing the abnormal sound?
oInternal wear of the devices related to the fan pump
and fan motor, lowering of sealing performance or
dirt

Clogging or sucked air on pump suction side

Check for abnormality
Measure the fan speed to check for abnormality.

Seized forward-reverse selector valve

heck before troubleshooting

Malfunction of suction safety valve

Seized brake circuit selector spool

Malfunction of EPC solenoid valve

q Check the level and type of the oil in the hydraulic tank.

Lowering of engine performance

Seized ON/OFF solenoid valve
q Check the hydraulic hoses, pump and motor for oil
leakage.

Malfunction of relief valve

q Check the fan for damage.

Malfunction of controller
Defective fan motor
Defective fan pump
(Note): If “Lowering of engine performance” is judged,
go to the troubleshooting for the engine system (S
mode).

Note
Remedy c E E E E E E
No. x x x
Troubleshooting E x x x x x x
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q

GD555-5,GD655-5,GD675-5 40-507
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

Troubleshooting of engine (S-mode) 40-508

Method of using troubleshooting chart 40-508
The troubleshooting chart consists of the "Ques-
tions", "Check items", "Causes", and "Troubleshoot-
ing" blocks.
The Questions and Check items are used to narrow
down high probability causes by simple inspection
or from symptoms without using troubleshooting
tools.
Next, use troubleshooting tools or perform direct in-
spection to check the selected Causes in the order
of probability to determine the real cause.
Questions:
Questions placed in the sections A and B in the
table on the next page are those to be answered
by the customer or operator.
Questions in section A are for basic information
about the failure. Depth and accuracy of their an-
swers to the questions in section B may depend
on their concerns on the machine condition.
Check items:
Check items placed in the section C in the table
on the right are to be simply checked by the tech-
nician to select highly probable causes.
Causes:
Various causes are listed is this block.
The technician will be able to narrows down the
probable causes by taking the actions listed in
the blocks A, B, and C.
Troubleshooting:
This section includes various items of trouble-
shooting that are performed in order to verify the
results of the diagnosis made by asking the
questions and inspecting the machine. The trou-
bleshooting is performed in order from the most
probable one by applying troubleshooting tools
or direct inspection.

40-508 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: Reference information for estimation of the cause
Q: Information and inspection result that indicate the cause of the failure
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w>Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.

GD555-5,GD655-5,GD675-5 40-509
(01)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

<Example of troubleshooting>; Exhaust smoke is

black.
Let us assume that the exhaust gas is black due to the "clogging of air cleaner". In this case, there is a causal
relationship with 3 troubles such as "Exhaust gas gradually became black", "Power was lost gradually", and
"Caution lamp for clogging of air cleaner blinks".

40-510 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
Method of using troubleshooting chart

If the cause column is viewed from the point of these 3 troubles, we can find the causal relationship with 5
troubles.
The following explains how to narrow down the probable causes by reviewing the causal relationship with
these troubles.

GD555-5,GD655-5,GD675-5 40-511
(01)
Troubleshooting of engine (S-mode)
S-1 Startability is poor

S-1 Startability is poor 40-512

General causes why startability is poor Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Defective electrical system
q Insufficient supply of fuel
q Insufficient intake of air
q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the fuel injection timing

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat

Defective alternator (generator section)

Defective alternator (regulator section)
electrically. Accordingly, even if the engine is cranked properly, the engine may

Stuck or seized supply pump plunger

not start until the crankshaft rotates two turns under the most disadvantageous

Defective intake air heater system

Defective or deteriorated battery

condition. This phenomenon does not mean a problem, however.

Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Defective injector
Check recent repair history.
Machine operation Operated for long period E E E
hours
Starting perfor- Became worse gradually Qw w Q
mance Engine starts easily when warm w w
Questions

Fuel other than specified one is used QQ Q

The filter was not replaced as specified by the Operation and Maintenance Manual. w wQ Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi- w
cate proper functioning of preheating system
(if installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator indicates a red zone (if indicator is installed) w
Air breather hole in fuel tank cap is clogged w
Fuel leaks from fuel piping w Q
When priming pump is operated, no resistance is felt or it is heavy w Q
Starting motor cranks engine slowly w
Even if air bleeding plug in fuel filter head is removed, fuel does
While engine is
not flow out
w
cranked:
w
Check items

Too many fuel is returned from injector

When exhaust manifold is touched immediately after starting engine, temperature of w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
Engine hunts. Q w Q
Blowby gas is excessive w
Check air cleaner. q
When compression pressure is measured, it is found to be low. q q
When air is bled from fuel system, air comes out. q
q
Troubleshooting

Check fuel filter.

Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q
Even if starting switch is turned to HEAT, intake air heater mount does not become q
warm.
Is voltage 20 - 30 V between alternator terminal B and terminal E when Yes q
engine is running at low idle speed? No q
Specific gravity of electrolyte and voltage of battery are low. q
Cleaning

Cleaning
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

40-512 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

S-2 Engine does not start 40-513

a) Engine does not crank. Cause

General causes why engine does not crank

Defective connection of battery cable terminal

q Internal parts of engine seized.
o See "S-4 Engine stops during operations".

Defective starting motor (motor section)

q Defective electrical system
q Defect in the power train component

Defective or deteriorated battery

Defective starting circuit wiring

Broken flywheel ring gear

Defective starting switch

Defective battery relay

Defective safety relay

Check recent repair history.
Machine operation
Questions

Operated for long period EE

hours
Condition of horn Horn does not sound. Q Q w
when starting switch is
Horn volume is low.
w
turned ON
Battery electrolyte is level low. w
Battery cable terminal is loose. w
When starting switch is turned ON, no operating sound is heard from battery relay. Q w
When starting switch is turned to START, starter pinion does not plunge. Q Q w
Check items

When starting switch Rotation speed is low. w

is turned to START, Unusual noise is heard around ring gear. w w
starter pinion plunges, Pinion returns halfway. w
but: Unusual noise is heard around relay and engine does not rotate. Q QQ
Check flywheel ring gear. q

Perform E-mode troubleshooting

Specific gravity of electrolyte and voltage of battery are low. q
Voltage (20 - 30 V) between battery relay terminal B and terminal E q
Troubleshooting

is not found.
Turn starting switch to When terminal B and terminal C of starting switch are connected, q
OFF position and con- engine cranks.
nect cable, and per- When terminal B at safety relay outlet and terminal C are con- q
form troubleshooting nected, engine cranks.
with starting switch at Even if terminal B at safety relay outlet and terminal C are con- q
ON nected, engine does not crank.
When terminal at safety switch and terminal B at starting motor are
connected, engine cranks. q
Replace
Replace

Replace
Replace
Replace
Replace
Repair

Remedy
–

GD555-5,GD655-5,GD675-5 40-513
(01)
Troubleshooting of engine (S-mode)
S-2 Engine does not start

b) Engine cranks but no exhaust smoke comes out. Cause

Leakage or clogging of fuel piping or air in the fuel piping

General causes why engine cranks but no exhaust smoke comes out

q Fuel is not being supplied.

q Supply of fuel is extremely small.
q Improper selection of fuel (particularly in winter)

Clogged air breather hole in fuel tank cap

Seized or prematurely worn feed pump

Defective common rail pressure limiter

Stuck or seized supply pump plunger

Malfunction of pressure relief valve

Defective IMV for supply pump
Broken supply pump shaft
Insufficient fuel in tank

Defective fuel injector

Clogging of fuel filter
Use of improper fuel
Check recent repair history.
Machine opera-
Questions

Operated for long period EE

tion hours
Exhaust smoke suddenly stopped coming out (at restarting after short
w Q w w E
time stoppage).
Fuel other than specified one is used. w
The filter was not replaced as specified by the Operation & Maintenance
w E Q
Manual.
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. Q w
Rust and water are found when fuel tank is drained. Q E EE
There is no fuel in the removed fuel filter. w w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Check items

Even if air bleeding plug in fuel filter head is removed,

Q Q w Q
While engine is fuel does not flow out.
cranked: Even if spill hose from injector is disconnected, little fuel
Q w w w Q
spills.
When air is bled from fuel system, air comes out. q
Check fuel filter or strainer. q
Troubleshooting

Check feed pump. q

Perform troubleshooting for the error "Low rail pressure" according to fail- q q
ure code (*1).
Perform troubleshooting for the error "IMV/PCV1 short or open circuit" q
according to failure code (*2).
Check pressure relief valve. q
Fuel flows out when pressure limiter return piping is disconnected. q
Cleaning
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Add

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA271] and [CA272]

40-514 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-2 Engine does not start

c) Exhaust smoke comes out but engine does not start (fuel is injected). Cause

Leakage or clogging of fuel piping or air in the fuel system

Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine does not start

q Lack of cranking force due to defective electrical system

q Insufficient supply of fuel

Worn valve system (valve, rocker lever, etc.)

Clogged injection nozzle, or defective spray

q Insufficient intake of air

Clogged air breather hole in fuel tank cap

q Improper selection of fuel

Stuck or seized supply pump plunger

Defective intake air heater system

Defective or deteriorated battery
Clogged air cleaner element

Worn piston ring or cylinder

Clogging of fuel filter

Use of improper fuel
Check recent repair history.
Machine operation Operated for long period
E E E
hours
Suddenly became unstartable. w w Q
Questions

Fuel other than specified one is used. QQ

The filter was not replaced as specified by the Operation & Maintenance Man-
w w
ual.
Oil must be added more frequently. w
When engine is preheated or when temperature is low, preheating monitor
does not indicate proper functioning of preheating system (if monitor is w
installed).
Dust indicator indicates a red zone (if indicator is installed). w
Air breather hole in fuel tank cap is clogged. Q
Rust and water are found when fuel tank is drained. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
Starting motor cranks engine slowly. w
When engine is cranked, unusual noise is heard around cylinder head. w
Check items

Even if air bleeding plug in fuel filter head is removed, fuel

Q w
While engine is does not flow out.
cranked: Even if spill hose from injector is disconnected, little fuel
w
spills.
Check air cleaner. q
Check valve system. q
When compression pressure is measured, it is found to be low. q
Troubleshooting

When air is bled from fuel system, air comes out. q

Check fuel filter or strainer. q
Perform troubleshooting for the error "Low rail pressure" according to failure q
code (*1).
Specific gravity of electrolyte and voltage of battery are low. q
Coolant temperature gauge indication is not correct (if the gauge is installed). q
Even if starting switch is turned to HEAT, intake air heater mount does not q
become warm.
Cleaning

Cleaning
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

GD555-5,GD655-5,GD675-5 40-515
(01)
Troubleshooting of engine (S-mode)
S-3 Engine does not pick up smoothly

S-3 Engine does not pick up smoothly 40-516

General causes why engine will not pick up smoothly Cause

Leakage or clogging of fuel piping or air in the fuel

q Insufficient intake of air
q Insufficient supply of fuel

Clogged injection nozzle, or defective spray

q Improper fuel injection

Clogged air breather hole in fuel tank cap

Defective contact of valve with valve seat
q Improper selection of fuel

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

q Controller is controlling in derate mode.
(limiting injection rate (power) because of an error in electrical system)

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogging of fuel filter

Check recent repair history.
Machine opera- Operated for long period EE E E
Questions

tion hours
Engine pickup suddenly became worse. w Q Q Q
Fuel other than specified one is used. ww w
The filter was not replaced as specified by the Operation & Maintenance Manual. w w
Engine oil must be added more frequently. w
Dust indicator indicates a red zone (if indicator is installed). w
Air breather hole in fuel tank cap is clogged w
Rust and water are found when fuel tank is drained. w
Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q
When exhaust manifold is touched immediately after starting engine, temperature of Q w
some cylinders is low.
Color of exhaust Blue under light load w
Check items

smoke: Black w Q w w
While engine is running, unusual noise is heard around cylinder head. w
While engine is running, interference sound is heard around turbocharger. w
High idle speed is normal, but speed suddenly drops when load is applied. Q w
Engine hunts. Q Q Q
Blowby gas is excessive. w
Check air cleaner. q
When compression pressure is measured, it is found to be low q q
Troubleshooting

Check valve clearance. q

When turbocharger is rotated by hand, it is found to be heavy. q
When air is bled from fuel system, air comes out. q
Check fuel filter or strainer. q
Perform troubleshooting for the error "Low rail pressure" according to failure code q
(*1).
Even if a cylinder is cut out, engine speed does not change. q
Cleaning

Cleaning
Replace
Replace

Replace
Replace
Replace
Repair

Repair
Adjust

Remedy

*1: Failure code [CA559] and [CA2249]

40-516 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-4 Engine stops during operation

S-4 Engine stops during operation 40-517

General causes why engine stops during operation Cause

Broken auxiliary equipment (pump or air compressor, etc.)

q Internal parts of engine seized
q Insufficient supply of fuel

Damage of valve system (valve, rocker lever, etc.)

q Engine overheating

Defective engine controller power supply wiring

q Defect in hydraulic pump

Clogged air breather hole in fuel tank cap

Broken or seized piston connecting rod

Stuck or seized supply pump plunger

Broken or seized crankshaft bearing

Clogging of feed pump gauze filter

Defective starting switch wiring

Clogged or leaking fuel piping

Broken or seized feed pump

Broken or seized gear train

Broken supply pump shaft

Defective hydraulic pump

Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
hours
Operated for long period EE
Unusual noise was heard and engine stopped
suddenly.
wwww QwQww
Questions

Condition when engine Engine overheated and stopped. wQ Q

stopped
Engine stopped slowly. w QQ QQ
Engine hunted and stopped. wQ QQQ QQ
Fuel other than specified one is used. QQQ Q
The filter was not replaced as specified by the Operation & Maintenance
Manual.
ww
Fuel level monitor indicates low level. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Fuel is leaking from fuel piping. w
Rust and water are found when fuel tank is drained. ww
Metal particles are found in oil drained from oil pan. ww QQ
Check items

It does not rotate at all. ww

When engine is rotated It rotate only in opposite direction. w
by hand: Crankshaft moves by amount of gear backlash. w w
Supply pump shaft does not turn. w
Engine operates, but stops when load is applied from machine. w
q
Perform H-mode troubleshooting.

Check valve system.

Inspect piston connecting rod. q
Check crankshaft bearing. q
Check gear train. q
Troubleshooting

Check fuel filter. q

Check feed pump gauze filter. q
Check feed pump. q
Perform troubleshooting for the error "Low rail pressure" according to fail- qq
ure code (*1).
Engine operates if auxiliary equipment (pump, air compressor, etc.) is q
removed.
Check engine controller power supply wiring. q
Check starting switch wiring. q
Cleaning

Cleaning
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Replace
Replace
Repair

Repair
Repair
Add

Remedy
–

*1: Failure code [CA559] and [CA2249]

GD555-5,GD655-5,GD675-5 40-517
(01)
Troubleshooting of engine (S-mode)
S-5 Engine runs rough or is unstable

S-5 Engine runs rough or is unstable 40-518

General causes why engine runs rough or is unstable Cause

Leakage or clogging of fuel piping or air in the fuel piping

q Air in fuel system
q Defective engine speed sensor (error at degree that does not generate failure code)

Clogged injector or defective spray (dirt in injector)

Defective Ne speed sensor, or wiring harness
Defective Ne speed sensor, or wiring harness
Clogged air breather hole in fuel tank cap
Insufficient fuel in tank

Clogging of fuel filter

Check recent repair history.
Machine operation
Operated for long period
E
hours
Questions

Occurs at a certain speed range. Q Q

Occurs at low idle. Q Q Q Q Q
Hunting
Occurs even when speed is raised. Q Q Q
Occurs on slope. w
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Fuel tank is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Troubleshooting Check items

Rust and water are found when fuel tank is drained. Q

Fuel is leaking from fuel piping. w
When priming pump is operated, no resistance is felt or it is heavy. w Q

When air is bled from fuel system, air comes out. q

Check fuel filter or strainer. q
Even if a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Eng Ne Speed Sensor Error" according to failure code (*1). q
q
Perform troubleshooting for "Eng Bkup Speed Sensor Error" according to failure code (*2).
Cleaning
Replace
Replace
Replace
Replace
Replace
Add

Remedy

*1: Failure code [CA689]

*2: Failure code [CA778]

40-518 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-6 Engine lacks power

S-6 Engine lacks power 40-519

General causes why engine lacks power Cause

q Insufficient intake of air

Clogged injector nozzle, or defective spray (dirt in injector)

q Insufficient supply of fuel

Defective installation of boost pressure sensor (air leak)

q Improper fuel injection

Defective boost pressure sensor or wiring harness

q Improper selection of fuel

Air leakage from air intake piping and aftercooler

q Engine overheating
o See "S-14 Coolant temperature becomes too high (overheating)".

Defective injector drive (signal or solenoid)

Clogged air breather hole in fuel tank cap
Defective contact of valve with valve seat
q Controller is controlling in derate mode.

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

(limiting injection rate (power) because of an error in electrical
system)

Clogged or leaking fuel piping

Clogged air cleaner element

Worn piston ring or cylinder

Improper valve clearance

Clogged fuel spill piping

Clogging of fuel filter
Check recent repair history.
Machine operation
Operated for long period E E E E
hours
Q Q Q Q Q
Questions

Suddenly w
Power was lost
Gradually Q Q Q Q Q Q
Fuel other than specified one is used. Q Q Q
The filter was not replaced as specified by the Operation & Maintenance Manual. w w
Oil must be added more frequently. Q Q
Dust indicator indicates a red zone (if indicator is installed). w w
Air breather hole in fuel tank cap is clogged. w w
Fuel is leaking from fuel piping. w
Power becomes insufficient after short stop of operation. w
Black w w
Color of exhaust gas:
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of
w w
some cylinders is low.
w
Check items

While engine is running, interference sound is heard around turbocharger.

While engine is running, unusual noise is heard around cylinder head. w
High idle speed is too high. Q
High idle speed is normal, but speed suddenly drops when load is applied. Q w Q Q
Engine does not pick up smoothly and combustion is irregular. w w Q Q w
Engine hunts. Q Q Q Q Q
Blowby gas is excessive. w w

Check air cleaner. q

Check air intake piping. q
When boost pressure is measured, it is found to be low. q q q
When compression pressure is measured, it is found to be low. q q
q
Troubleshooting

Check valve clearance.

Check fuel piping. q
Check fuel filter or strainer. q
Check spill port check valve. q
Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q q
Check boost pressure sensor mount. q
Perform troubleshooting for "Boost pressure sensor error" according to failure code
(*2).
q
Cleaning

Cleaning
Replace
Replace

Replace

Replace
Replace
Replace
Replace

Replace
Replace
Repair

Repair

Repair
Adjust

Remedy

*1: Failure code [CA559] and [CA2249]

*2: Failure code [CA122] and [CA123]

GD555-5,GD655-5,GD675-5 40-519
(01)
Troubleshooting of engine (S-mode)
S-7 Exhaust smoke is black (incomplete combustion)

S-7 Exhaust smoke is black (incomplete combustion) 40-520

Cause
General causes why exhaust smoke is black

q Insufficient intake of air

q Improper fuel injection
q Improper selection of fuel

Defective coolant temperature sensor or wiring harness

q Engine overheating.

Air leak at tubing between turbo and cylinder head

o See "S-14 Coolant temperature becomes too high (overheating)".
q Controller is controlling in derate mode.

Defective contact of valve with valve seat

(limiting injection rate (power) because of an error in electrical system)

Seizure or interference at turbocharger

Stuck or seized supply pump plunger

Improper fuel injection pressure

Clogged air cleaner element

Worn piston ring or cylinder

Crushed or clogged muffler

Clogged or seized injector

Prematurely worn injector
Improper valve clearance

Improper injection timing

Check recent repair history.
Machine operation Operated for long period E E E E
hours
Suddenly became black. w w QQQ
Color of exhaust
w Q Q
Questions

Gradually became black.

smoke
Is blue under light load w
Fuel other than specified one is used. QQ
Engine oil must be added more frequently. w
Suddenly w Q QQ
Power was lost
Gradually Q Q Q Q
Dust indicator indicates a red zone (if indicator is installed). w
Muffler is crushed. w
Air leak at tubing between turbocharger and cylinder head, and loose clamp w
Engine is operated in low-temperature mode at normal temperature. QQQ
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
ders is low. Qw
While engine is running, interference sound is heard around turbocharger. w
w
Check items

While engine is running, unusual noise is heard around cylinder head.

Torque converter stall speed or pump relief speed is high. (Fuel is injected excessively.)
Q
Exhaust noise is unusual. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q QQQ Qw
Blowby gas is excessive. w
Too much fuel is returned from injector. w
Inspect air cleaner. q
When turbocharger is rotated by hand, it is found to be heavy. q
When compression pressure is measured, it is found to be low. q q
Troubleshooting

Chack valve clearance. q

If muffler is removed, exhaust sound improves. q
Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q q
When a cylinder is cut out, engine speed does not change. q
Perform troubleshooting for "Coolant temperature sensor error" according to failure code (*2). q
Check the condition by using monitoring function of the machine monitor. qq
Cleaning
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair

Repair
Adjust

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

40-520 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-8 Oil consumption is excessive (or exhaust smoke is blue)

S-8 Oil consumption is excessive (or exhaust smoke is blue) 40-521

General causes why oil consumption is excessive Cause

Turbocharger
q Excessive oil carry-over

Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high idle

Worn/damaged valve (stem, guide, seal)

(Do not idle the engine for more than 20 minutes continuously.)
q External leakage of oil

Dust sucked in at air intake system

Clogged breather or breather hose

q Wear of parts in lubrication system

Worn or damaged rear oil seal

Oil leakage from oil drain plug

Worn seal at compressor end

Worn piston ring or cylinder

Oil leakage from oil cooler

Oil leakage from oil piping

Worn seal at turbine end

Oil leakage from oil filter

Broken piston rings

Broken oil cooler

Check recent repair history.
Machine operation Operated for long period EEE E
Questions

hours
Oil consumption suddenly increased. w Q
Engine oil must be added more frequently. w Q
Oil becomes contaminated quickly. Q Q w
Outside of engine is dirty with oil. w w w w w
Loose hose clamps are found in air intake system. w
Inside of air outlet pipe at turbo compressor side is dirty with oil. w
Inside of turbo exhaust outlet pipe is dirty with oil. Q w
Check items

Oil in coolant w
Oil level in rear gear housing is increasing. w
Exhaust smoke is blue under light load. w w
Excessive Q Q w w
Amount of blowby gas
None w
When intake manifold is removed, dust is found inside. q
When intake manifold is removed, inside is abnormally dirty. q
Troubleshooting

Excessive play of turbocharger shaft q q

Check breather or breather hose. q
When compression pressure is measured, it is found to be low. q q
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q q
External leakage of oil from engine q q q q
Cleaning
Replace
Replace

Replace
Replace

Replace
Replace
Repair
Repair

Repair

Repair
Repair
Repair
Repair

Remedy

GD555-5,GD655-5,GD675-5 40-521
(01)
Troubleshooting of engine (S-mode)
S-9 Oil becomes contaminated early

S-9 Oil becomes contaminated early 40-52

General causes why oil becomes contaminated early Cause

Clogged turbocharger lubrication oil drain tube

Defective sealing at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil

Clogged breather or breather hose

q Operation under excessive load

Defective oil filter safety valve

Worn piston ring or cylinder
Worn valve or valve guide

Exhaust smoke is bad.

Clogged oil cooler
Clogged oil filter
Check recent repair history.
Questions

Machine operation hours Operated for long period EEE

Fuel other than specified one is used. Q Q
Oil must be added more frequently. w
Metal particles are found in the removed oil filter. Q Q w
Inside of exhaust pipe is dirty with oil. w
Engine oil temperature rises quickly. w
Blue under light load w
Check items

Color of exhaust smoke

Black w
Excessive Q Q w Q
Amount of blowby gas
None w

Excessive play of turbocharger shaft q

Troubleshooting

When compression pressure is measured, it is found to be low. q q

(See S-7)
Check breather or breather hose. q
Check oil cooler. q
Check oil filter. q
Spring of oil filter safety valve is stuck or broken. q
Check turbocharger lubrication oil drain tube. q
Cleaning

Cleaning
Replace
Replace
Replace

Replace
Replace
Replace

Remedy
–

40-522 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-10 Fuel consumption is excessive

S-10 Fuel consumption is excessive 40-523

General causes why fuel consumption is excessive Cause

Defective coolant temperature sensor or wiring harness

q Leakage of fuel
q Improper fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel

Fuel leakage from fuel filter, piping, etc.

Defective atomization by injector

Improper common rail pressure
Defective supply pump plunger

Defective operation of injector

Fuel leakage at cylinder head

Defective feed pump oil seal

Improper injection timing

Check recent repair history.
Machine opera- EE E
Questions

Operated for long period

tion hours
Is more than that on other machines of same model. Q QQQ
Fuel consump-
Gradually increased. Q Q
tion:
Suddenly increased. QQ
External leakage of fuel from engine w
Combustion is irregular. w
Engine oil level raised and oil smells of diesel fuel. w w
When exhaust manifold is touched immediately after starting engine, temperature of w
Check items

some cylinders is low.

Low idle speed is high. Q
Torque converter stall speed or pump relief speed is high. Q
Color of exhaust Black QQ QQ
smoke White Q
Remove head cover and check for fuel leak. q
Check oil seal of supply pump. q
Troubleshooting

Perform troubleshooting for the error "Low rail pressure" according to failure code (*1). q
Even if a cylinder is cut out, engine speed does not change. q
Too much fuel is returned from injector. q
Perform troubleshooting for "Coolant temperature sensor error" according to failure q
code (*2).
Check the condition by using monitoring function of machine monitor. q q
Replace
Replace

Replace
Replace
Replace
Replace
Repair
Repair

Repair

Remedy

*1: Failure codes [CA559] and [CA2249]

*2: Failure codes [CA144] and [CA145]

GD555-5,GD655-5,GD675-5 40-523
(01)
Troubleshooting of engine (S-mode)
S-11 Oil is in coolant (or coolant spurts or coolant level goes down)

S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 40-524
General causes why oil is present in coolant Cause

q Internal leakage in lubrication system

q Internal leakage in cooling system

Broken hydraulic oil cooler or power train oil cooler

Broken cylinder head or cylinder head gasket

Broken oil cooler core or O-ring

Internal cracks in cylinder block
Holes caused by pitting
Check recent repair history.
Machine operation
E E
Questions

Operated for long period

hours
Suddenly Q Q Q
Oil level rose:
Gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Unusual air bubbles are found in radiator, or coolant spurts. w
Troubleshooting Check items

Hydraulic oil or power train oil is milky. w

When hydraulic oil or power train oil is drained, water is found in oil.
w

Pressure tightness test result of cylinder head shows oil leakage. q

Check cylinder block. q q

Pressure tightness test result of oil cooler shows oil leakage. q

Replace
Replace
Replace
Replace
Replace

Remedy

40-524 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-12 Oil pressure drops

S-12 Oil pressure drops 40-525

General causes why oil pressure drops Cause

Defective coolant temperature sensor or wiring harness

q Leakage, clogging, or wear on lubrication system
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation and Maintenance
Manual is not observed.
q Deterioration of oil due to overheating

Leaking, crushed, clogged oil piping

Clogged or broken pipe in oil pan
Clogged strainer in oil pan

Defective regulator valve

Coolant or fuel in oil
Lack of oil in oil pan
Worn main bearing

Defective oil pump

Clogged oil filter

Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Oil pressure monitor indicates low oil pressure (if monitor is installed). Qw
Non-specified oil is being used. Q Q
The filter was not replaced as specified by the Operation and Maintenance Manual. w
Indicates pressure drop at low idle. w
Oil pressure
Indicates pressure drop at low and high idle. Q wwwQ
monitor:
Indicates pressure drop on slope. w
(if installed)
Sometimes indicates pressure drop. w Q
Oil pressure monitor indicates low oil pressure (if monitor is installed). w w
Oil level in oil pan is low. w
External lubrication piping is leaking or crushed. w
Troubleshooting Check items

Oil is milky or smells of diesel fuel. w

Metal particles are found in oil drained from oil pan. w
Metal particles are found in the removed oil filter. w Q
Metal particles are found in oil filter. q
Inspect oil pan strainer and pipe. qq
See S-13.

Oil pump rotation is heavy or there is play in oil pump. q

Valve and spring of regulator valve are fatigued or damaged. q
Check oil filter. q
If oil level sensor is replaced, oil level monitor indicates correct oil level. q
Cleaning
Cleaning
Replace

Replace

Replace

Replace
Repair
Adjust
Add

Remedy
–

GD555-5,GD655-5,GD675-5 40-525
(01)
Troubleshooting of engine (S-mode)
S-13 Oil level rises (coolant or fuel in oil)

S-13 Oil level rises (coolant or fuel in oil) 40-526

General causes why oil level rises Cause

Broken cylinder head or cylinder head gasket

q Coolant in oil (milky)
q Fuel in oil (oil smells of diluted diesel fuel)
a If oil is in coolant, perform troubleshooting for "S-11 Oil is in coolant"

Internal cracks in cylinder block

Broken oil cooler core or O-ring

Worn or damaged rear oil seal

Defects in supply pump

Holes caused by pitting
Broken injector O-ring
Check recent repair history.
Questions

Machine opera- Operated for long period

E EE
tion hours
Fuel must be added more frequently. w w
Coolant must be added more frequently. Q Q
Oil in coolant QQQQ w
Oil smells of diesel fuel. w w
Oil is milky. Q Q
While engine is running, drops of water come from muffler. Q
If radiator cap is removed and engine is run at low idle, an unusual number of bubbles
Troubleshooting Check items

w Q
appears, or coolant spurts.
Exhaust smoke is white. Q
Oil level in rear gear housing decreases. w
Oil level in hydraulic tank decreases.
When compression pressure is measured, it is found to be low. q
Remove injector and check O-ring. q
Check cylinder block. qq
Check rear oil seal. q
Pressure tightness test result of oil cooler shows oil leakage. q
Remove and check supply pump. q
Replace
Replace
Replace
Replace

Replace
Replace
Repair

Remedy

40-526 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-14 Coolant temperature rises too high (overheating)

S-14 Coolant temperature rises too high (overheating) 40-527

General causes why coolant temperature rises too high Cause
q Lack of cooling air (deformation or damage of fan)

Broken cylinder head or cylinder head gasket

q Drop in heat dissipation efficiency
q Problem in coolant circulation system

Defective radiator cap (pressure valve)

Defective coolant temperature gauge
q Rise in power train oil temperature

Rise of power train oil temperature

Clogged or crushed radiator fins
Internal cracks in cylinder block

Clogged or broken oil cooler

Holes caused by pitting

Clogged radiator core

Defective thermostat
Malfunction of fan
Lack of coolant
Check recent repair history.
Machine opera-
Operated for long period E E EE
tion hours
Questions

Suddenly occurred. Qw
Overheating
Tends to occur always. Q Qww
Coolant tem- Indicates quick temperature rise. Q Q w
perature gauge:
Does not go down from red range. w
(if installed)
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed).
Engine oil level has risen and oil is milky. wwQ
Milky oil is floating on coolant. QQw
Unusual air bubbles are found in radiator or coolant spurts. w
When light bulb is held behind radiator core, no light passes through. w
Check items

Radiator shroud and inside of underguard are clogged with dirt or mud. w
Coolant is leaking because of cracks in hose or loose clamps. w
Coolant flows out from radiator overflow hose. w
Power train oil temperature gauge enters red range faster than engine
w
coolant temperature gauge (if gauges are installed).
When compression pressure is measured, it is found to be low. q Perform H-mode troubleshooting.
Check cylinder. qq
Check oil cooler. q
q
Troubleshooting

Temperature difference between upper and lower tanks of radiator is large.

When operation of thermostat is tested, it does not open at specified open-
q
ing temperature.
Temperature difference between upper and lower tanks of radiator is
q
slight.
Inspect radiator core. q
When operation of radiator cap is tested, its opening pressure is low. q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace

Replace

Replace
Replace
Repair

Repair
Repair
Add

Remedy
–

GD555-5,GD655-5,GD675-5 40-527
(01)
Troubleshooting of engine (S-mode)
S-15 Unusual noise is made

S-15 Unusual noise is made 40-528

General causes why unusual noise is heard Cause

Improper fuel injection timing (defect in low coolant temperature sensor or boost temperature sensor)
q Abnormality due to defective parts
q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external noise before starting trouble-
shooting.
a The engine is operated in the low-temperature mode while it is not warmed up suf-
ficiently. Accordingly, the engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the acceleration mode and its
sound becomes a little larger for up to about three seconds. This does not indicate
abnormality, however.

Air leak at tubing between turbocharger and cylinder head

Defective inside of muffler (partition board out of position)

Damage of valve system (valve or rocker lever)

Excessively worn piston ring or cylinder

Seizure or interference at turbocharger

Dislocated or seized bushing

Improper gear train backlash

Clogged or seized injector

Improper valve clearance

Dirt caught in injector

Check recent repair history.
Machine operation hours Operated for long period E
Questions

Gradually occurred. Q
Abnormal noise
Suddenly occurred. QQ Q
Fuel other than specified one is used. Q
Engine oil must be added more frequently. w
Metal particles are found in the removed oil filter. w w
Air leaks at tubing between turbocharger and cylinder head. w
While engine is running, interference sound is heard from turbocharger. w
While engine is running, unusual noise is heard around cylinder head. w w
While engine is running, beat noise is heard around muffler. w
wQ
Check items

When exhaust manifold is tounched immediately after starting engine, temperature of some cylinders is
low.
Blue under light load w
Color of exhaust smoke
Black Qw Q
Engine does not pick up smoothly and combustion is irregular. w
Unusual noise is loud when engine is accelerated. Q Q Q
Blowby gas is excessive. w
When turbocharger is rotated by hand, it is found to be heavy. q
Check valve system. q
If muffler is removed, unusual noise disappears. q
Troubleshooting

Check valve clearance. q

If muffler is removed, unusual noise disappears. q
Check gear train. qq
Even if a cylinder is cut out, engine speed does not change. qq
Unusual noise is heard only when engine is cranked. q
Check by using monitoring function of machine monitor. q
Replace
Replace
Replace
Replace

Replace
Replace
Replace
Replace
Replace
Replace
Adjust

Remedy

40-528 GD555-5,GD655-5,GD675-5
(01)
 Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

S-16 Vibration is excessive 40-529

General causes why vibration is excessive Cause

Improper fuel injection timing (problem with coolant or boost temperature sensor)
q Defective parts (premature wear or breakage)
q Misalignment between engine and chassis
q Abnormal combustion
a If unusual noise is made and vibration is excessive, carry out troubleshooting also
for "S-15 Unusual noise is made".

Loose engine mount bolts or broken cushions

Worn main bearing or connecting rod bearing
Stuck valve system (valve, rocker lever, etc.)

Broken parts in output shaft or gear housing

Misalignment of engine and chassis
Improper gear train backlash
Worn camshaft bushing
Check recent repair history.
Machine opera-
Questions

Operated for long period E E E

tion hours
Suddenly increased. Q Q
Vibration
Gradually increased. Q Q Q
Non-specified oil is being used. Q Q
Metal particles are found in the removed oil filter. w w
Metal particles are found in oil drained from oil pan. w w
Oil pressure is low at low idle. Q Q
Check items

Vibration occurs at mid-range speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust smoke is black. w Q

Check valve system. q

Check main bearing and connecting rod bearing. q
Troubleshooting

Check gear train. q

Check camshaft bushing. q
Check the condition by using monitoring function of machine monitor. q
Check engine mounting bolts and cushions. q
When axial and radial alignment is checked, misalignment is found. q
Check inside of output shaft and rear gear housing. q
Replace
Replace
Replace
Replace
Replace
Replace

Replace
Adjust

Rem-
edy

GD555-5,GD655-5,GD675-5 40-529
(01)
Troubleshooting of engine (S-mode)
S-16 Vibration is excessive

GD555-5,GD655-5,GD675-5
GD555-5,GD655-5,GD675-5
SEN0521527-00 50-1

MOTOR GRADER
Shop Manual 50-1

GD555-5
GD655-5
GD675-5

Machine model Serial number

GD555-5 55001 and up
GD655-5 55001 and up
GD675-5 55001 and up

50 Disassembly and assembly 50-1

GD555-5,GD655-5,GD675-5 50-1
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