Wa320 5

TROUBLESHOOTING OF HST CONTROLLER
SYSTEM (HST MODE)
Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302

Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-305
Failure Code [989F00] (HST motor protection caution (00)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
Failure Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX)) . . . . . . . . . . . . . . . . . 20-308
Failure Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC)) . . . . . . . . . . . 20-310
Failure Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . 20-312
Failure Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . 20-314
Failure Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ)) . . . . . . . . . . . . . . 20-316
Troubleshooting Code [HST-1] (Defective HST controller power source
(HST controller does not function)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
Troubleshooting Code [HST-2] (Travel speed does not shifted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-320
Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled . . . . . . . . . . . . 20-324
Troubleshooting Code [HST-4] (Travel speed limit cannot be changed
when gear speed selector switch is in "1st" position) . . . . . . . . . . . . . . . . 20-326
Troubleshooting Code [HST-5] (Travel speed is not increased) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
WA320-5 20-301
(2)..
(2)
20-302
989F00
989F00
AB00L6
989FN1
15B0NX
D5ZHL6
DX20KZ
DX19KZ
DHE4L6
DDS5L6
DLE2LC
2G42ZG
DGE3L6
DD18LD
DD17LD
DD16LD
DD15LD
DAJ0KR
DAF0KT
AB00MA
AA1ANX
DDK3KB
DGE2KX
DHH1KX
DW26KZ
DGR4KA
DGR1KX
DGH1KX
B@BAZK
B@C7NS
B@BCZK
B@BAZG
B@BCNS
B@CRNS
Failure code
(Codes related to monitor)
E01
E01
E03
E02
E01
E01
E01
E01
E03
E01
E01
E01
E01
E03
E00
E01
E03
E01
E02
E02
E03
E02
E01
E01
E00
E03
E03
E03
E03
E03
E03
E01
E01
E03
Action code
(Codes related to HST controller)

TESTING AND ADJUSTING
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
q
q
Defective machine monitor
q
q
q
q
q
q
q
q
Defective HST controller
q
Defective starting switch
q
Defective monitor panel mode selector switch 1 t
q
Defective monitor panel mode selector switch 1 U
q
Defective monitor panel mode selector switch 2 <
FAILURE CODE AND POSSIBLE CAUSES TABLE
q
Defective monitor panel mode selector switch 2 >
q
q
q
Defective forward-reverse lever
q
Deterioration of battery
q
Defective battery relay
Defective fuse/fusible link
q
Defective alternator
q
Clogging of air cleaner
Possible causes
q
Defective air cleaner clogging sensor
BEFORE TROUBLESHOOTING CODE DISPLAY
Defective engine speed sensor

q
Defective HST motor 2 solenoid

q
q

q
q
q Defective clutch solenoid
Lowering of engine oil pressure
q
q
Defective engine oil pressure sensor

q
Lowering of engine oil level

q
Defective engine oil level sensor

WA320-5
q
Overheating of engine coolant
Defective engine coolant temperature
q
q
(high temperature) sensor
WA320-5
q
(low temperature) sensor
q
Lowering of coolant level
q
Defective coolant level sensor
q
Defective HST oil pressure sensor
q
Clogging of HST oil filter
q
Defective HST oil filter clogging sensor
q
Overheating of HST oil
q
q
Defective HST oil temperature sensor
q
Lowering of brake oil pressure
q
Defective brake oil pressure sensor
q
Overheating of axle oil
q
q
q
Defective axle oil temperature sensor
Possible causes
q
Lowering steering oil pressure
q
Defective steering oil pressure sensor
Defective boom angle sensor
Defective boom pressure sensor (bottom side)
Defective boom pressure sensor (head side)
Defective subtotal switch
Defective cancel switch
Defective alarm buzzer
q
q
q
q
q
q
Defective relay
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Disconnection in wiring harness
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Grounding fault in wiring harness
q
q
q
q
q
q
q
Short circuit with power source in wiring harness
(2)
20-303
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM

FUSE BOX CONNECTION TABLE
a This connection chart shows the equipment that each fuse box power source supplies power directly to
("switch power source" means the power supplied when the starting switch is ON; "permanent power source"
means the power supplied when the starting switch is OFF).
Category Fuse No. Fuse capacity Power supply destination

1 20A Starting switch
2 10A Hazard lamp
3 10A HST control A
Permanent power source
4 10A Parking brake 1
(Fuse box 1)
5 10A Meter, panel
6 10A Car radio A, Room lamp
7 10A Spare power supply (battery +24 V)
8 10A Head lamp (left side)
9 10A Head lamp (right side)
10 10A Turn signal lamp
Switch power source 11 10A Back lamp, stop lamp

(Fuse box 1) 12 20A HST control B
13 10A Work equipment positioner
14 10A Wiper
15 10A Car radio B
1 20A Air conditioner A
2 20A Air conditioner B
3 10A Beacon lamp
4 - (Spare 1)
5 10A Load-meter
6 20A Spare power supply (+24 V when key is ON)
7 10A DC converter
Switch power source 8 10A Parking brake 2
(Fuse box 2)
9 10A Horn
10 10A Side marker lamp (left side)
11 10A Side marker lamp (right side)
12 20A Front working lamp
13 20A Rear working lamp
14 - (Spare 2)
15 - (Spare 3)
20-304 WA320-5
(2)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
INFORMATION CONTAINED IN TROUBULESHOOTING TABLE

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
Controller
Action Code Failure Code
Code Trouble Trouble displayed in trouble data
Panel display Panel display Panel display
Description of Condition when machine monitor or controller detected trouble.
Trouble
Machine moni-
tor or control- Action to take to protect system or equipment when machine monitor or controller detected trouble.
ler Reaction
Effect on Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.
Related Information related to troubleshooting or error that occurred.

Information
Causes Standard Value in Normal State and Remarks on Troubleshooting
<Data to fill in>

1 Normal standard values used to judge probable cause
Remarks regarding decision-making
<Condition when wiring harness is defective>

Disconnection
There is defective connection of connector or disconnection in wiring harness
2 Short circuit with ground
Wiring harness not wired to ground (GND) circuit is in contact with ground (GND)
circuit
Short circuit with power source
Wiring harness not wired to power supply (24 V) circuit is in contact with power
Possible Probable cause when
trouble occurred supply (24 V) circuit
Causes and
Standard (the numbers are index
3 <Points to remember when troubleshooting>
Values numbers and do not
indicate the order of pri- 1) Method of displaying connector No. and handling T-adapter
ority) Unless there is special instruction, insert or connect the T-adapter as follows
If there is no indication for the male or female terminal of the connector No.,
disconnect the connector and insert the T-adapter in both the male and
female terminals
If there is indication for the male or female terminal of the connector No., dis-
4
connect the connector and connect the T-adapter to only the terminal indi-
cated (either the male terminal or female terminal)
<Points to remember when troubleshooting>
2) Given order for pin numbers and handling tester lead
Unless there is a special instruction, connect tester (+) lead and (-) lead as fol-
lows to carry out troubleshooting
Connect the (+) lead to the wiring harness for the pin No. given first
5
Connect the (-) lead to the wiring harness for the pin No. given last
WA320-5 20-305
(1)..d
Related circuit diagram
This is part of electrical circuit diagram which shows the portion where the failure occurred.
Connector No.: Indicates (Type - numbers of a pin) (color)
Arrow: Roughly indicates the location in the machine where it is installed.
Phenomena code table
a For problem codes marked "See list", see the list below.
Phenomena Details Disconnection Details
code
KA Disconnection L0 Fill signal ON 2 or more channels
KB Short circuit L1 Fill signal is ON when command current is OFF
KK Drop in power source voltage, input L2 Fuel pressure is higher than maximum set value
KQ Non match in model selection signal L3 Corresponding component cannot be controlled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
Engine signals do not match operating condition or
KT Abnormality inside controller L6 stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit in power supply line LC Speed signals for 2 systems do not match
Switch has been kept pressed for abnormally long
KZ Disconnection or short circuit LD time
MA Function impossible LH Fill signal is OFF when command current is ON
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
20-306 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [989F00]
Failure Code [989F00] (HST motor protection caution (00))

Controller
Action Code Failure Code Code Trouble HST motor protection caution (00)
E00 989F00 HST
Not considered to be a failure.
Description of The travel speed exceeds the allowable speed the HST motor on down shifting.
Trouble (This code is displayed when the gear is shifted down to the 1st or 2nd while the machine is traveling at speed of 10
km/h or higher in the 3rd or 4th gear position.)
Machine moni-
tor or control- Activates an alarm.
ler Reaction
Effect on When the gear shift-down operation is performed, the gear is not shifted down.
Machine

Related
Information
WA320-5 20-307
(2)
TESTING AND ADJUSTING FAILURE CODE [DHH1KX]
Failure Code [DHH1KX] (HST oil pressure sensor input signal

outside range (KX))
Controller
Code Trouble HST oil pressure sensor input signal outside range (KX)
E03 DHH1KX HST
Description of There is disconnection, short circuit with ground, short circuit with power source in HST oil pressure sensor system, so
Trouble HST oil pressure sensor signal is not input.
Machine moni- Error is sent to machine monitor through CAN communications, and machine monitor turns HST safety relay ON (cuts
tor or control-
motor 1, clutch solenoid circuit).
ler Reaction
Effect on Travels but drive power is low
Machine
Related The HST oil pressure can be checked in the monitoring function (Code: 32600).
Information

1) Turn starting switch OFF. 2) Disconnect connector T11. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON
Defective HST oil pressure
1
sensor Between T11 (A) and (C) Voltage 0.5 - 4.5 V
Between T11 (A) and (B) Voltage 4-6V
1) Turn starting switch OFF. 2) Disconnect connectors L41 and T11. 3) Connect T-
adapter
Wiring harness between L41 (Female) (3) and
Wiring harness discontinu- T11 (Female) (C) Resistance 1z and below
2 ity (Disconnection or defec-
tive contact) Wiring harness between L41 (Female) (4) and Resistance 1z and below
T11 (Female) (A)
Resistance 1z and below
T11 (Female) (B)
adapter
Wiring harness between L41 Resistance between L41 1Mz and
Possible (Female) (3) and T11 (Female) (Female) (3), T11 (Female) (C)
Causes and 3 Wiring harness ground fault (C) and chassis ground above
Standard
Values Wiring harness between L41 Resistance between L41 1Mz and
(Female) (12) and T11 (Female) (12), T11 (Female)
(Female) (B) (B) and chassis ground above
adapter. 4) Turn starting switch ON
Wiring harness between L41 Voltage between L41 (Female)
(Female) (3) and T11 (Female) (3), T11 (Female) (C) and chas- 1V and below
(C) sis ground
4 Hot short-circuiting
between harnesses Wiring harness between L41 Voltage between L41 (Female)
(Female) (4) and T11 (Female) (4), T11 (Female) (A) and chas- 1V and below
(A) sis ground
(Female) (12) and T11 (12), T11 (Female) (B) and 1V and below
(Female) (B) chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L41. 3) Insert T-adapter.
5 Defective HST controller
Between L41 (3) and (4) Voltage 0.5 - 4.5 V
Between L41 (12) and (4) Voltage 4-6V
20-308 WA320-5
(2)
TESTING AND ADJUSTING FAILURE CODE [DHH1KX]
9JF00512
WA320-5 20-309
(2)
TESTING AND ADJUSTING FAILURE CODE [DLE2LC]
Failure Code [DLE2LC] (Engine revolution sensor revolution

speed signal mismatch (LC))
Controller
Code Trouble Engine revolution sensor revolution speed signal mismatch (LC)
E03 DLE2LC HST
Description of There is an abnormality in the speed calculated from the speed sensor signal and signal speed from the engine revo-
Trouble lution signal.
tor or control- motor 1, clutch solenoid circuit).
ler Reaction Operates the HST safety relay to output error codes DX19KZ and DX20KZ.

Machine
Related The engine speed can be checked in the monitoring function (Code: 01005).
Information

1) Turn starting switch OFF. 2) Disconnect connector E12. 3) Connect T-adapter
1 Defective engine revolu- Between E12 (Male) (1) and (2) Resistance 500 - 1,000z
tion sensor
1Mz and
Between E12 (Male) (1), (2) and chassis ground Resistance above
1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12. 3) Connect T-
adapter
2 Wiring harness ground fault Wiring harness between L42 Resistance between L42
Possible 1Mz and
Causes and (Female) (4) and E12 (Female) (Female) (4), E12 (Female) (1) above
Standard (1) and chassis ground
Values
1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12. 3) Insert T-adapter.
Hot short-circuiting
3 Wiring harness between L42 Voltage between L42 (Female)
between harnesses
(Female) (4) and E12 (Female) (4), E12 (Female) (1) and chas- 1V and below
(1) sis ground
Between L42 (Female) (4) and (11) Voltage 0.5V and
(AC range) above
9JF00513
20-310 WA320-5
(2)
TESTING AND ADJUSTING FAILURE CODE [DW26KZ]
Failure Code [DW26KZ] (Motor 2 solenoid system discontinuity or

short-circuiting (KZ))
Controller
Code Trouble Motor 2 solenoid system discontinuity or short-circuiting (KZ)
E03 DW26KZ HST
Description of Excessive electricity flows when output to motor 2 solenoid circuit is ON; no electricity flows when output is ON or
Trouble electricity flows when output is ON.
Effect on Travel speed does not increase.

Machine Travel speed indicator on machine monitor stays at 0 km/h and does not move

Related
Information

1) Turn starting switch OFF. 2) Disconnect connector T07. 3) Connect T-adapter
Between T07 (Female) (1) and (2) Resistance 10 - 30z
1 Defective motor 2 solenoid Between T07 (Female) (3) and (4) Resistance 10 - 30z
Between T07 (Female) (1), (3) and chassis 1Mz and
Resistance
ground above
1) Turn starting switch OFF. 2) Disconnect Connectors L41, T07 and fuse FS1 (12)
terminal. 3) Connect T-adapter
Wiring harness discontinu-
2 ity (Disconnection or defec- Wiring harness between T07 (Female) (1) and Resistance 1z and below
L41 (Female) (5)
tive contact)
Wiring harness between T07 (Female) (2) and
chassis ground
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L41 and fuse FS1 (12).
Causes and 3) Connect T-adapter
Standard 3 Wiring harness ground fault
Values Wiring harness between T07 Resistance between T07 1Mz and
(Female) (1) and L41 (Female) (Female) (1), L41 (Female) (5)
(5) and chassis ground above

Turn travel speed selector
Voltage 20 - 30 V
switch 1st
switch 2nd Voltage 20 - 30 V
4 Defective HST controller Between L41
(5) and chas- Turn travel speed selector Voltage 20 - 30 V
switch 3rd
sis ground
Voltage 20 - 30 V
switch 4th (10km/h and below)
switch 4th (10 - 38km/h) Voltage 2V and below
20-312 WA320-5
(2)
TESTING AND ADJUSTING FAILURE CODE [DW26KZ]
TJW02989
WA320-5 20-313
(2)
TESTING AND ADJUSTING FAILURE CODE [DX19KZ]
Failure Code [DX19KZ] (Motor 1 solenoid system discontinuity or

Controller
Code Trouble Motor 1 solenoid system discontinuity or short-circuiting (KZ)
E03 DX19KZ HST
Description of Excessive electricity flows when output to motor 1 solenoid circuit is ON; no electricity flows when output is ON or
Trouble electricity flows when output is ON.
ler Reaction Operates the HST safety relay to output error codes DX20KZ.

Machine
Related Motor 1 solenoid current can be checked in the monitoring function (Code:80000).
Information

1 Defective motor 1 solenoid Between T06 (Female) (1) and (2) Resistance 15 - 35z
ground Resistance above
1) Turn starting switch OFF. 2) Interchange relay (L111) with normal relay. 3) Turn
starting switch ON. 4) Operate FNR switch
The condition Relay (L111)
Does condition become normal when HST safety is abnormal is normal
relay (L111) is interchanged with normal relay? The condition Defective
is normal relay (L111)
Defective HST safety relay 1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check
2
(L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check.
4) Applies impressed voltage between L111 (Male) (1) - (2)
Applies 24V impressed voltage
Between L111 between L111 (Male) (1) - (2) Resistance 1z and below
(Male) (3) and
(6) Does not apply voltage Resistance 1Mz and
between L111 (Male) (1) - (2) above
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T06 and fuse
Causes and FS1 (12). 3) Connect T-adapter
Standard
Values Wiring harness between T06 (Female) (1) and
L41 (Female) (6) Resistance 1z and below
Wiring harness between T06 (Female) (2) and Resistance 1z and below
Wiring harness discontinu- L111 (Female) (6)
tive contact) Wiring harness between L111 (Female) (3) and
chassis ground
Wiring harness between fuse FS1 (12) and L111 Resistance 1z and below
(Female) (1)
1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T06 and fuse
FS1 (12). 3) Connect T-adapter
Wiring harness between T06 Resistance between T06
(Female) (1) and L41 (Female) (Female) (1), L41 (Female) (6) 1Mz and
above
(6) and chassis ground
4 Wiring harness ground fault (Female) (2) and L111 (Female) (Female) (2), L111 (Female) (6) 1Mz and
above
Wiring harness between fuse Resistance between fuse FS1
FS1 (12) and L111 (Female) (12), L111 (Female) (1) and 1Mz and
above
(1) * chassis ground
In the above case of marked mark (*), the fuse is blown.
20-314 WA320-5
(2)

Turn travel speed selector Voltage 2 - 20V
Possible switch 1st
Causes and Turn travel speed selector
Standard Voltage 2 - 20V
5 Defective HST controller Between L41 switch 2nd
Values
(6) and chas- Turn travel speed selector
sis ground switch 3rd and 4th Voltage 2 - 20V

switch 3rd and 4th (10km/h and Voltage 3V and below
below)
WA320-5 20-315
(2)
Failure Code [DX20KZ] (Clutch solenoid system discontinuity or

Controller
Code Trouble Clutch solenoid system discontinuity or short-circuiting (KZ)
E03 DX20KZ HST
Description of Excessive electricity flows when output to clutch solenoid circuit is ON; no electricity flows when output is ON or elec-
Trouble tricity flows when output is ON.
Effect on Travel speed does not switch.

Machine Does not control 3rd or 4th, or does not control 1st or 2nd.
Related The clutch solenoid current can be checked in the monitoring function (Code:80100).
Information

1 Defective clutch solenoid Between T05 (Female) (1) and (2) Resistance 15 - 35z
ground Resistance above
Does condition become normal when HST safety is abnormal is normal
Defective HST safety relay 1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check
2
(L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L111. 3) Solid part check,
Between L111 between L111 (Male) (1) - (2) Resistance 1z and below
(Male) (3) and
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L23, L41, L111, T05 and fuse
Causes and FS1 (12). 3) Connect T-adapter
Standard
Values L41 (Female) (14) Resistance 1z and below
Wiring harness discontinu- L111 (Female) (6)
chassis ground
(Female) (1)
1) Turn starting switch OFF. 2) Disconnect Con-
nectors L23, L41, L111, T05 and fuse FS1 (12). Resistance 1z and below
3) Connect T-adapter
1Mz and
(Female) (1) and L41 (Female) (Female) (1), L41 (Female) (14) above
4 Wiring harness ground fault Wiring harness between T05 Resistance between T05
1Mz and
1Mz and
FS1 (12) and L111 (Female) (12), L111 (Female) (1) and above
In the above case of marked mark (*), the fuse is blown.
20-316 WA320-5
(2)

Turn travel speed selector Voltage 3 - 15V
Possible switch 1st
Causes and Turn travel speed selector
Standard Between L41 Voltage 3 - 15V
5 Defective HST controller switch 2nd
Values (14) and
chassis Turn travel speed selector
switch 3rd and 4th Voltage 3 - 15V
ground
switch 3rd and 4th (10km/h and Voltage 4V and below
below)
WA320-5 20-317
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-1]
Troubleshooting Code [HST-1] (Defective HST controller power

source (HST controller does not function))
Controller
Action Code Failure Code Defective HST controller power source (HST controller does not func-
Code Trouble tion)
- - -
Description of HST controller power source system is defective, so HST controller does not work.
Trouble
Machine moni-
tor or control- No action.
ler Reaction

Machine Machine monitor announces failure code DAJOKR for defective HST controller communications

Related
Information

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L102 and fuse FS1 ter-
minal. 3) Connect T-adapter
Wiring harness between L41 (Female) (8) and Resistance 1z and below
L102 (Female) (5)
Wiring harness between fuse FS1 (3) and L102
Wiring harness discontinu- Resistance 1z and below
(Female) (3)
tive contact) Wiring harness between fuse FS1 (12) and L102
(Female) (1) Resistance 1z and below
chassis ground
chassis ground
Does condition become normal The condition Relay (L102) is normal

when HST safety relay (L102) is abnormal
is interchanged with normal The condition
relay? Defective relay (L102)
is normal
Defective HST power 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check
Possible 2
Causes and source safety relay (L102) Between L102 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check.
Between Resistance 1z and below
between L102 (Male) (1) - (2)
L102 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L102 (Male) (1) - (2) Resistance above
1) Turn starting switch OFF. 2) Replace diode (D12) to correct diode. 3) Turn starting
switch START
The condition is abnormal Diode (D12) is normal
The condition is normal Defective diode (D12)
Measure at diode range
D12 (Male) (1) o (2) Continuity
3 Defective diode (D12) D12 (Male) (3) o (2) Continuity
D12 (Male) (1) o (3) Discontinuity
a Connect the (+) pole of the tester to the left side of D12 ( ) o ( ).
20-318 WA320-5
(2)

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L102 and fuse FS1 ter-
minal. 3) Connect T-adapter
(Female) (8) and L102 (Female) (8), L102 (Female) (5)
(Female) (5) and chassis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
Possible 4 Wiring harness ground fault (3), L102 (Female) (3) and
Causes and FS1 (3) and L102 (Female) (3) chassis ground above
Standard
Values Wiring harness between fuse Resistance between fuse FS1 1Mz and
FS1 (12) and L102 (Female) (12), L102 (Female) (1) and
(1) chassis ground above
a In the above case, the all fuses are blown.

5 Defective HST controller 4) Connect connector. 5) Turn starting switch ON
Between L41 (8) and (16) Voltage 20 - 30V
9JF00531
WA320-5 20-319
(2)
Troubleshooting Code [HST-2] (Travel speed does not shifted)

Controller
Action Code Failure Code Code Trouble Travel speed does not shifted
- - -
Description of The speed selector switch system is defective, so the travel speed cannot be changed.
Trouble
Machine moni-
ler Reaction
Effect on Travel speed does not shifted
Machine

Related
Information

1) Turn starting switch OFF. 2) Disconnect connector L03. 3) Connect T-adapter
2nd Resistance 1z and below
Between L03 (Female) (1) and
(2) Other than 1Mz and
Resistance
the above above
1Mz and
1st Resistance above
Between L03 (Female) (1) and 2nd Resistance 1Mz and

(3) above
3rd Resistance 1z and below
Defective travel speed
1 selector switch 4th Resistance 1z and below
4th Resistance 1z and below
Resistance
the above above
1st Resistance 1z and below
Possible 1Mz and
Causes and 2nd Resistance
Between L03 (Female) (3) and above
Standard
Values (4) 1Mz and
3rd Resistance above
Does condition become normal when shift control is abnormal is normal
Defective shift control relay 1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check
2 (L103) Between L103 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check,
L103 (Male)
20-320 WA320-5
(2)

Defective travel speed Between L54 (Female) (1) and (3) Resistance 4 - 6 kz
3
potentiometer Between L54 (Female) (1) and (2) Resistance 0.25 - 5 kz
Between L54 (Female) (2) and (3) Resistance 0.25 - 5 kz
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103, J07 and fuse FS1
terminal. 3) Connect T-adapter
(Female) (3)
Wiring harness discontinu- Wiring harness between fuse FS1 (12) and L103
4 ity (Disconnection or defec- Resistance 1z and below
tive contact) (Female) (1)
L03 (Female) (4)
J07 (Female) (1) Resistance 1z and below
J07 (Female) (18)
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103 and fuse FS1 ter-
Standard minal. 3) Connect T-adapter
Values
Wiring harness between L42 Resistance between L42
(Female) (12) and L103 (Female) (12), L103 (Female) 1Mz and
above
(Female) (5) (5) and chassis ground
5 Wiring harness ground fault FS1 (12) and L103 (Female) (12), L103 (Female) (3) and 1Mz and
above
(3) chassis ground
FS1 (12) and L103 (Female) (12), L103 (Female) (1) and 1Mz and
above
(1) chassis ground
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103. 3) Insert T-

adapter.
Hot short-circuiting 4) Turn starting switch ON
6
(Female) (12) and L103 (12), L103 (Female) (5) and 1V and below
(Female) (5) chassis ground
7 Defective HST controller Between L42 Travel speed "1st", "4th" Voltage 20 - 30V
(12) and
chassis selector
switch "2nd", "3rd" Voltage 1V and below
ground
WA320-5 20-321
(2)
9JF00532
20-322 WA320-5
(2)
Troubleshooting Code [HST-3] HST Output Control (Traction

control) cannot be controlled
Controller
Code Trouble HST output control (Traction control) cannot be controlled
- - -
Description of The traction control switch system is defective, so the HST output control cannot be controlled.
Trouble
Machine moni-
ler Reaction
Effect on The HST output control (Traction control) cannot be controlled.
Machine
Related Traction control ON-OFF output signal can be checked in the monitoring function (Code: 80200).
Information

1) Turn starting switch OFF. 2) Disconnect connector L56. 3) Connect T-adapter.
Defective traction control Between L56 Traction control switch ON Resistance 1z and below
1
switch (Female) (3)
Traction control switch OFF Resistance 1Mz and
and (2) above
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L56 and fuse FS1 termi-
nal. 3) Connect T-adapter.
2 ity (Disconnection or defec- L56 (Female) (2) Resistance 1z and below
tive contact)
(Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L56 and fuse FS1 termi-
Possible
Causes and (Female) (3) and L56 (Female) (Female) (3), L56 (Female) (2) 1Mz and
Standard above
Values (3) and chassis ground
3 Wiring harness ground fault
Resistance between fuse FS1
Wiring harness between fuse (12), L56 (Female) (3) and 1Mz and
FS1 (12) and L56 (Female) (3) above
chassis ground
1) Turn starting switch OFF. 2) Disconnect connectors L41 and L56. 3) Connect T-
adapter. 4) Turn starting switch ON.
4 between harnesses Wiring harness between L42 Voltage between L42 (Female)
(Female) (3) and L56 (Female) (3), L56 (Female) (2) and chas- 1V and below
(2) sis ground
1) Turn starting switch OFF. 2) Disconnect Connector L42. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
5 Defective HST controller Between L42 Traction control switch ON Voltage 20 - 30V
(3) and chas-
sis ground Traction control switch OFF Voltage 1V and below
20-324 WA320-5
(2)
9JF00533
WA320-5 20-325
(2)
Troubleshooting Code [HST-4] (Travel speed limit cannot be

changed when gear speed selector switch is in "1st" position)
Controller
Action Code Failure Code Code Travel speed limit cannot be changed when gear speed selector switch
Trouble
is in "1st" position
- - -
Description of There is disconnection, short circuit with ground, short circuit with power source in speed potentiometer system, so
Trouble speed potentiometer signal is not input.
Machine moni-
tor or control- No action
ler Reaction
Effect on Travel speed cannot be controlled when the travel speed selector switch is at 1st.
Machine (Speed is fixed at 4 km/h or 13 km/h)
Related The speed potentiometer is displayed by real-time monitoring code 50302 {speed limit is taken as follows: max.
Information (13 km/h = 100%)/min. (4 km/h = 0%)

Defective travel speed Between L54 (Female) (1) and (3) Resistance 4 - 6kz
1
potentiometer Between L54 (Female) (1) and (2) Resistance 0.25 - 5kz
Between L54 (Female) (2) and (3) Resistance 0.25 - 5kz
2nd Resistance 1z and below
the above Resistance above
1st Resistance 1Mz and

above
Between L03 (Female) (1) and 1Mz and

2nd Resistance
(3) above
3rd Resistance 1z and below
2 Defective travel speed 4th Resistance 1z and below
selector switch
the above Resistance above
1st Resistance 1z and below
Possible
Causes and 1Mz and
2nd Resistance above
Standard Between L03 (Female) (3) and
Values (4)
3rd Resistance 1Mz and
above
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L54, L03. 3) Connect T-
adapter
L54 (Female) (1)
L54 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L54, L03. 3) Connect T-
adapter
(Female) (10) and L54 (Female) (10) and chassis 1Mz and
above
(Female) (1) ground
4 Wiring harness ground fault Wiring harness between L41
(Female) (1), L54 (Female) (2) Resistance between L41 1Mz and
(Female) (1) and chassis
and L03 (Female) (1) ground above
30
1Mz and
(Female) (2), L54 (Female) (3) (Female) (2) and chassis
and L03 (Female) (3) ground above
20-326 WA320-5
(2)

1) Turn starting switch OFF. 2) Disconnect connector L41, L54 and L03.
3) Connect T-adapter. 4) Turn starting switch ON
(Female) (10) and L54 1V and below
5 between harnesses Wiring harness between L41
Possible Voltage between L41 (Female)
(Female) (1), L54 (Female) (2) 1V and below
Causes and and L03 (Female) (1) (1) and chassis ground
Standard
Values Wiring harness between L41 Voltage between L41 (Female)
(Female) (2), L54 (Female) (3) 1V and below
and L03 (Female) (3) (2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect Connectors L41.

3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON
6) Travel speed selector switch 1ST
Between L41 (10) and (2) Voltage 4 - 6V
Between L41 (1) and (2) Voltage 0.5V - 5V
9JF00511
WA320-5 20-327
(2)
Troubleshooting Code [HST-5] (Travel speed is not increased)

Action Code Failure Code Controller Code
Trouble Travel speed is not increased (Abnormality in speed sensor system)
- - -
Description of The travel speed signal does not input due to disconnection or short-circuit with ground in travel speed sensor signal.
Trouble
Machine moni-
tor or controller No action.
Reaction
Effect on Travel speed does not increase.

Machine Travel speed indicator on machine monitor stays at 0 km/h and does not move
Related
Information

1) Turn starting switch OFF. 2) Disconnect Connectors L41, L42, L102 and T09.
Wiring harness between T09 (Female) (4) and L42
(Female) (5)
Wiring harness between T09 (Female) (3) and L41 Resistance 1z and below
(Female) (13)
chassis ground Resistance 1z and below
Wiring harness discontinuity Wiring harness between T09 (Female) (1) and L41
1 (Disconnection or defective (Female) (7), between L41 (Female) (8) and L102 Resistance 1z and below
contact) (Female) (5)
fuse FS1 (3) Resistance 1z and below

chassis ground
D12 (Female) (2)
Wiring harness between D12 (Female) (3) and
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L42, L102 and T09.
Wiring harness between T09 Resistance between T09 1Mz and
1Mz and
Possible (Female) (3) and L41 (Female) (Female) (3), L41 (Female) (13) above
Causes and
Standard Resistance between T09
Values Wiring harness between T09 (Female) (1), L41 (Female) (7)
(Female) (1) and L41 (Female) 1Mz and
(7), between L41 (Female) (8) and chassis ground, between above
L41 (Female) (8), L102 (Female)
2 Wiring harness ground fault and L102 (Female) (5) * (5) and chassis ground
Resistance between L102
Wiring harness between L102 1Mz and
(Female) (3) and fuse FS1 (3) * (Female) (3) and fuse FS1 (3) above
and chassis ground
(Female) (1) and D12 (Female) (Female) (1) and D12 (Female) 1Mz and
above
(2) * (2) and chassis ground
Wiring harness between D12 Resistance between D12 1Mz and

(Female) (3) and fuse FS1 (12)
(Female) (3) and fuse FS1 (12) * and chassis ground above
a In the above case of marked mark (*), the fuse is blown.

1) Turn starting switch OFF. 2) Disconnect connector T09. 3) Insert T-adapter. 4) Con-
nect connector. 5) Turn starting switch ON. 6) Move machine slightly and repeat fol-
lowing action: stop machine o measure voltage
Between T09 (1) and (2) Voltage 20 - 30V
Between T09 (3) and (2) Voltage 5 V and above

(Pulse)
3 Defective travel speed sen- a Measure the voltages according to the position where the machine is stopped.
sor
Move machine forward in mea- Voltage 20 - 30V
Between T09 surement condition
(4) and (2) Move machine in reverse in
measurement condition Voltage 5 V and above
WARNING When moving the machine forward and in reverse when measuring the
voltage, be particularly careful to ensure safety.
20-328 WA320-5
(2)
TROUBLESHOOTING OF TRAVEL DAMPER
SYSTEM (ECSS MODE)
Related electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352

ECSS-1 Malfunction of travel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
WA320-5 20-351
(2)..
TESTING AND ADJUSTING RELATED ELECTRICAL CIRCUIT DIAGRAM
RELATED ELECTRICAL CIRCUIT DIAGRAM

a For the connection table of the fuse box, see HST-mode, MON-mode, E-mode, etc.
a For how to read the troubleshooting table, see HST-mode, MON-mode, E-mode, etc.
a Before carrying out the troubleshooting, understand the contents of the related circuit diagram.
20-352 WA320-5
(3)
TESTING AND ADJUSTING ECSS-1
ECSS-1 MALFUNCTION OF TRAVEL DAMPER

a For how to read the troubleshooting table, see HST-mode, MON-mode, E-mode, etc. Before carrying out the
troubleshooting, understand the contents of the troubleshooting table.
Specification of load meter (STD)
Malfunction of travel damper
a) Travel damper does not operate.
Action Code Error code Controller Code Malfunction of travel damper
Trouble
- - - a) Travel damper does not operate
Contents of trou- The travel damper does not operate.

ble
Action of None in particular.
machine monitor
Problem that
appears on The travel damper does not operate.
machine
Related informa- If the fuse is broken, check for grounding fault.
tion
Causes Standard value in normal state/Remarks on troubleshooting

1) Turn starting switch OFF
2) Disconnect connector L09.
Defective travel damper 3) Connect T-adapter.
1
switch
Between L09 (male) Travel damper switch: ON Resistance Max. 1 z
(2) and (3) Travel damper switch: OFF Resistance Min. 1 Mz
1) Turn starting switch OFF.
2) Relay: Replace L110 with normal relay.
3) Turn starting switch ON.
4) Operate travel damper switch.
When relay L110 is No Relay L110 is normal.
replaced, does condition
become normal? Yes Relay L110 is defective.
2) Disconnect relay L110.
Defective travel damper 3) Check relay unit.
2
relay (L110)
Possible causes Between relay L110 (male) (1) and (2) Resistance 200 - 400z
and standard 1) Turn starting switch OFF..
value in normal 2) Disconnect relay L110.
state
3) Check relay unit.
4) Apply normal voltage between relay L110 (male) (1) and (2).
When 24 V is applied between Resistance Max. 1 z
Between L110 (male) and (1) and (2)
(3) and (5) When normal voltage is not
Resistance Min. 1 Mz
applied between and (1) and (2)
2) Replace travel damper solenoid (F07) with normal solenoid.
Travel damper solenoid is
When solenoid (F07) is No
normal.
Defective travel damper replaced, does condition
3 become normal? Travel damper solenoid is
solenoid (F07) Yes defective.
1) Turn starting switch OFF..
2) Disconnect connector F07.
3) Connect T-adapter.
Between F07 (male) (1) and (2) Resistance 21 - 24z
WA320-5 20-353
(2)
.
2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal
Condition becomes normal. Diode (D05) is defective.
Check diode unit.
Check continuity from (2) to (1) in diode range. There is continuity.
4 Defective diode (D05)
Check continuity from (1) to (2) in diode range. There is not continuity.
Check continuity from (3) to (1) in diode range There is not continuity.
a Apply (+) pin of circuit tester to left line.
5 Defective travel damper 4) Turn starting switch ON.
controller
Between L14 (4) and Travel speed: 0 - 5 km/h Voltage Max. 1 V
chassis ground Travel speed: Above 6 km/h Voltage 20 - 30 V
Possible causes
and standard 2) Disconnect connectors L09, L110, L14, LT1, T09, D05, FL2, and F07 and fuse termi-
value in normal nal FS1
state 3) Connect T-adapter.
Wiring harness between fuse FS1 (13) and J05 (1), (6) and
Resistance Max. 1 z
L14 (female) (1)
Wiring harness between fuse FS1 (13) and J05 (1), (7) and
L09 (female) (2) Resistance Max. 1 z
Wiring harness between L09 (female) (3) and L110 (female) Resistance Max. 1 z
(3)
Wiring harness between L14 (female) (2) and chassis
Resistance Max. 1 z
ground
Disconnection in wiring Wiring harness between L14 (female) (3) and LT1 (male) (2) Resistance Max. 1 z
harness (Disconnection in
6
wiring harness or defec- Wiring harness between L14 (female) (4) and L110 (female) Resistance Max. 1 z
tive contact) (1)
Wiring harness between L110 (female) (2) and chassis
ground Resistance Max. 1 z
Wiring harness between L110 (female) (5) and J08 (14), (15) Resistance Max. 1 z
and D06 (female) (1)
Wiring harness between L110 (female) (5) and J08 (14), (16)
Resistance Max. 1 z
and FL2 (male) (4)
Wiring harness between LT1 (female) (2) and T09 (female)
(3) Resistance Max. 1 z
Wiring harness between FL2 (female) (4) and F07 (female) Resistance Max. 1 z
(1)
Wiring harness between F07 (female) (2) and chassis
Resistance Max. 1 z
ground
20-354 WA320-5
(2)

2) Disconnect connectors L09, L110, L14, LT1, T09, J08, D05, FL2, and F07 and fuse ter-
minal FS1
Between this
Wiring harness between fuse FS1 (13) and wiring harness
J05 (1), (6) and L14 (female) (1) and chassis Resistance Min. 1 Mz
ground
Between this
Wiring harness between fuse FS1 (13) and wiring harness
J05 (1), (7) and L09 (female) (2) and chassis
ground
Between this
Wiring harness between L09 (female) (3) wiring harness Resistance Min. 1 Mz
and L110 (female) (3) and chassis
ground
Between this
Wiring harness between L14 (female) (3) wiring harness
and LT1 (male) (2) (A) and chassis
Possible causes ground
and standard
value in normal 7 Grounding fault in wiring Between this
state harness Wiring harness between L14 (female) (4) wiring harness Resistance Min. 1 Mz
and L110 (female) (1) and chassis
ground
Between this
and J08 (14), (15) and D06 (female) (1) and chassis Resistance Min. 1 Mz
ground
Between this
and J08 (14), (16) and FL2 (male) (4) and chassis
ground
Between this
Wiring harness between LT1 (female) (2) wiring harness Resistance Min. 1 Mz
and T09 (female) (3) (A) and chassis
ground
Between this
Wiring harness between FL2 (female) (4) wiring harness
and F07 (female) (1) and chassis Resistance Min. 1 Mz
ground
a When grounding fault occurs in a wiring harness other than the ones marked with (A),
the fuse is broken.
WA320-5 20-355
(2)
b) Travel damper is not reset

Action Code Error code Controller Code Malfunction of travel damper
Trouble
- - - b) Travel damper is not reset
Contents of trou- The travel damper is not reset.

ble
Action of None in particular.
machine monitor
The travel damper is not reset when the travel speed is above 6 km/h and the travel damper switch is turned OFF.
Problem that The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is turned ON.
appears on
machine The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is turned OFF.
(The travel damper is not reset under any condition.).
Related informa-
tion

Defective travel damper 3) Connect T-adapter.
1 switch
Between L09 (male) Travel damper switch: ON Resistance Max. 1 z
(2) and (3) Travel damper switch: OFF Resistance Min. 1 Mz
2) Relay: Replace L110 with normal relay.
4) Operate travel damper switch.
When relay L110 is No Relay L110 is normal.
become normal? Yes Relay L110 is defective.
Possible causes 2) Disconnect relay L110.
and standard Defective travel damper 3) Check relay unit.
2 relay (L110)
value in normal
state Between relay L110 (male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF..
2) Disconnect relay L110.
4) Apply normal voltage between relay L110 (male) (1) and (2).
When 24 V is applied between
and (1) and (2) Resistance Max. 1 z
Between L110 (male)
(3) and (5) When normal voltage is not Resistance Min. 1 Mz
applied between and (1) and (2)
2) Replace travel damper solenoid (F07) with normal solenoid.
Defective travel damper
3 solenoid (F07) (Not reset Travel damper solenoid is
under any condition) When solenoid (F07) is No
normal.
become normal? Travel damper solenoid is
Yes
defective.
20-356 WA320-5
(2)

2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal
Condition becomes normal. Diode (D05) is defective.
Check diode unit.
Check continuity from (3) to (1) in diode range There is not continuity.
a Apply (+) pin of circuit tester to left line.
5 Defective travel damper 4) Turn starting switch ON.
controller
Possible causes
and standard Between L14 (4) and Travel speed: 0 - 5 km/h Voltage Max. 1 V
value in normal chassis ground Travel speed: Above 6 km/h Voltage 20 - 30 V
state
2) Disconnect connectors L09, L110, L14, J08, D05, FL2, and F07.
Max. 1V
Wiring harness between
L09 (female) (3) and L110 Between this wiring harness and (Travel damper is not reset
chassis ground when speed is above 6 km/
(female) (3) h and switch is OFF)
Wiring harness between Max. 1V

Between this wiring harness and (Travel damper is not reset
L14 (female) (4) and L110 chassis ground when speed is below 5 km/h
Short circuit with power (female) (1)
6 and switch is ON)
source in wiring harness
L110 (female) (5) and J08 Between this wiring harness and Max. V
(Travel damper is not reset
(14), (15) and D06 chassis ground under any condition)
(female) (1)
Max. 1V
L110 (female) (5) and J08 Between this wiring harness and (Travel damper is not reset
(14), (16) and FL2 (male) chassis ground
(4) under any condition)
Wiring harness between Between this wiring harness and Max. 1V

FL2 (female) (4) and F07 (Travel damper is not reset
(female) (1) chassis ground under any condition)
WA320-5 20-357
(2)
TROUBLESHOOTING OF MONITOR
SYSTEM (MON MODE)
Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-404

Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-406
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-407
Failure Code [15B0NX] (HST oil filter clogged (NX)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-409
Failure Code [2G42ZG] (Decreased brake oil pressure (ZG)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
Failure Code [989F00] (HST motor protection caution (00)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
Failure Code [989FN1] (HST overrunning (N1)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-412
Failure Code [AA1ANX] (Clogging of air cleaner (NX)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-414
Failure Code [AB00L6] (Defective battery charging circuit (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-416
Failure Code [AB00MA] (Defective battery charging circuit (MA)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-417
Failure Code [B@BAZG] (Degreased engine oil pressure (ZG)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
Failure Code [B@BAZK] Lowering of engine oil level (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
Failure Code [B@BCNS] (Engine coolant temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . 20-420
Failure Code [B@BCZK] (Alarm indicating low coolant level (ZK)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421
Failure Code [B@C7NS] (Axle oil temperature overheating (NS)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-422
Failure Code [B@CRNS] (HST oil temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-423
Failure Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6)) . . . . . . . . . . . . . . . . . . . . . . . . 20-424
Failure Code [DAF0KT] (Controller inside failure (KT)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-426
Failure Code [DAJ0KR] (HST controller communication failure (KR)) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-428
Failure Code [DD15LD] (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)) . . 20-430
Failure Code [DD16LD] (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)). . 20-431
Failure Code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)) . . 20-432
Failure Code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)) . . 20-433
Failure Code [DDK3KB] (Multiple directional lever FR signal input (KB)) . . . . . . . . . . . . . . . . . . . . . . . . . 20-434
Failure Code [DDS5L6] (Decreased steering oil pressure (L6)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-436
Failure Code [DGE2KX] (Engine coolant temperature (High temperature) sensor system failure (KX)) . 20-437
Failure Code [DGE3L6] (Engine coolant temperature (Low temperature) sensor system failure (L6)) . . 20-438
Failure Code [DGH1KX] (HST oil temperature sensor system failure (KX)) . . . . . . . . . . . . . . . . . . . . . . . 20-439
Failure Code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA)) . . . . . . . . . . . . . . . . . . 20-440
Failure Code [DGR4KX] (Axle oil temperature sensor system failure (KX)) . . . . . . . . . . . . . . . . . . . . . . . 20-441
Failure Code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6)) . . . . . . . . . . . . . . . . . . . 20-442
Troubleshooting Code [MON-1] (The parking brake indicator lamp does not light ON) . . . . . . . . . . . . . . 20-444
Troubleshooting Code [MON-2] (The brake oil pressure caution lamp does not light ON) . . . . . . . . . . . . 20-448
Troubleshooting Code [MON-3] (The engine coolant temperature caution lamp does not light ON,
or after the engine starts, the engine coolant temperature gauge
does not rise. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-449
Troubleshooting Code [MON-4] (The HST oil temperature caution lamp does not light ON,
or after the engine starts, the HST oil temperature gauge
does not rise. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-450
Troubleshooting Code [MON-5] (The fuel level gauge does not rise or decrease. ) . . . . . . . . . . . . . . . . . 20-451
Troubleshooting Code [MON-6] (The radiator coolant level caution lamp does not light ON). . . . . . . . . . 20-452
Troubleshooting Code [MON-7] (The steering oil pressure caution lamp does not light ON) . . . . . . . . . . 20-453
Troubleshooting Code [MON-8] (The emergency steering oil pressure indicator lamp
does not light ON). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-454
WA320-5 20-401
(1)..
(3)
Troubleshooting Code [MON-9] (Input failure in monitor panel mode selector switch 1 [t]
(Panel switch 1)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
Troubleshooting Code [MON-10] (Input failure in monitor panel mode selector switch 1 [U]
(Panel switch 2)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
Troubleshooting Code [MON-11] (Input failure in monitor panel mode selector switch 2 [<]
(Panel switch 3)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
Troubleshooting Code [MON-12] (Input failure in monitor panel mode selector switch 2 [>]
(Panel switch 4)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
Troubleshooting Code [MON-13] (The alarm buzzer does not sound or stop) . . . . . . . . . . . . . . . . . . . . . . 20-460
Troubleshooting Code [MON-14] Engine oil level caution lamp does not light up. . . . . . . . . . . . . . . . . . . . 20-462
Troubleshooting Code [MON-15] Air cleaner clogging indicator lamp does not light up . . . . . . . . . . . . . . . 20-464
Troubleshooting Code [MON-16] The wiper does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
Troubleshooting Code [MON-17] The lamps do not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
20-402 WA320-5
(1)
(2)
20-404
989F00
989F00
AB00L6
989FN1
15B0NX
D5ZHL6
DX20KZ
DX19KZ
DHE4L6
DDS5L6
DLE2LC
2G42ZG
DGE3L6
DD18LD
DD17LD
DD16LD
DD15LD
DAJ0KR
DAF0KT
AB00MA
AA1ANX
DDK3KB
DGE2KX
DHH1KX
DW26KZ
DGR4KA
DGR1KX
DGH1KX
B@BAZK
B@C7NS
B@BCZK
B@BAZG
B@BCNS
B@CRNS
Failure code
(Codes related to monitor)
E01
E01
E03
E02
E01
E01
E01
E01
E03
E01
E01
E01
E01
E03
E00
E01
E03
E01
E02
E02
E03
E02
E01
E01
E00
E03
E03
E03
E03
E03
E03
E01
E01
E03
Action code
(Codes related to HST controller)

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
q
q
Defective machine monitor
q
q
q
q
q
q
q
q
Defective HST controller
q
Defective starting switch
q
Defective monitor panel mode selector switch 1 t
q
Defective monitor panel mode selector switch 1 U
q
Defective monitor panel mode selector switch 2 <
FAILURE CODE AND POSSIBLE CAUSES TABLE
q
Defective monitor panel mode selector switch 2 >
q
q
q
Defective forward-reverse lever
q
Deterioration of battery
q
Defective battery relay
Defective fuse/fusible link
q
Defective alternator
q
Clogging of air cleaner
Possible causes
q
Defective air cleaner clogging sensor
Defective engine speed sensor

q

q
q

q
q
q Defective clutch solenoid
Lowering of engine oil pressure
q
q
Defective engine oil pressure sensor

q
Lowering of engine oil level

q
Defective engine oil level sensor

WA320-5
q
Overheating of engine coolant
q
q
(high temperature) sensor
WA320-5
q
(low temperature) sensor
q
Lowering of coolant level
q
Defective coolant level sensor
q
Defective HST oil pressure sensor
q
Clogging of HST oil filter
q
Defective HST oil filter clogging sensor
q
Overheating of HST oil
q
q
Defective HST oil temperature sensor
q
Lowering of brake oil pressure
q
Defective brake oil pressure sensor
q
Overheating of axle oil
q
q
q
Defective axle oil temperature sensor
Possible causes
q
Lowering steering oil pressure
q
Defective steering oil pressure sensor
Defective boom angle sensor
Defective boom pressure sensor (bottom side)
Defective boom pressure sensor (head side)
Defective subtotal switch
Defective cancel switch
Defective alarm buzzer
q
q
q
q
q
q
Defective relay
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Disconnection in wiring harness
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Grounding fault in wiring harness
q
q
q
q
q
q
q
Short circuit with power source in wiring harness
(2)
20-405


2 10A Hazard lamp
3 10A HST control A
(Fuse box 1)
5 10A Meter, panel

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 - (Spare 1)
5 10A Load-meter
7 10A DC converter
Switch power source 8 10A Parking brake 2
(Fuse box 2)
9 10A Horn
14 - (Spare 2)
15 - (Spare 3)
20-406 WA320-5
(2)

Controller
Trouble
Machine moni-
ler Reaction
Machine ler.

Information
<Data to fill in>


Disconnection
circuit
Causes and
female terminals
4
5
WA320-5 20-407
(1)..d
Phenomena code table
a For problem codes marked "See list", see the list below.
Phenomena Details Disconnection Details
code
KA Disconnection L0 Fill signal ON 2 or more channels
KB Short circuit L1 Fill signal is ON when command current is OFF
KK Drop in power source voltage, input L2 Fuel pressure is higher than maximum set value
KQ Non match in model selection signal L3 Corresponding component cannot be controlled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
Engine signals do not match operating condition or
KT Abnormality inside controller L6 stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit in power supply line LC Speed signals for 2 systems do not match
Switch has been kept pressed for abnormally long
KZ Disconnection or short circuit LD time
MA Function impossible LH Fill signal is OFF when command current is ON
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
20-408 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [15B0NX]
Failure Code [15B0NX] (HST oil filter clogged (NX))

Controller
Code Trouble HST oil filter clogged (NX)
E01 15B0NX MON
Description of When HST oil temperature went above 50oC: signal circuit of HST oil filter clogging sensor changed to CLOSE (con-
Trouble nected to GND)
Machine moni-
tor or control- Trigger an alarm.
ler Reaction
Effect on If it is used as it is, there is danger that dirt will circulated in the HST circuit
Machine
Related
Information
1 HST oil filter clogged Clean or replace
1) Turn starting switch OFF. 2) Disconnect connector T13.
2 Defective HST oil filter Between T13 1Mz and

clogging sensor Filter is normal Resistance above
and chassis
ground Filter clogged Resistance 1z and below
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector T13.
Standard
Values 3 Wiring harness ground fault Resistance between L23
Wiring harness between L23 (Female) (6), T13 and chassis 1Mz and
(Female) (6) and T13 above
ground
4 Defective machine monitor Filter is nor-
Between L23 (Female) (6) and Voltage 20 - 30V
mal
chassis ground
Filter clogged Voltage 1V and below
WA320-5 20-409
(1)..d
TESTING AND ADJUSTING FAILURE CODE [2G42ZG]
Failure Code [2G42ZG] (Decreased brake oil pressure (ZG))

Controller
Code Trouble Decreased brake oil pressure (ZG)
E03 2G42ZG MON
Description of When engine was running (continuously for more than 30 seconds), signal from accumulator oil pressure sensor went
Trouble below 4.6 MPa {45 kg/cm2}.
Machine moni-
tor or control- Trigger an alarm.
ler Reaction
Effect on If it is used as it is, there is danger that the brake will have no effect.
Machine
Related
Information

Accumulator (Brake) oil pressure is normal
Decrease brake oil pres- a If the oil pressure is not normal, carry out troubleshooting for the hydraulic,
1
sure
mechanical system.
1) Turn starting switch OFF. 2) Disconnect connector T12. 3) Connect T-adapter.
Defective brake oil pres- Oil pressure is normal (6MPa Resistance 1z and below
2
sure sensor
Between T12 {61.2kg/cm2})
(Male) (1) and
(2) Oil pressure is low (4MPa 1Mz and
{40.8kg/cm2}) Resistance above
Turn starting switch OFF. 2) Disconnect Connectors T12, L23. 3) Connect T-adapter.
Possible Wiring harness discontinu- Wiring harness between T12 (Female) (1) and
Causes and
Standard tive contact)
Values chassis ground
1) Turn starting switch OFF. 2) Disconnect Connectors T12, L23. 3) Connect T-
adapter.
4 Wiring harness ground fault Wiring harness between L23 Resistance between L23 1Mz and
(Female) (19) and T12 (Female) (19), T12 (Female)
above
5 Defective machine monitor Between L23 Oil pressure is normal Voltage 1V and below
(Female) (19) (5.88MPa {60kg/cm2})
and chassis Oil pressure is low (3.92MPa
ground {40kg/cm2}) Voltage 20 - 30V
20-410 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [989F00]
Failure Code [989F00] (HST motor protection caution (00))

Controller
Action Code Failure Code Code Trouble HST motor protection caution (00)
E00 989F00 MON
Not considered to be a failure.
Description of The travel speed exceeds the allowable speed the HST motor on down shifting.
Trouble (This code is displayed when the gear is shifted down to the 1st or 2nd while the machine is traveling at speed of 10
km/h or higher in the 3rd or 4th gear position.)
Machine moni-
ler Reaction
Effect on When the gear shift-down operation is performed, the gear is not shifted down.
Machine
Related
Information
WA320-5 20-411
(3)
(1)..d
TESTING AND ADJUSTING FAILURE CODE [989FN1]
Failure Code [989FN1] (HST overrunning (N1))

Controller
Action Code Failure Code Code Trouble HST overrunning (N1)
E02 989FN1 MON
Description of Travel speed exceeds 45 km/h.

Trouble Automatic speed reduction when travel speed exceeds 40 km/h does not work.
Machine moni-
ler Reaction
Effect on If the machine is driven as it is, HST motor may be broken (seized).
Machine
Related
Information

2) Operate machine monitor
1 ---
Other code is displayed at Carry out troubleshooting for applicable code dis-
same time played
When machine was used in
Possible 2 Overrunning HST way that would cause HST to Inspect and repair cause of problem and damage
to HST.
Causes and overrun
Standard
Values 1) Start engine.
2) Operate machine monitor
3) Travel on flat ground.
Travel speed goes above 40 Carry out troubleshooting for HST controller sys-
3 Defective machine monitor km/h. tem failure codes DW26KZ and DX19KZ.
Travel speed does not go Inspect and repair cause of problem and damage
above 40 km/h. (Less than 40
km/h) to HST.
20-412 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AA1ANX]
Failure Code [AA1ANX] (Clogging of air cleaner (NX))

Controller
Code Trouble Clogging of air cleaner (NX)
E01 AA1ANX MON
Description of The signal circuit of the dust indicator (air cleaner clogging sensor) is closed (in contact with the ground).
Trouble
Machine moni-
tor or control- The alarm is turned ON.
ler Reaction
Effect on The air cleaner is clogged (The engine may be damaged).
Machine
Related
Information

1 Clogging of air cleaner Clean or replace.
2) Disconnect connector E26.
Defective dust indicator (air 4) Start engine.
2 cleaner clogging sensor)
Between E26 Air cleaner is normal. Resistance Min. 1 Mz
(female) (1)
and (2) Air cleaner is clogged. Resistance Max. 1 z
Possible 2) Disconnect connector E26.
Causes and Short circuit with chassis 3) Connect T-adapter.
Standard 3 ground in wiring harness
Values Wiring harness between L23 Resistance between L23
(female) (7) and E26 (female) (female) (7), E26 (female) (1), Min. 1 Mz
4) Connect connector.
4 Defective machine monitor 6) Start engine.
Between L23 Air cleaner is normal. Voltage 20 - 30 V
(female) (7)
and chassis Air cleaner is clogged. Voltage Max. 1 V
ground
20-414 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AA1ANX]
9JF01293
WA320-5 20-415
(1)..d
TESTING AND ADJUSTING FAILURE CODE [AB00L6]
Failure Code [AB00L6] (Defective battery charging circuit (L6))

Controller
Action Code Failure Code Defective battery charging circuit (L6)
Code Trouble (Alternator terminal R signal detected when engine stopped)
E03 AB00L6 MON
Description of The alternator terminal R signal input voltage is 12V or higher before the engine started.
Trouble
Machine moni-
ler Reaction
Effect on The engine cannot be started.

Machine The service meter increases simply by starting switch ON.
Related
Information

Engine
started Voltage 28 - 29V
Between alternator terminal R (Throttle 1/2
1 Defective alternator [E02 (1)] and chassis ground or more).
Engine 1.5V and
Voltage
stopped. below
Possible adapter. 4) Turn starting switch ON.
Causes and 2 Wiring harness between L23 Voltage between L23 (Female)
Standard between harnesses
(Female) (12) and E02 (12), E02 (Female) (1) and 1V and below
Values (Female) (1) chassis ground
Engine
started
3 Defective machine monitor Voltage 28 - 29V
Between L23 (Female) (12) (Throttle 1/2
and chassis ground or more).
Engine 1.5V and
Voltage
stopped. below
20-416 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AB00MA]
Failure Code [AB00MA] (Defective battery charging circuit (MA))

Controller Defective battery charging circuit (MA)
Code Trouble (No signal from alternator terminal R when engine stopped, Abnormal
E03 AB00MA MON detection)
Description of During engine operation, the input voltage to the alternator terminal R signal is below 5V.
Trouble
Machine moni-
ler Reaction
The battery is deteriorated.
Effect on The engine cannot be started.
Machine
The service meter does not work.
Related
Information

1 Battery is deteriorated. ---
Engine
started Voltage 28 - 29V
Between alternator terminal R (Throttle 1/2
2 Defective alternator or more).
[E02 (1)] and chassis ground
Engine 1.5V and
Voltage
stopped. below
Wiring harness discontinu- adapter.
Possible tive contact) Wiring harness between L23 (Female) (12) and Resistance 1z and below
E02 (Female) (1)
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E02. 3) Connect T-
Values adapter.
(Female) (12) and E02 (Female) (12), E02 (Female) 1Mz and
above
Engine
started
5 Defective machine monitor Voltage 28 - 29V
Between L23 (Female) (12) (Throttle 1/2
and chassis ground or more).
Engine 1.5V and
stopped. Voltage below
WA320-5 20-417
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@BAZG]
Failure Code [B@BAZG] (Degreased engine oil pressure (ZG))

Controller
Code Trouble Degreased engine oil pressure (ZG)
E01 B@BAZG MON
Description of The engine oil pressure sensor circuit is always in the CLOSE state 15 minutes after the engine started.
Trouble
Machine moni-
ler Reaction
Effect on The engine oil pressure is low (The engine may be damaged).
Machine
Related
Information

Degrease engine oil pres-
1 ---
sure
1) Turn starting switch OFF. 2) Disconnect connector E15. 3) Connect T-adapter.
Defective engine oil pres- Engine Resistance 1z and below

2 Between engine oil pressure stopped.
sure sensor (switch) sensor terminal (E15) and
chassis ground Engine rotat- 1Mz and
Resistance
ing. above
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E15. 3) Connect T-
Standard adapter.
Values 3 Wiring harness ground fault
(Female) (10), E15 and chassis
(Female) (10) and E15 ground above

Engine
4 Defective machine monitor stopped. Voltage 1V and below
Between L23 (Female) (10)
and chassis ground Engine rotat- Voltage 20 - 30V
ing.
20-418 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [B@BAZK]
Failure Code [B@BAZK] Lowering of engine oil level (ZK)

Controller
Action Code Failure Code Code Trouble Lowering of engine oil level (ZK)
E01 B@BAZK MON
Description of The engine oil level sensor circuit is OPEN.
Trouble
Machine moni-
tor or control- None in particular.
ler Reaction
Effect on The engine oil level is low (The engine may be damaged).
Machine
Related
Information

1 Lowering of engine oil level ---
2 Defective engine oil level
sensor Between E27 When oil level is normal Resistance Max. 1 z
(male) (1) and When oil level is insufficient
chassis Resistance Min. 1 Mz
(low)
Possible 2) Disconnect connectors L23 and E27.
Causes and 3) Connect T-adapter.
Standard 3 Short circuit with chassis
Values ground in wiring harness Resistance between L23
Wiring harness between L23 (female) (20), E27 and chassis Min. 1 Mz
(female) (20) and E27
ground
4 Defective machine monitor 5) Turn starting switch ON.
Between L23 When oil level is normal Voltage Max. 1 V
(female) (20)
and chassis When oil level is insufficient Voltage 20 - 30 V
ground (low)
9JF01296
WA320-5 20-419
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@BCNS]
Failure Code [B@BCNS] (Engine coolant temperature overheating

(NS))
Controller
Code Trouble Engine coolant temperature overheating (NS)
E02 B@BCNS MON
Description of The engine coolant temperature is above 105C
Trouble
Machine moni- Activates an alarm (Turns the engine coolant temperature caution lamp ON at 102C or above and issues this failure
tor or control-
code at 105C or above).
ler Reaction
Effect on The engine coolant temperature overheat alarm is issued (The engine may be damaged if operation continues).
Machine
Related The engine coolant temperature can be checked with the monitoring function (Code: 04101).
Information

Overheating engine coolant
1 temperature ---

Defective engine coolant Normal tem-
2 temperature sensor (high perature Resistance 35 - 50kz
temperature) Between E14 (Male) (1) and (2) (25C).
When 100C Resistance 3.1 - 4.5kz
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, E14. 3) Connect T-
Standard adapter.
Values 3 Wiring harness ground fault Wiring harness between L21 Resistance between L21
above
4 Defective machine monitor Normal tem-

Between L21 (Female) (16) perature Resistance 35 - 50kz
and chassis ground (25C).
When 100C Resistance 3.1 - 4.5kz
20-420 WA320-5
(3)
(1)
TESTING AND ADJUSTING FAILURE CODE [B@BCZK]
Failure Code [B@BCZK] (Alarm indicating low coolant level (ZK))

Controller
Code Trouble Alarm indicating low coolant level (ZK)
E01 B@BCZK MON
Description of The coolant level sensor circuit is opened.
Trouble
Machine moni-
ler Reaction
Effect on The coolant level is low (The engine may be damaged).
Machine
Related
Information

1 Decrease coolant level. ---
1) Turn starting switch OFF. 2) Disconnect connector B05. 3) Connect T-adapter.
Reserve tank low level and
Defective coolant level sen- Between B Resistance 1z and below
2 above (normal).
sor (Male) (1) and
(2) Reserve tank low level and 1Mz and
Resistance
below (abnormal). above
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05. 3) Connect T-
Possible
adapter.
Causes and
Standard Wiring harness discontinu-
Values 3 ity (Disconnection or defec- Resistance 1z and below
tive contact) B05 (Female) (1)
Wiring harness between B05 (Female) (2) and
Chassis ground Resistance 1z and below

Between L23 Reserve tank low level and

4 Defective machine monitor Voltage 1V and below
(Female) (8) above (normal).
and chassis Reserve tank low level and
ground below (abnormal). Voltage 20 - 30V
WA320-5 20-421
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@C7NS]
Failure Code [B@C7NS] (Axle oil temperature overheating (NS))

Controller
Code Trouble Axle oil temperature overheating (NS)
E02 B@C7NS MON
Description of The axle oil temperature is overheating.
Trouble
Machine moni-
ler Reaction
Effect on The brake may be damaged if operation continues.
Machine
Related This failure code is displayed if the probability of a failure in the electrical system is low.
Information The axle oil temperature is displayed by monitoring code 30202.

Overheating axle oil tem-
1 ---
perature.
1) Turn starting switch OFF. 2) Disconnect connector F14. 3) Connect T-adapter.
Possible Defective axle oil tempera- Between F14 Normal temperature (25C). Resistance 35 - 50kz
2
Causes and ture sensor (Male) (1) and
Standard (2) When 100C Resistance 3.1 - 4.5kz
Values
3 Defective machine monitor Between L21 Normal temperature (25C). Resistance 35 - 50kz
(Female) (8)
and chassis When 100C Resistance 3.1 - 4.5kz
ground
20-422 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [B@CRNS]
Failure Code [B@CRNS] (HST oil temperature overheating (NS))

Controller
Code Trouble HST oil temperature overheating (NS)
E02 B@CRNS MON
Description of The HST oil temperature is above 110C.
Trouble
Machine moni-
ler Reaction
Effect on The HST may be damaged if operation continues.
Machine
Related This failure code is displayed if the probability of a failure in the electrical system is low.
Information The HST oil temperature is display by monitoring code 30100.

Overheating HST oil tem-
1 ---
perature.
Possible Defective HST oil tempera- Between T10 Normal temperature (25C). Resistance 35 - 50kz
2
Causes and ture sensor (Male) (1) and
Standard (2) When 100C Resistance 3.1 - 4.5kz
Values
(Female) (14)
ground
WA320-5 20-423
(1)..d
TESTING AND ADJUSTING FAILURE CODE [D5ZHL6]
Failure Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure
(L6))
Controller
Code Trouble Starting switch "C" (IGN "C") input failure (L6)
E01 D5ZHL6 MON
Description of When engine was running, starting switch C (IGN C) terminal signal turned ON, or did not turn ON when starting
Trouble switch was at START
Machine moni-
ler Reaction
Effect on No reaction.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect starting switch terminals. 3) Connect T-
adapter.
1 Defective starting switch Between Starting switch START. Resistance 1z and below
starting
switch termi- 1Mz and
Other than the above. Resistance
nal B and C above
2) Interchange relay (L106) with normal relay
Does condition become normal when neutral is abnormal. is normal.
safety relay (L106) is interchanged with normal
relay? The condition Defective
is normal. relay (L106)
Defective neutral safety 1) Turn starting switch OFF. 2) Disconnect connector L106. 3) Solid part check.
2 relay (L106) Between L106 (Male) (1) and (2) Resistance 200 - 400z
Between between L106 (Male) (1) - (2) Resistance 1z and below
L106 (Male)
Possible between L106 (Male) (1) - (2) Resistance above
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect Connectors L02, L15, L23 and fuse L106.
Values 3) Connect T-adapter.
L106 (Female) (3)
L106 (Female) (5)
tive contact)
chassis ground
L15 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L02, L15, L23 and L106.
1Mz and
(Female) (3) and L106 (Female) (3), L106 (Female) (3)
above
(Female) (3) and chassis ground
4 Wiring harness ground fault 1Mz and
(Female) (3) and L106 (Female) (3), L106 (Female) (5) above
(Female) (5) and chassis ground
1Mz and
a In the above case, the fuse is blown.
20-424 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [D5ZHL6]

1) Turn starting switch OFF. 2) Disconnect Connectors L23, L106. 3) Connect T-
adapter.
5 between harnesses Wiring harness between L23 Voltage between L23 (Female)
Possible (Female) (3) and L106 (3), L106 (Female) (5) and 1V and below
Causes and (Female) (5) chassis ground
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L23. 3) Insert T-adapter.
6 Defective machine monitor Between L23 Starting switch START. Voltage 20 - 30V
(Female) (3)
and Chassis Other than the above. Voltage 1V and below
ground
WA320-5 20-425
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DAF0KT]
Failure Code [DAF0KT] (Controller inside failure (KT))

Controller
Code Trouble Controller inside failure (KT)
E03 DAF0KT MON
Description of Abnormality has occurred inside controller.
Trouble
Machine moni-
ler Reaction
Effect on Abnormality in data recorded inside monitor, monitor operation possible
Machine
Related
Information
Possible Causes Standard Value in Normal State and Remarks on Troubleshooting

Causes and
Standard Abnormality inside machine monitor, so troubleshooting cannot be carried out.
1 Defective machine monitor (Abnormality may be repaired by initializing machine monitor.)
Values
20-426 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DAJ0KR]
Failure Code [DAJ0KR] (HST controller communication failure (KR))

Controller
Action Code Failure Code Code Trouble HST controller communication failure (KR)
E03 DAJ0KR MON
Description of Communications (CAN) data cannot be received from HST controller.
Trouble
Machine moni- Activates an alarm.

tor or control- HST controller holds at condition before abnormality occurred.
ler Reaction HST controller actuates with mode that ignores CAN communications.
Movement of machine becomes abnormal.

Effect on Speed range is not displaied.
Machine
Speedometer always displays 0 km/h.
Related
Information

adapter.
40 - 80z
(Female) (6), L42 (Female) (16) (Female) (2) and (6)
(Female) (2), L42 (Female) (8) (Female) (2) and (6) 40 - 80z
1 Defective wiring harness Wiring harness between L22 Resistance between L22 1Mz and
(Female) (6), L42 (Female) (16) ground above

(Female) (2), L42 (Female) (8) ground above
a Check that terminal resistances CAN1, CAN 2 are connected.

a Resistance value of terminal resistances CAN1, CAN 2: 120z
1) Turn starting switch OFF. 2) Replace HST controller. 3) Turn starting switch ON.
Possible
Causes and Communication is abnormal. HST control-
Standard When HST controller is ler is normal.
Values 2 Defective HST controller
replaced, do communications Defective
become normal? Communication is normal. HST control-
ler
1) Turn starting switch OFF. 2) Disconnect Connectors CAN1, CAN2. 3) Connect T-
adapter.
3 Defective terminal resis-
tance Wiring harness between CAN1 (Male) (A) and (B) Resistance 100 - 130z
Wiring harness between CAN2 (Male) (A) and (B) Resistance 100 - 130z
1) Turn starting switch OFF. 2) Replace machine monitor. 3) Turn starting switch ON.
Machine
Communication is abnormal. monitor is
When machine monitor is normal.
replaced, do communications
4 Defective machine monitor become normal? Defective
Communication is normal. Machine
monitor
a When replacing the machine monitor, carry out adjustments.
For details, see TESTING AND ADJUSTING, Adjusting machine monitor.
20-428 WA320-5
(3)
TESTING AND ADJUSTING FAILURE CODE [DAJ0KR]
WA320-5 20-429
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DD15LD]
t]
Failure Code [DD15LD] (Monitor panel mode selector switch 1 [t
(Panel switch 1) input error (LD))
Controller
Action Code Failure Code Monitor panel mode selector switch 1 [t] (Panel switch 1) input error
Code Trouble
(LD)
E01 DD15LD MON
Description of The monitor panel mode selector switch 1 [t] (Panel switch 1) input circuit is always in the CLOSE state for more
Trouble thirty seconds.
Machine moni-
ler Reaction
Effect on The monitor does not work.
Machine
Related
Information

When monitor panel mode
Defective monitor panel Between L10 selector switch 1 [t] is turned Resistance 1z and below
1
mode selector switch 1 [t] (Female) (2) ON.
and (3) 1Mz and
Other than above. Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10. 3) Connect T-
Causes and adapter. 4) Turn starting switch ON.
Standard 2 Hot short-circuiting
Values between harnesses Wiring harness between L21 Voltage between L21 (Female)
(3) sis ground
Between L21 When monitor panel mode

3 Defective machine monitor
(Female) (1) selector switch 1 [t] is turned Voltage 20 - 30V
and chassis ON.
ground Other than above. Voltage 1V and below
20-430 WA320-5
(1)
U]
Failure Code [DD16LD] (Monitor panel mode selector switch 1 [U
Controller
Action Code Failure Code Monitor panel mode selector switch 1 [U] (Panel switch 2) input error
Code Trouble
(LD)
E01 DD16LD MON
Description of The monitor panel mode selector switch 1 [U] (Panel switch 2) input circuit is always in the CLOSE state for more
Trouble thirty seconds.
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L10 selector switch 1 [U] is turned Resistance 1z and below
1
mode selector switch 1 [U] (Female) (2) ON.
and (1) 1Mz and
Standard 2 Hot short-circuiting
Values between harnesses Wiring harness between L21 Voltage between L21 (Female)
(1) sis ground

(Female) (2) selector switch 1 [U] is turned Voltage 20 - 30V
and chassis ON.
ground Other than above. Voltage 1V and below
WA320-5 20-431
(1)..d
Failure Code [DD17LD] (Monitor panel mode selector switch 2 [<]

Controller
Action Code Failure Code Monitor panel mode selector switch 2 [<] (Panel switch 3) input error
Code Trouble
(LD)
E01 DD17LD MON
Description of The monitor panel mode selector switch 2 [<] (Panel switch 3) input circuit is always in the CLOSE state for more thirty
Trouble seconds.
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L11 selector switch 2 [<] is turned Resistance 1z and below
1
mode selector switch 2 [<] (Female) (2) ON.
and (3) 1Mz and


(Female) (4) selector switch 2 [<] is turned Voltage 1V and below
and chassis ON.
ground Other than above. Voltage 20 - 30V
20-432 WA320-5
(1)
Failure Code [DD18LD] (Monitor panel mode selector switch 2 [>]

Controller
Action Code Failure Code Monitor panel mode selector switch 2 [>] (Panel switch 4) input error
Code Trouble
(LD)
E01 DD18LD MON
Description of The monitor panel mode selector switch 2 [>] (Panel switch 4) input circuit is always in the CLOSE state for more thirty
Trouble seconds.
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L11 selector switch 2 [>] is turned Resistance 1z and below
1
mode selector switch 2 [>]. (Female) (2) ON.
and (1) 1Mz and


(Female) (5) selector switch 2 [>] is turned Voltage 1V and below
and chassis ON.
WA320-5 20-433
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DDK3KB]
Failure Code [DDK3KB] (Multiple directional lever FR signal input

(KB))
Controller
Code Trouble Multiple directional lever FR signal input (KB)
E03 DDK3KB MON
Description of Multiple signals (F and R signal) are input due to short-circuited directional lever.
Trouble
Machine moni- Input signal is displayed as it is (F and R light up at same time).

tor or control- When engine is started, machine moves even when directional lever is at N position.
ler Reaction Activates an alarm.
Effect on Does not travel.

Machine The power train may be damaged.
Related
Information

Hot short-circuiting (Female) (10) and L15 (10), L15 (Female) (2) and 1V and below
1 between harnesses (Female) (2) chassis ground
(4) sis ground
When directional lever is turned
Between L15 Resistance 1z and below
F.
Possible (Female) (1)
Causes and and (2) Other than above. Resistance 1Mz and
Standard 2 Defective directional lever above
Values When directional lever is turned
Between L15 Resistance 1z and below
R.
(Female) (1)
and (4) 1Mz and
Other than above. Resistance
above
Between L15 When directional lever is turned

Voltage 20 - 30V
(Female) (1) F.
3 Defective machine monitor and (2) Other than above. Voltage 1V and below
Between L15 When directional lever is turned

Voltage 20 - 30V
(Female) (1) R.
and (4) Other than above. Voltage 1V and below
20-434 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DDK3KB]
WA320-5 20-435
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DDS5L6]
Failure Code [DDS5L6] (Decreased steering oil pressure (L6))

Controller
Code Trouble Decreased steering oil pressure (L6)
E03 DDS5L6 MON
Description of The steering oil pressure sensor signal circuit is always in the CLOSE state during the engine is revolved.
Trouble
Machine moni-
ler Reaction
Effect on The steering may be not worked if operation continues.
Machine
Related This warning is given only when the emergency steering is installed.
Information

Steering oil pressure is normal.
Decrease steering oil pres- a If the oil pressure is not normal, carry out troubleshooting for the hydraulic,
1 sure
mechanical system.

Steering oil pressure is low
2 Defective steering oil pres- Between F11 (Engine stopped). Resistance 1z and below
sure sensor (switch) (Male) (A)
and (C) Steering oil pressure is normal 1Mz and
(Engine started). Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L22, F11. 3) Connect T-
Causes and adapter.
Standard
Values 3 Wiring harness ground fault Wiring harness between L22 Resistance between L22
(Female) (3) and F11 (Female) 1Mz and
(Female) (3), F11 (Female) (C) above
(C) and chassis ground
Steering oil pressure is normal.
[0.9 MPa {9.2 kg/cm2}] and Voltage 20 - 30V
4 Defective machine monitor Between L22 above
(Female) (3)
and Chassis Steering oil pressure is abnor-
ground mal (low). Voltage 1V and below
[0.5 MPa {5.1 kg/cm2}] and
below
20-436 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DGE2KX]
Failure Code [DGE2KX] (Engine coolant temperature

(High temperature) sensor system failure (KX))
Controller
Code Trouble Engine coolant temperature (High temperature) sensor system failure (KX)
E01 DGE2KX MON
Description of The engine coolant temperature sensor input voltage is less 0.98V.
Trouble
Machine moni-
ler Reaction
Effect on The engine coolant temperature gauge is in the MAX position.
Machine
Related The engine coolant temperature is displayed by real-time monitoring code 04101.
Information

Defective engine coolant
1 temperature (High temper- Between E14 Normal temperature (25C). Resistance 35 - 50kz
ature) sensor (Male) (1) and
(2) When 100C Resistance 3.1 - 4.5kz
Possible adapter.
Causes and 2 Wiring harness ground fault
Standard Wiring harness between L21 Resistance between L21
Values above
(Female) (16)
ground
WA320-5 20-437
(1)..d
(3)
TESTING AND ADJUSTING FAILURE CODE [DGE3L6]
Failure Code [DGE3L6] (Engine coolant temperature

(Low temperature) sensor system failure (L6))
Controller
Code Trouble Engine coolant temperature (Low temperature) sensor system failure (L6)
E01 DGE3L6 MON
Description of After starting the engine, and running it for more than 30 minutes, engine coolant temperature (low temperature) sensor
Trouble signal becomes abnormal 4.5V
Machine moni-
tor or control- The Activates an alarm.
ler Reaction
Effect on After starting switch is turned ON, system always carries out automatic preheating.
Machine
Related The engine coolant temperature (low temperature) is displayed by real-time monitoring code 04101.
Information

1 temperature (Low tempera- Between E13 Normal temperature (25C). Resistance 3.1 - 5.7kz
ture) sensor (Male) (A)
and (B) When 100C Resistance 0.2 - 0.7kz
Possible Wiring harness discontinu-
Causes and adapter.
Standard tive contact) Wiring harness between L21 (Female) (6) and 1Mz and
Values E13 (Female) (A) Resistance above
3 Defective machine monitor Between L21 Normal temperature (25C). Resistance 3.1 - 5.7kz
(Female) (6)
ground
20-438 WA320-5
(3)
(1)
TESTING AND ADJUSTING FAILURE CODE [DGH1KX]
Failure Code [DGH1KX] (HST oil temperature sensor system

failure (KX))
Controller
Code Trouble HST oil temperature sensor system failure (KX)
E01 DGH1KX MON
Description of The HST oil temperature sensor input voltage is less 0.98V.
Trouble
Machine moni-
ler Reaction
Effect on The HST oil temperature gauge is in the MAX position.
Machine
Related The HST oil temperature is displayed by real-time monitoring code 30100.
Information

Defective HST oil tempera- Between T10 Normal temperature (25C). Resistance 35 - 50kz
1
ture sensor (Male) (1) and
1) Turn starting switch OFF. 2) Disconnect Connectors L21, T10. 3) Connect T-
Possible adapter.
(Female) (14) and T10 (Female) (14), T10 (Female) 1Mz and
Values above
(Female) (14)
ground
WA320-5 20-439
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DGR4KA]
Failure Code [DGR4KA] (Axle oil temperature sensor system

discontinuity (KA))
Controller
Code Trouble Axle oil temperature sensor system discontinuity (KA)
E01 DGR4KA MON
Description of The axle oil temperature sensor signal is 4.5 V or above.
Trouble
Machine moni-
ler Reaction
Effect on The axle oil temperature is displayed by real-time monitoring code 30202.
Machine
Related
Information

Defective axle oil tempera- Between F14 Normal temperature (25C). Resistance 35 - 50kz
1
1) Turn starting switch OFF. 2) Disconnect Connectors L21, F14. 3) Connect T-
Possible Wiring harness discontinu- adapter.
Causes and 2 ity (Disconnection or defec-
Standard tive contact) Wiring harness between L21 (Female) (8) and
Values F14 (Female) (1) Resistance 1z and below

Defective machine monitor Between L21 Normal temperature (25C). Resistance 35 - 50kz
3
(Female) (8)
ground
20-440 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DGR4KX]
Failure Code [DGR4KX] (Axle oil temperature sensor system

failure (KX))
Controller
Code Trouble Axle oil temperature sensor system failure (KX)
E01 DGR4KX MON
Description of The brake oil temperature sensor input voltage is less 0.98V.
Trouble
Machine moni-
ler Reaction
Effect on The axle oil temperature is displayed by real-time monitoring code 30202.
Machine
Related
Information

Defective axle oil tempera- Between F14 Normal temperature (25C). Resistance 35 - 50kz
1
Possible adapter.
(Female) (8) and F14 (Female) (Female) (8), F14 (Female) (1) 1Mz and
Values above
(Female) (8)
ground
WA320-5 20-441
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DHE4L6]
Failure Code [DHE4L6] (Engine oil pressure sensor system

discontinuity (L6))
Controller
Code Trouble Engine oil pressure sensor system discontinuity (L6)
E01 DHE4L6 MON
Description of The engine oil pressure sensor circuit is always in the CLOSE state when the engine is stopped.
Trouble
Machine moni-
ler Reaction
Effect on
Machine
Related
Information

Engine
Defective engine oil pres- Between engine oil pressure Resistance 1z and below
1 sure sensor (switch) stopped.
sensor terminal E15 and chas-
sis ground Engine rotat- 1Mz and
ing. Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L22, E15. 3) Connect T-
Causes and Wiring harness discontinu- adapter.
Standard 2 ity (Disconnection or defec-
Values tive contact) Wiring harness between L23 (Female) (10) and
E15 (Female) (C) Resistance 1z and below

3 Defective machine monitor Engine

Voltage 1V and below
Between L23 (Female) (10) stopped.
and Chassis ground Engine rotat-
ing. Voltage 20 - 30V
20-442 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-1]
Troubleshooting Code [MON-1] (The parking brake indicator lamp

does not light ON)
Controller
Code Trouble The parking brake indicator lamp does not light ON
- - -
Description of When the parking brake lever is pulled, the parking brake indicator lamp does not light up.
Trouble
Machine moni-
tor or control- No reaction.
ler Reaction
Effect on When the parking brake lever is pulled, the parking brake indicator lamp does not light up.
Machine
Related If the parking brake does not work normally, carry out troubleshooting after carrying out the applicable troubleshoot-
Information ing.

starting switch ON. 4) Operate parking brake switch.
Does condition become normal Relay (L104)

The condition is abnormal.
when parking brake indicator is normal.
lamp relay (L104) is inter- Defective
changed with normal relay? The condition is normal. relay (L104)
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1 indicator lamp relay (L104) Between L104 (Male) (1) and (2) Resistance 200 - 400z
L104 (Male)
2) Replace L101 with normal relay.
4) Operate parking brake switch.
When mechanical parking No Relay (L101)

brake relay (L101) is replaced, is normal.
Possible does condition becomes nor- Relay (L101)
Causes and mal? Yes
is defective.
Standard
Values 1) Turn starting switch OFF.
Defective mechanical park- 2) Disconnect connector L101.
2 ing brake relay (L101) 3) Check relay unit.
Between L101 (male) (1) and (2) Resistance 200 - 400z
4) Apply normal voltage between L101 (male) (1) and (2).
Between Apply 24 V between (1) and (2). Resistance 1z and below

L101 (male) Do not apply 24 V between (1) 1Mz and
(3) and (4) Resistance
and (2). above
Defective parking brake
Parking brake lever is placed
lever middle position detec- Between L47 Resistance 1z and below
3 tion switch (Mechanical LOCK to MIDDLE.
(Male) (1) and
type) (2) Parking brake lever is placed 1Mz and
MIDDLE to FREE. Resistance above
Defective parking brake Set parking brake lever to bot-
lever lowest position detec- tom position. Resistance 1z and below
4 Between L53
tion switch (Mechanical (Male) (1) and
type) Set parking brake lever to any
(2) 1Mz and
position other than bottom posi- Resistance
above
tion.
20-444 WA320-5
(1)

1) Turn starting switch OFF. 2) Disconnect Connectors L23, L47, L53, L104 and fuse
T18. 3) Connect T-adapter. 4) Check that connector L20 is connected to L18.

chassis ground
chassis ground
tive contact) Wiring harness between L104 (Female) (1) and Resistance 1z and below
J12 (Female) (7)
J12 (Female) (5)
Wiring harness between J12 (Female) (6) and
L47 (Female) (2)
fuse FS1 (4)
1) Turn starting switch OFF. 2) Disconnect connector L23, L53, L47, L104. 3) Con-
nect T-adapter.
Possible Wiring harness between L23 Resistance between L23

(Female) (18) and L104 (Female) (18), L104 (Female) 1Mz and
Causes and above
Standard (Female) (5) * (5) and chassis ground
(Female) (1) and J12 (Female) 1Mz and
(Female) (1) and chassis above
(7) ground
Wiring harness between J10 Resistance between L53
6 Wiring harness ground fault (Female) (19) and L53 (Female) (2) and chassis 1Mz and
above
(Female) (2) ground
(Female) (1) and J12 (Female) (Female) (1) and chassis 1Mz and
above
(5), (6) and L47 (Female) (2) ground
Wiring harness between L47 (Female) (1) and chassis 1Mz and
(Female) (1) and fuse FS1 (4) above
ground
a In the above case (Other than marked mark (*)), the fuse is blown.
Defective junction connec-

7 tor (J10) and (J12) Carry out inspection, and if any abnormality is found, repair or replace.

8 Defective machine monitor Between L23 Parking brake lever is placed Voltage 1V and below
(Female) (18) PARKING.
and chassis Parking brake lever is placed
ground Voltage 20 - 30V
other than FREE.
WA320-5 20-445
(1)..d
20-446 WA320-5
(1)
TJW02990
WA320-5 20-447
(1)..d
Troubleshooting Code [MON-2] (The brake oil pressure caution

lamp does not light ON)
Controller
Code Trouble The brake oil pressure caution lamp does not light ON
- - -
Description of The brake oil pressure sensor signal circuit is always in the CLOSE state.
Trouble
Machine moni-
ler Reaction
Effect on The brake oil pressure caution lamp does not light ON when accumulator oil pressure is decreased.
Machine
Related
Information

Brake oil pressure is normal
Defective brake oil pres- (When 5.88MPa {60kg/cm2} Resistance 1zand below
1 Between T12 and above).
sure sensor (Male) (1) and
(2) Steering oil pressure is abnor-
1Mz and
mal (When 3.92MPa {40kg/ Resistance above
cm2} and below).
Possible
Causes and adapter.
Standard 2 Wiring harness ground fault Wiring harness between L23 Resistance between L23
Values (Female) (19) and T12 (Female) (19), T12 (Female) 1Mz and
above
4) Connect connector. 5) Start engine.
Brake oil pressure is normal
Between L23 (When 5.88MPa {60kg/cm2} Voltage 1V and below
3 Defective machine monitor and above).
(Female) (19)
and Chassis Steering oil pressure is abnor-
ground mal (When 3.92MPa {40kg/ Voltage 20 - 30V
cm2} and below).
20-448 WA320-5
(2)
Troubleshooting Code [MON-3] (The engine coolant temperature

caution lamp does not light ON, or after the engine starts, the
engine coolant temperature gauge does not rise. )
Action Code Failure Code Controller

Code The engine coolant temperature caution lamp does not light ON, or after
Trouble
the engine starts, the engine coolant temperature gauge does not rise.
- - -
Description of The engine coolant temperature sensor circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Effect on The engine coolant temperature caution lamp does not light ON.
Machine After the engine starts, the engine coolant temperature gauge does not rise.
Related The engine coolant temperature is displayed by real-time monitoring code 04101.
Information

1 Defective engine coolant Between E14 Normal temperature (25C) Resistance 35 - 50kz
temperature sensor (Male) (1) and
Possible adapter.
Causes and Wiring harness discontinu- Wiring harness between L21 (Female) (16) and
Standard 2 ity (Disconnection or defec- Resistance 1z and below
tive contact) E14 (Female) (1)
Values
Wiring harness between E14 (Female) (2) and

Between L21 Normal temperature (25C) Resistance 35 - 50kz
3 Defective machine monitor (Female) (16)
and Chassis When 100C Resistance 3.1 - 4.5kz
ground
WA320-5 20-449
(1)..d
(4)
Troubleshooting Code [MON-4] (The HST oil temperature caution

lamp does not light ON, or after the engine starts, the HST oil
temperature gauge does not rise. )

Code The HST oil temperature caution lamp does not light ON, or after the
Trouble
engine starts, the HST oil temperature gauge does not rise.
- - -
Description of The HST oil temperature sensor circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Effect on The HST oil temperature caution lamp does not light ON.
Machine After the engine starts, the HST oil temperature gauge does not rise.
Related The HST oil temperature is displayed by real-time monitoring code 30100.
Information

1 Defective HST oil tempera- Between T10 Normal temperature (25C). Resistance 35 - 50kz
Possible adapter.
Causes and Wiring harness discontinu- Wiring harness between L21 (Female) (14) and
Standard 2 ity (Disconnection or defec- Resistance 1z and below
tive contact) T10 (Female) (1)
Values

Between L21 Normal temperature (25C). Resistance 35 - 50kz
3 Defective machine monitor (Female) (14)
and Chassis When 100C Resistance 3.1 - 4.5kz
ground
20-450 WA320-5
(1)
(4)
Troubleshooting Code [MON-5] (The fuel level gauge does not rise
or decrease. )
Controller
Code Trouble The fuel level gauge does not rise or decrease.
- - -
Description of An abnormality has occurred in the fuel level sensor circuit.
Trouble
Machine moni-
ler Reaction
Effect on The fuel level gauge does not rise or decrease.
Machine
Related The fuel level is displayed by real-time monitoring code 04202.
Information

1) Turn starting switch OFF. 2) Disconnect connector R21. 3) Connect T-adapter.
FULL Resistance 1 - 5z
1 Defective fuel level sensor
Between R21 (Male) (1) and (2) 1/2 LEVEL Resistance 29 - 36z
EMPTY Resistance 103 - 117z
1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21. 3) Connect T-
adapter.
2 ity (Disconnection or defec- R21 (Female) (1) Resistance 1z and below
Possible tive contact)
Causes and Wiring harness between R21 (Female) (2) and
Standard Resistance 1z and below
chassis ground
Values
1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21. 3) Connect T-
adapter.
(Female) (13) and R21 (Female) (13), R21 (Female) 1Mz and
above
FULL Resistance 1 - 5z
4 Defective machine monitor Between L23 (Female) (13)
and Chassis ground 1/2 LEVEL Resistance 29 - 36z
EMPTY Resistance 103 - 117z
WA320-5 20-451
(1)..d
(4)
Troubleshooting Code [MON-6] (The radiator coolant level caution

Controller
Code Trouble The radiator coolant level caution lamp does not light ON
- - -
Description of The radiator coolant level sensor signal circuit is always in the CLOSE state.
Trouble
Machine moni-
ler Reaction
Effect on The radiator coolant level caution lamp does not light ON, when the radiator coolant level (Coolant water volume) is
Machine insufficient.
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector B05. 3) Connect T-adapter.
Between B05 Reserve tank low level or more

Defective radiator coolant Resistance 1z and below
1 level sensor (Male) (1) and (Normal).
chassis Reserve tank low level or less 1Mz and
ground (Abnormal). Resistance above
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05. 3) Connect T-
Possible adapter.
Causes and
Standard Wiring har-
2 Wiring harness ground fault ness between Resistance between L23
Values
L23 (Female) (Female) (8), B05 (Female) (1) Resistance 1z and below
(8) and B05 and chassis ground
(Female) (1)
Between L23 Reserve tank low level or more 1Mz and

Resistance
3 Defective machine monitor (Female) (8) (Normal). above
and Chassis Reserve tank low level or less 1Mz and
ground (Abnormal). Resistance above
20-452 WA320-5
(1)
(4)
Troubleshooting Code [MON-7] (The steering oil pressure caution

Controller
Code Trouble The steering oil pressure caution lamp does not light ON
- - -
Description of The steering oil pressure sensor signal circuit is always in the CLOSE state during the engine is revolved.
Trouble
Machine moni-
ler Reaction
Effect on The steering may be not worked if operation continues.
Machine
Related This warning is given when the emergency steering (option) is installed.
Information

adapter.
Defective steering oil pres- Steering oil pressure is low
1 Between F11 Resistance 1z and below
sure sensor (switch) (Engine stopped).
(Male) (A)
and (C) Steering oil pressure is normal 1Mz and
(Engine started). Resistance above
Possible adapter.
Causes and Wiring harness discontinu-
Standard Wiring harness between L22 (Female) (3) and
Values F11 (Female) (C)
tive contact)
Wiring harness between F11 (Female) (A) and

Between L22 Steering oil pressure is low

(Female) (3) (Engine stopped).
and Chassis Steering oil pressure is normal
ground (Engine started). Voltage 20 - 30V
WA320-5 20-453
(1)..d
Troubleshooting Code [MON-8] (The emergency steering oil

pressure indicator lamp does not light ON)
Controller
Code Trouble The emergency steering oil pressure indicator lamp does not light ON
- - -
Description of The emergency steering oil pressure sensor circuit is always in the OPEN state during the engine is revolved.
Trouble
Machine moni-
ler Reaction
Effect on The emergency steering does not work, so if the machine continues to be used, there is danger that the steering itself
Machine will stop working.
Related This indicator lights up only when the emergency steering (option) is installed.
Information

adapter.
Defective steering oil pres- Steering oil pressure is low. 1Mz and
1 Between F12 Resistance
sure sensor (switch) (While engine is stopped) above
(Male) (A)
and (B) Steering oil pressure is normal.
(While engine is running)
Possible adapter.
Causes and Wiring harness discontinu-
Standard 2 ity (Disconnection or defec- Wiring harness between L22 (Female) (5) and Resistance 1z and below
Values F12 (Female) (B)
tive contact)

3 Defective machine monitor Between L22 Steering oil pressure is low. Voltage 20 - 30V
(Female) (5) (While engine is stopped)
and Chassis Steering oil pressure is normal.
ground (While engine is running) Voltage 1V and below
20-454 WA320-5
(1)
Troubleshooting Code [MON-9] (Input failure in monitor panel

t] (Panel switch 1))
mode selector switch 1 [t
Controller
Code Trouble Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1)
- - -
Description of The monitor panel mode selector switch 1 [t] (Panel switch 1) input circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Machine
Related
Information

1 Defective monitor panel Between L10 selector switch 1 [t] is turned Resistance 1z and below
mode selector switch 1 [t] (Female) (2) ON.
and (3) 1Mz and
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
2 ity (Disconnection or defec- Wiring harness between L21 (Female) (1) and Resistance 1z and below
L10 (Female) (3)
tive contact)
fuse FS1 (5)
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5). 3)
Standard Connect T-adapter.
1Mz and
(Female) (2), fuse FS1 (5) and
(Female) (2) and fuse FS1 (5) chassis ground above

4 Defective machine monitor Between L21 selector switch 1 [t] is turned Voltage 20 - 30V
(Female) (1) ON.
and chassis
ground 1V and below
Other than above. Voltage
WA320-5 20-455
(1)..d

U] (Panel switch 2))
mode selector switch 1 [U
Controller
Action Code Failure Code Input failure in monitor panel mode selector switch 1 [U] (Panel switch
Code Trouble
2)
- - -
Description of The monitor panel mode selector switch 1 [U] (Panel switch 2) input circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L10 selector switch 1 [U] is turned Resistance 1z and below
1
mode selector switch 1 [U] (Female) (2) ON.
and (1) 1Mz and
above
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
tive contact) L10 (Female) (1)
fuse FS1 (5)
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse FS1 (5).
Standard 3) Connect T-adapter.
above
(Female) (2) and fuse FS1 (5) (Female) (2), fuse FS1 (5) and
above
chassis ground

4 Defective machine monitor Between L21 selector switch 1 [U] is turned Voltage 20 - 30V
(Female) (2) ON.
and chassis
ground 1V and below
Other than above. Voltage
20-456 WA320-5
(1)

mode selector switch 2 [<] (Panel switch 3))
Controller
Code Trouble Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3)
- - -
Description of The monitor panel mode selector switch 2 [<] (Panel switch 3) input circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L11 selector switch 2 [<] is turned Resistance 1z and below
1
mode selector switch 2 [<] (Female) (2) ON.
and (3) 1Mz and
adapter.
Wiring harness discontinu- Wiring harness between L21 (Female) (4) and
Possible tive contact) L11 (Female) (3)
Causes and Wiring harness between L11 (Female) (2) and
chassis ground
Values
(3) sis ground

4 Defective machine monitor selector switch 2 [<] is turned Voltage 1V and below
(Female) (4)
and chassis ON.
WA320-5 20-457
(1)..d

mode selector switch 2 [>] (Panel switch 4))
Controller
Code Trouble Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4)
- - -
Description of The monitor panel mode selector switch 2 [>] (Panel switch 4) input circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel Between L11 selector switch 2 [>] is turned Resistance 1z and below
1
mode selector switch 2 [>] (Female) (2) ON.
and (1) 1Mz and
adapter.
Possible tive contact) L11 (Female) (1)
Causes and Wiring harness between L11 (Female) (2) and
chassis ground
Values
(1) sis ground

4 Defective machine monitor selector switch 2 [>] is turned Voltage 1V and below
(Female) (5)
and chassis ON.
20-458 WA320-5
(1)
Troubleshooting Code [MON-13] (The alarm buzzer does not

sound or stop)
Controller
Code
Trouble The alarm buzzer does not sound or stop
- - -
Description of
The alarm buzzer does not sound or stop.
Trouble
Machine moni-
ler Reaction
Effect on
The alarm buzzer does not sound or stop.
Machine
Related
Information

adapter.
tive contact)
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L46. 3) Connect T-adapter.

Wiring harness between L46 (Female) (1), fuse FS1 (5) and 1Mz and
2 Wiring harness ground fault a In the above case, the fuse is blown.

above
Possible
Causes and a In this case, the buzzer does not stop sounding.
Standard
Values
4) Connect connector. 5) 5 seconds lapsed after the starting switch was turned ON.
Alarm buzzer
3 Defective alarm buzzer The alarm buzzer sounds.
is normal.
chassis ground
The alarm buzzer does not Defective
sound. alarm buzzer.

Turn starting switch ON. Voltage 20 - 30V
For 2 seconds after the starting

4 Defective machine monitor Between L21 switch was turned ON. (The Voltage 20 - 30V
(Female) (11) alarm buzzer sounds.)
and chassis
ground For 1 second after 2 seconds
lapsed after the starting switch
Voltage 1V and below
was turned ON. (The alarm
buzzer does not sound.)
20-460 WA320-5
(1)
WA320-5 20-461
(1)..d
Troubleshooting Code [MON-14] Engine oil level caution lamp

does not light up
Controller
Code Trouble Engine oil level caution lamp does not light up
- - -
Description of The engine oil level sensor circuit is kept closed.
Trouble
Machine moni-
ler Reaction
Effect on While the engine oil level is insufficient, the radiator coolant caution lamp does not light up.
Machine
Related The input signal of the engine oil level sensor can be checked with the monitoring function (Code: 40903, D_IN_27).
Information

Defective engine oil level
1 sensor Between E27 Oil level is normal Resistance Max. 1 z
(male) (1) and
chassis Oil level is insufficient (low) Resistance Min. 1 Mz
ground
Possible 2) Disconnect connectors L23 and E27.
Standard Short circuit with chassis Wiring har-
2
Values ground in wiring harness ness between Resistance between L23
L23 (female) (female) (20), E27 (female) (1) Resistance Max. 1 z
(20) and E27 and chassis ground
(female) (1)
3 Defective machine monitor Between L23 Oil level is normal Resistance Max. 1 V
(female) (20)
and chassis Oil level is insufficient (low) Resistance 20 - 30 V
ground
20-462 WA320-5
(1)
Troubleshooting Code [MON-15] Air cleaner clogging indicator

lamp does not light up
Controller
Code Trouble Air cleaner clogging caution lamp does not light up
- - -
Description of While the air cleaner is clogged, the sensor circuit is open (clogging is not detected).
Trouble
Machine moni-
ler Reaction
Effect on The air cleaner clogging caution lamp does not light up.
Machine
Related
Information

Defective dust indicator 5) Start engine.
1 (air cleaner clogging
sensor) Voltage:
Air cleaner is normal
Between E26 (female) (1) and 20 - 30 V
(2) Voltage:
Air cleaner is clogged
Max. 1 V
Possible 2) Disconnect connector E26.
Disconnection in wiring
Standard 2 harness (Disconnection or Wiring harness between L23 (female) (7) and
Values Resistance Max. 1 z
defective contact) E26 (female) (1)
Wiring harness between E26 (female) (2) and Resistance Max. 1 z
chassis ground
5) Start engine.
Air cleaner is normal Voltage:
Between L23 (female) (7) and 20 - 30 V
chassis ground Voltage:
Air cleaner is clogged
Max. 1 V
20-464 WA320-5
(1)
WA320-5 20-465
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE
TROUBLESHOOTING [MON-16,
CODE 17]
[MON-16]
Troubleshooting Code [MON-16] The wiper does not function

a Defects in the wiper system is given in the TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE), so
see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).
Troubleshooting Code [MON-17] The lamps do not work properly

a Defects in the lamp system (lamps do not work properly) is given in the TROUBLESHOOTING OF ELECTRI-
CAL SYSTEM (E MODE), so see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E
MODE).
20-466 WA320-5
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502

Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-503
Troubleshooting Code [E-1] (The engine does not start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
Troubleshooting Code [E-2] (The engine does not stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
Troubleshooting Code [E-3] (Preheating is impossible or constant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function) . . . . . . . . . . . . . 20-518
Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation). . . . . . . . . . . . . . . . . 20-524
Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation) . . . . . . . . . . . . . . 20-528
Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and cancellation). . . . . . . 20-531
Troubleshooting Code [E-8] (Travel direction is not changed normally) . . . . . . . . . . . . . . . . . . . . . . . . 20-532
Troubleshooting Code [E-9] (The wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-538
Troubleshooting Code [E-10] (The window washer does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-544
Troubleshooting Code [E-11] (Lamps do not work properly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-548
Troubleshooting Code [E-12] (The horn does not sound) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-560
Troubleshooting Code [E-13] (Defective the air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-562
WA320-5 20-501
(2)
(1)..


2 10A Hazard lamp
3 10A HST control A
(Fuse box 1) 4 10A Parking brake 1
5 10A Meter, panel

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 - (Spare 1)
5 10A Load-meter
7 10A DC converter
Switch power source
(Fuse box 2)
9 10A Horn
14 - (Spare 2)
15 - (Spare 3)
20-502 WA320-5
(2)
(1)

Controller
Trouble
Machine moni-
ler Reaction
Machine ler.

Information
<Data to fill in>


Disconnection
circuit
Causes and
female terminals
4
5
WA320-5 20-503
(1)..d
20-504 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
Troubleshooting Code [E-1] (The engine does not start)

a) - 1 Defective starting motor system (When direction selector actuation switch is turned OFF)
Controller
Action Code Failure Code The engine does not start
Code Trouble
a) Defective starting motor system
- - -
Description of The engine does not start due to defective starting motor system.
Trouble
Machine moni-
ler Reaction
Effect on The engine does not start.
Machine
If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Related applicable code.
Information
If the fuses are blown, check the wiring harness is short-circuited with the ground.

Specific gravity 1.26V and above
1 Defective battery
Voltage 24V and above
1) Turn starting switch OFF. 2) Replace battery relay with normal relay.
When battery relay is replaced, No Battery relay is normal.
does condition becomes nor-
mal? Yes Battery relay is defective.
1) Turn starting switch OFF. 2) Disconnect battery relay. 3) Check relay unit.
2 Defective battery relay Between battery relays R15 and R16 Resistance 30 - 70z
1) Turn starting switch OFF. 2) Disconnect battery relay. 3) Check relay unit.
4) Apply normal voltage between battery relays R15 and R16.
Apply 24 V between R15 and
Between bat- R16. Resistance 1z and below
tery relays
R04 and R01 Do not apply 24 V between R15 Resistance 1Mz and
and R16. above
Possible
Causes and 1) Turn starting switch OFF. 2) Interchange relay (L106) with normal relay. 3) Turn
starting switch ON.
Standard
Values Does condition become normal Relay (L106)
The condition is abnormal. is normal.
when neutral safety relay
(L106) is interchanged with nor- Defective
mal relay? The condition is normal. relay (L106)
Defective neutral safety 1) Turn starting switch OFF. 2) Disconnect connector L106. 3) Solid part check.
3
relay (L106) Between L106 (Male) (1) and (2) Resistance 200 - 400z
L106 (Male)
Resistance
When directional lever is turned Resistance 1z and below
4 Defective directional lever Between L15 N.
(Female) (1)
and (3) 1Mz and
20-506 WA320-5
(1)

1) Turn starting switch OFF. 2) Interchange relay (one of L133, L136, or L137) with
normal relay. 3) Turn starting switch ON.
Relay (L133,
Does condition become normal The condition is abnormal. L136, L137)
when neutral safety relay (one is normal.
of L133, L136, or L137) is inter- Defective
changed with normal relay? The condition is normal. relay (L133,
L136, L137)
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
Defective multi-function 3) Solid part check.
5 related relay (L133, L136,
L137) Between (Male) (1) - (2) of one of L133, L136, or
Resistance 200 - 400z
L137
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
3) Solid part check. 4) Applies impressed voltage between (Male) (1) - (2) of one of
L133, L136, or L137
Between Applies 24V impressed voltage
(Male) (3) - between L106 (Male) (1) - (2)
(5) of one of
L133, L136, Does not apply voltage 1Mz and
Resistance
or L137 between L106 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace both diodes (D08, D15) with normal diodes.
3) Turn starting switch START.
Defective diode (D08, D15)
a Only when defect The condition is abnormal. Diode (D08, D15) is normal.
6
occurs in both at the The condition is normal. Defective diode (D08, D15)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
1) Turn starting switch OFF. 2) Replace diode (D07) with normal diode. 3) Turn start-
ing switch START.
Possible The condition is abnormal. Diode (D07) is normal.
Causes and
Standard The condition is normal. Defective diode (D07)
Values Measure between (1) o (2) with diode range Continuity
Measure between (3) o (2) with diode range Continuity
Measure between (2) o (3) with diode range Discontinuity
a Put (+) pole of tester in contact with left side.
1) Turn starting switch OFF. 2) Disconnect connector L106, D08, D15, terminal E01,
R01 and E10. 3) Connect T-adapter.
D08 (Female) (2) Resistance 1z and below
ity (Disconnection or defec- Resistance 1z and below
D15 (Female) (2)
8 tive contact)
a Starting motor related Wiring harness between D08 (Female) (1) and Resistance 1z and below
harness E01 (Female) (1)
E01 (Female) (1)
Wiring harness between R01 and starting motor
terminal B (E10)
1) Turn starting switch OFF. 2) Disconnect connector D07, E02, terminal R16, R15,
R07, R04, R02 and R05. 3) Connect T-adapter.
Wiring harness between R16 and chassis ground Resistance 1z and below
ity (Disconnection or defec- Wiring harness between R15 and D07 (Female) (2) Resistance 1z and below
9 tive contact) Wiring harness between E02 (Female) (2) and
a Battery relay related R15 Resistance 1z and below
harness Wiring harness between R04 and R02 Resistance 1z and below
Wiring harness between R01 and R05 Resistance 1z and below
Wiring harness between battery and R04 Resistance 1z and below
WA320-5 20-507
(1)..d

1) Turn starting switch OFF. 2) Disconnect connector L02, D07, terminal R03 and
fuse FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L02 (Female) (1), FS1
ity (Disconnection or defec- (1) and R03 Resistance 1z and below
10 tive contact)
a Starting switch related Wiring harness between L02 (Female) (2) and
harness D07 (Female) (1)
L23 (Female) (1)
1) Turn starting switch OFF. 2) Disconnect connector L15, terminal R06 and fuse
FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L15 (Female) (1), FS1
ity (Disconnection or defec- Resistance 1z and below
(2) and R06
11 tive contact)
a Directional lever Wiring harness between L15 (Female) (3) and Resistance 1z and below
related harness L106 (Female) (1)
Possible chassis ground
Causes and 1) Turn starting switch OFF. 2) Disconnect connector E01, E02, D07. 3) Connect T-
Standard adapter. 4) Turn starting switch ON.
Values 12 Hot short-circuiting
between harnesses Wiring harness between E01 Voltage between E01 (Female)
(Female) (2), E02 (Female) (1) (2), E02 (Female) (1) and chas- 1V and below
and D07 (Female) (3) sis ground
1) Disconnect starting switch terminal. 2) Solid part check.
13 Defective starting switch
Turn starting switch START. Between terminal B and C 1z and below
1) Solid part check.
14 Defective starting motor If the check of the individual part shows that it is normal, the starting motor is
normal.
Between Engine started (Throttle 1/2 and
alternator ter- Voltage 26.5 - 29V
above)
15 Defective alternator minal R [E02
(1)] and chas- Engine stopped Voltage 1V and below
sis ground
1) Turn starting switch OFF. 2) Disconnect connector TEL. 3) Connect T-adapter.
Defective short connector
16 Wiring harness between TEL (Female) (7) and
TEL Resistance 1z and below
(8)
20-508 WA320-5
(1)
a) - 2 Defective starting motor system (When the directional selector actuation switch is turned ON)
a Perform the inspection and troubleshooting in this section in addition to a) -1.
Controller
Code Trouble a) Defective starting motor system
- - -
Description of The engine does not start due to defective starting motor system.
Trouble
Machine moni-
ler Reaction
Machine
applicable code.
Related If the fuses are blown, check the wiring harness is short-circuited with the ground.
Information
When the directional selector actuation switch is operated, the directional lever must be in the "N" position and the
directional selector switch must be in the "N" position.

Specific gravity 1.26V and above
1 Defective battery
Voltage 24V and above
1) Turn starting switch OFF. 2) Interchange relay (L132, L133, L134) with normal
relay. 3) Turn starting switch ON.
Relay (L132,
Does condition become normal The condition is abnormal. L133, L134)
when neutral safety relay is normal.
(L132, L133, L134) is inter- Defective
changed with normal relay? The condition is normal. relay (L132,
L133, L134)
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Defective neutral safety check.
2
relay (L132, L133, L134)
Between L132, L133, L134 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Possible check. 4) Applies impressed voltage between L132, L133, L134 (Male) (1) - (2)
Causes and
Standard Applies 24V impressed voltage
Values Between between L132, L133, L134 Resistance 1z and below
L132, L133, (Male) (1) - (2)
L134 (Male) Does not apply voltage
(3) and (5) between L132, L133, L134 Resistance 1Mz and
(Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector MF1. 3) Connect T-adapter.
Defective directional select When direction select switch is Resistance 1z and below
3 Between MF1 turned N.
switch (Female) (1)
and (3) 1Mz and
above
1) Turn starting switch OFF. 2) Replace both diodes (D18) with normal diodes.
Defective diode (D18)
a Only when defect The condition is abnormal. Diode (D18) is normal.
4
occurs in both at the The condition is normal. Defective diode (D18)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
WA320-5 20-509
(1)..d
b) Defective fuel cut solenoid system

Controller
Code Trouble
b) Defective fuel cut solenoid system
- - -
Description of The fuel cut solenoid system is defective, so the engine does not start.
Trouble
Machine moni-
ler Reaction
Machine
Related applicable code.
Information
If the fuses are blown, check the wiring harness is short-circuited with the ground.

1) Turn starting switch OFF. 2) Interchange relay (R13) with normal relay. 3) Turn
starting switch ON.
Relay (R13)
Does condition become normal The condition is abnormal.
is normal.
when pull relay (R13) is inter-
changed with normal relay? Defective
The condition is normal.
relay (R13)
Defective fuel cut solenoid 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1 pull relay (R13) Between R13 (Male) (1) and (2) Resistance 50 - 90z
1) Turn starting switch OFF. 2) Disconnect connector R13. 3) Solid part check.
4) Applies impressed voltage between R13 (Male) (1) - (2)
Between R13 between R13 (Male) (1) - (2) Resistance 1z and below
(Male) (3) and
between R13 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
2 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
Between R08 Turn starting switch ON. Voltage 20 - 30V
Defective fuel cut solenoid (1) and (2)
3 timer
Turn starting switch OFF. Voltage 1V and below
2 - 4 sec after turning starting 16V and
Possible Between R08 switch ON Voltage above
Causes and (3) and (4)
Standard Other than above. Voltage 1V and below
Values 1) Turn starting switch OFF. 2) Replace diode (D03 or D04) with a normal diode.
Defective diode
4
(D03 or D04) The condition is abnormal. Diode (D03 or D04) is normal.
The condition is normal. Defective diode (D03 or D04)
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D04, D08, D15, terminal
E01, E03, E11, E23, E24, R05, R08, R09, R10, R12 and R13. 3) Connect T-adapter.
Wiring harness between E24 and chassis ground Resistance 1z and below
chassis ground
Wiring harness between E03 and R09 Resistance 1z and below
chassis ground
Wiring harness discontinu- Wiring harness between E23 and L02 (Female) (4) Resistance 1z and below
tive contact) Wiring harness between E23 and R08 (Female) (1) Resistance 1z and below
Wiring harness between R08 (Female) (2) and
chassis ground
R13 (Female) (1) Resistance 1z and below

R13 (Female) (2)
1) Disconnect starting switch terminal. 2) Solid part check.
6 Defective starting switch
Turn starting switch START. Between terminal B and ACC 1z and below
20-510 WA320-5
(1)
TJW02991
WA320-5 20-511
(1)..d
Troubleshooting Code [E-2] (The engine does not stop)

Controller
Code Trouble The engine does not stop
- - -
Description of The engine does not stop.
Trouble
Machine moni-
ler Reaction
Effect on The engine does not stop.
Machine
Related If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Information applicable code.

1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
1 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
Possible 4) Connect connector.
Defective fuel cut solenoid
Causes and 2 timer Turn starting switch ON. Voltage 20 - 30V
Standard Between R08
Values (1) and (2) Turn starting switch OFF. Voltage 1V and below
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D08, terminal E03,
E23 and R09. 3) Connect T-adapter. 4) Turn starting switch OFF.
Hot short-circuiting Wiring harness between E03, Voltage between E03 (Harness 1V and below
3 R09 and D03 (Female) (1) side) and chassis ground
between harnesses
Wiring harness between E23, Voltage between E23 (Harness
L02 (Female) (4) and R08 1V and below
(Female) (1) side) and chassis ground
20-512 WA320-5
(1)
TJW02991
WA320-5 20-513
(1)..d
Troubleshooting Code [E-3] (Preheating is impossible or constant)

a) Preheating is impossible

Code Preheating is impossible or constant
Trouble
a) Preheating is impossible
- - -
Description of Preheating is impossible. (The engine coolant temperature at 0C and below.)
Trouble
Machine moni-
ler Reaction
Effect on Preheating is impossible.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
Between E06 and chassis ground Resistance 19 - 25z
1 Defective intake air heater When relay is ON (impressed
relay voltage 24V between E06 - Resistance 1z and below
Between E07 chassis ground).
and E08
When the relay OFF (Other Resistance 1Mz and
than above). above
Defective intake air heater 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2
(Ribbon heater) Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
Causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
L115 (Male)
1) Turn starting switch OFF. 2) Replace diode (D05) with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D05)
Measure between (1) o (2) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-514 WA320-5
(3)
(1)

1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter.
Wiring harness between E08 and E09 Resistance 1z and below
Wiring harness between R07 and E07 Resistance 1z and below
Wiring harness between E06, J08 and L115
5 ity (Disconnection or defec- (Female) (5)
tive contact) Wiring harness between fuse FS2 (5) and L115
(Female) (1)
L22 (Female) (4)
1) Turn starting switch OFF. 2) Disconnect connector D05, L115, L22, fuse FS2 (5),
E06, E07 E08, E09 and R07. 3) Connect T-adapter.
Wiring harness between E08 Resistance between E08, E09 1Mz and
and E09 * and chassis ground above
Wiring harness between R07 Resistance between R07, E07 1Mz and
and E07 * and chassis ground above
Resistance between E06, J08,
Wiring harness between E06, 1Mz and
J08 and L115 (Female) (5) * L115 (Female) (5) and chassis above
ground
Possible
Causes and Wiring harness between fuse Resistance between fuse FS2
1Mz and
Standard FS2 (5) and L115 (Female) (5), L115 (Female) (3) and above
Values (3) * chassis ground
6 Wiring harness ground fault Wiring harness between fuse Resistance between fuse FS2
1Mz and
FS2 (5) and L115 (Female) (5), L115 (Female) (1) and above
Wiring harness between J08 Resistance between J08
1Mz and
(Female) (12) and D05 (Female) (12), D05 (Female) above
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to intake air heater (ribbon heater)
a If it is marked * , the fuse is blown

Wiring harness between L21 (Female) (6), E13 (A) and 1Mz and
(Female) (6) and E13 (A) above
chassis ground
a The above is wiring harness related to the engine coolant temperature (low tem-
perature) sensor

7 temperature (Low tempera- Between E13 Normal temperature (25C). Resistance 3.1 - 5.7kz
ture) sensor (Male) (A)
and (B) When 100C Resistance 0.2 - 1.0kz
1) Turn starting switch OFF. 2) Replace junction connector (J06, J09, J11) with nor-
mal junction connector
Defective junction connec-
8
tor (J06, J09, J11) Condition is abnormal. Junction connector (J06, J09, J11) is normal.
Condition is normal. Defective junction connector (J06, J09, J11).
WA320-5 20-515
(1)..d
(3)
b) Preheating is constant

Code Preheating is impossible or constant
Trouble
b) Preheating is constant
- - -
Description of Preheating is constant.
Trouble
Machine moni-
ler Reaction
Effect on Preheating is constant.
Machine
If the failure code DGE3L6 for abnormality in engine coolant temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
Information
The engine coolant temperature (low temperature) is displayed by real-time monitoring code 04103.

1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
Between E06 and chassis ground Resistance 19 - 25z
Defective intake air heater When relay is ON (impressed
1 relay voltage 24V between E06 - Resistance 1z and below
Between E07 chassis ground).
and E08
When the relay OFF (Other 1Mz and
than above). Resistance above
1) Turn starting switch OFF. 2) Replace relay L115 with normal relay. 3) Turn starting
switch ON.
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
2
relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Causes and 4) Applies impressed voltage between L115 (Male) (1) - (2)
Standard
Values Applies 24V impressed voltage
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter. 4) 1 minute after starting switch is turned ON.
Wiring harness between E08 Voltage between E08, E09 and
3 Hot short-circuiting and E09 chassis ground 1V and below
between harnesses
Wiring harness between E06, Voltage between E06, J08,
L115 (Female) (5) and chassis 1V and below
J06 and L115 (Female) (5) ground
1) Turn starting switch OFF. 2) Disconnect connectors L22 and L115.
4 Short circuit with chassis
ground in wiring harness Wiring harness between L22 Resistance between L22
1Mz and
(female) (4) and L115 (female) (female) (4), L115 (female) (2) above
Defective mechanical mon- 4) Connect connector. 5) 1 minute after starting switch is turned ON.
5
itor 16 V and
Voltage between L22 (4) and chassis ground above
20-516 WA320-5
(3)
(1)
WA320-5 20-517
(1)..d
Troubleshooting Code [E-4] (The parking brake (Mechanical type)

does not function)
a) Parking brake dragging prevention does not function (mechanical type)
Controller The parking brake (Mechanical type) does not function
Code Trouble a) Parking brake dragging prevention does not function (mechanical
- - - type)
Description of Parking brake dragging prevention does not function

Trouble
Machine moni-
ler Reaction
Effect on Parking brake dragging prevention does not function
Machine
Related
Information

switch ON. 4) Operate parking brake switch.
Does condition become normal when parking abnormal. normal.
brake neutral safety relay L112 is replaced with
normal relay? Condition is Defective
normal. relay L112.
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1 neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
L112 (Male)
Possible 1) Turn starting switch OFF. 2) Disconnect connector D01, L19, L112, T01. 3) Con-
Causes and nect T-adapter.
Standard
Values 1Mz and
2 Wiring harness ground fault (Female) (5) and J08 (7), (9) (Female) (5), T01 (Female) (4) above
and T01 (Female) (2), (4) and chassis ground
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2) 1Mz and
above
and T01 (Female) (2) and chassis ground
1) Turn starting switch OFF. 2) Replace diode D01 with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D01)
20-518 WA320-5
(1)
b) Parking brake "non-applied" indicator does not light up (mechanical type)

Controller The parking brake (Mechanical type) does not function
Code Trouble b) Parking brake "non-applied" indicator does not light up (mechanical
- - - type)
Description of Parking brake "non-applied" indicator does not light up

Trouble
Machine moni-
ler Reaction
Effect on Parking brake "non-applied" indicator does not light up
Machine
Related
Information

Defective parking brake Place parking brake lever 1Mz and

Between L53 Resistance
1 lowest switch LOCK. above
(Male) (3) and
(2) Place parking brake lever
FREE.
Place parking brake lever 1Mz and
2 Defective parking brake Between L47 LOCK to MIDDLE. Resistance above
middle switch (Male) (3) and
(1) Place parking brake lever MID-
DLE to FREE. Resistance 1z and below
Possible 1) Turn starting switch OFF. 2) Replace relay L101 with normal relay. 3) Turn starting
Causes and
switch ON. 4) Operate parking brake switch.
Standard
Values Relay L101 is
Does condition become normal Condition is abnormal.
normal.
when parking brake relay L101
is replaced with normal relay? Defective
Condition is normal. relay L101.
Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
20-520 WA320-5
(1)

1) Turn starting switch OFF. 2) Disconnect connector L47, L53, fuse FS1 terminal.

J12 (6), (7) and L53 (Female) (1)
J10 (19), (18) and L21 (Female) (13)
4 ity (Disconnection or defec- Wiring harness between L53 (Female) (2) and
tive contact) J10 (Female) (19), (20) and J05 (14), (16) and Resistance 1z and below
L101 (Female) (1)
J10 (Female) (19), (20) and J05 (14), (17) and Resistance 1z and below
L101 (Female) (5)
chassis ground
Possible J12 (Female) (6), (4) and L101 (Female) (3)
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L101, L47, L53, both ends of
Values fuse FS1 terminal. 3) Connect T-adapter.
Wiring harness between fuse 1Mz and
ground
5 Wiring harness ground fault (Female) (2) and J12 (6), (5) (Female) (2), L53 (Female) (1)
above
and L53 (Female) (1) and chassis ground
(Female) (2) and J12 (6), (4) (Female) (2), L101 (Female) (3)
above
and L101 (Female) (3) and chassis ground
6 Defective junction connec- Carry out inspection, and if any abnormality is found, repair or replace.
tor (J05), (J10) and (J12)
4) Connect connector. 5) Turn starting switch
Between L21 Place parking brake lever

(13) and LOCK to MIDDLE.
chassis Place parking brake lever
FREE.
WA320-5 20-521
(1)..d
20-522 WA320-5
(1)
WA320-5 20-523
(1)..d
Troubleshooting Code [E-5] (Defective boom kick-out function and

cancellation)
Controller
Code Trouble Defective boom kick-out function and cancellation
- - -
Description of Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch system, lift
Trouble arm PPC detent system and lift arm detent relay system.
Machine moni-
ler Reaction
Effect on Boom kick-out does not function or cannot be cancelled.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector L113. 3) Replace lift arm detent
relay (L113) with normal relay. 4) Operate boom kick-out.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
1 Defective lift arm detent Between L113 (Male) (1) and (2) Resistance 200 - 400z
relay (L113)
L113 (Male)
Resistance
Defective lift arm PPC 1) Turn starting switch OFF. 2) Disconnect connector L36. 3) Connect T-adapter.
2
detent Between L36 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F04. 3) Interchange lift arm
positioner proximity switch (F04) with bucket positioner proximity switch (F03). 4)
Operate boom kick-out.
Possible
Causes and 3 Defective lift arm posi- Defective boom kick-out prox-
tioner proximity switch Boom kick-out function is normal.
Standard imity switch F04
Values
Boom kick-out proximity switch
Boom kick-out does not function.
F04 is normal.
1) Turn starting switch OFF. 2) Disconnect connector F04, L113, L36 and fuse FS1
terminal. 3) Connect T-adapter.
fuse FS1 (13)
Wiring harness between F04 (Female) (B) and
L113 (Female) (2)
Wiring harness between F04 (Female) (C) and Resistance 1z and below
chassis ground
tive contact) fuse FS1 (13)
fuse FS1 (13)
L36 (Female) (1)
chassis ground
a With all the above items, the boom kick-out does not function
20-524 WA320-5
(1)

Wiring harness between F04 Resistance between F04 1Mz and
(Female) (B) and L113 (Female) (B), L113 (Female)
(Female) (2) (2) and chassis ground above

above
a In this case, the boom kick-out detent does not function (lever returns to neutral)
5 Wiring harness ground fault Resistance between F04
Wiring harness between F04 (Female) (A), FS1 (13) and
1Mz and
(Female) (A) and fuse FS1 (13) chassis ground above
Possible
Causes and
Standard Wiring harness between L113 (Female) (1), fuse FS1 (13) and
1Mz and
Values (Female) (1) and fuse FS1 (13) chassis ground
above

a In this case, the fuse is blown and no detents function (lever returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connector L113, L36. 3) Connect T-

Wiring harness between L113 Voltage between L113
Hot short-circuiting (Female) (5) and L36 (Female) (Female) (5), L36 (Female) (1) 1V and below
6 between harnesses (1) and chassis ground
a In this case, the boom kick-out does not function (lever does not return to neu-
tral)
WA320-5 20-525
(1)..d
20-526 WA320-5
(1)
Troubleshooting Code [E-6] (Defective bucket positioner function

and cancellation)
Controller
Code Trouble Defective bucket positioner function and cancellation
- - -
Description of Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system,
Trouble bucket PPC detent system and bucket detent relay system.
Machine moni-
ler Reaction
Effect on Bucket positioner does not function or cannot be cancelled.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector L114. 3) Replace bucket detent
relay (L114) with normal relay. 4) Operate bucket positioner.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
1 Defective bucket detent Between L114 (Male) (1) and (2) Resistance 200 - 400z
relay (L114)
L114 (Male)
Resistance
Defective bucket PPC 1) Turn starting switch OFF. 2) Disconnect connector L37. 3) Connect T-adapter.
2
detent Between L37 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F03. 3) Interchange bucket
positioner proximity switch (F03) with lift arm positioner proximity switch (F04). 4)
Operate bucket positioner.
Possible
Causes and 3 Defective bucket posi- Defective bucket positioner
tioner proximity switch Bucket positioner function is normal.
Standard proximity switch F03
Values
Bucket positioner proximity
Bucket positioner does not function.
switch F03 is normal.
fuse FS1 (13)
Wiring harness between F03 (Female) (B) and
L114 (Female) (2)
Wiring harness between F03 (Female) (C) and Resistance 1z and below
chassis ground
tive contact) fuse FS1 (13)
fuse FS1 (13)
L37 (Female) (1)
chassis ground
a With all the above items, the bucket positioner does not function
20-528 WA320-5
(1)

Wiring harness between F03 Resistance between F03 1Mz and
(Female) (B) and L114 (Female) (B), L114 (Female)
above
a In this case, the bucket positioner detent does not function (lever does not return
to neutral)

5 Wiring harness ground fault a In this case, the bucket positioner does not function (lever returns to neutral)
Resistance between F03

Possible Wiring harness between F03 1Mz and
(Female) (A), FS1 (13) and
Causes and (Female) (A) and fuse FS1 (13) chassis ground
above
Standard
Values Resistance between L114
(Female) (1) and fuse FS1 (13) above
chassis ground
a In this case, the fuse is blown and no detents function (lever returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connector L114, L37. 3) Connect T-

Wiring harness between L114 Voltage between L114
Hot short-circuiting (Female) (5) and L37 (Female) (Female) (5), L37 (Female) (1) 1V and below
6
between harnesses (1) and chassis ground
a In this case, the bucket positioner does not function (lever does not return to
neutral)
WA320-5 20-529
(1)..d
20-530 WA320-5
(1)
Troubleshooting Code [E-7] (Defective lift arm FLOATING holding

function and cancellation)
Controller
Code Trouble Defective lift arm FLOATING holding function and cancellation
- - -
Description of Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING PPC detent
Trouble system.
Machine moni-
ler Reaction
Effect on Lift arm FLOATING holding does not function or cannot be cancelled.
Machine
Related
Information
Defective lift arm FLOAT- 1) Turn starting switch OFF. 2) Disconnect connector L35. 3) Connect T-adapter.
1
ING PPC detent Between L35 (Male) (1) and (2) Resistance 30 - 50z
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector L35 and fuse FS1 terminal. 3)
Standard Connect T-adapter.
Values Wiring harness discontinu-
2 ity (Disconnection or defec- (Female) (1) Resistance 1z and below
tive contact)
chassis ground
WA320-5 20-531
(2)
Troubleshooting Code [E-8] (Travel direction is not changed

normally)
a) When directional lever is set in "F", machine does not travel forward
Action Code Error code Controller

Code Travel direction is not changed normally
Trouble
a) When directional lever is set in "F", machine does not travel forward
- - -
Contents of The machine does not travel forward since the directional lever system, forward relay system, or forward solenoid
trouble valve system is defective.
Action of
machine moni-
tor
Problem that
appears on The machine does not travel forward.
machine
If error code "DDK3KB" is displayed to indicate simultaneous input of directional lever FR signals, carry out the trou-
bleshooting for it first.
Related infor- When the parking brake lever is pulled, if the parking brake omission caution lamp goes off and the parking brake indi-
mation
cator lamp does not light up, carry out the troubleshooting for "MON-1 Parking brake indicator lamp does not light up"
before carry out the following troubleshooting.

When direc-
1 Defective directional lever tional lever is Resistance Max. 1 z
in "F".
Between L15 (female) (1) and (2)
When direc-
tional lever is Resistance Min. 1 Mz
not in "F".
1. Turn starting switch OFF.
2. Replace L112 with normal relay.
3. Turn starting switch ON.
4. Operate parking brake.
Possible Relay (L112)
Causes and No is normal.
When parking brake neutral safety relay (L112) is
Standard
Values replaced, does condition become normal? Relay (L112)
Yes
is defective.
2 Defective parking brake 3) Check relay unit.
neutral safety relay (L112)

Between
L112 (male) When normal voltage is not
(3) and (5) applied between and (1) and Resistance Min. 1 Mz
(2)
20-532 WA320-5
(2)
(1)

Relay (L108)
No
When forward relay (L108) is replaced, does con- is normal.
dition become normal? Relay (L108)
Yes is defective.
Defective forward relay
3 (L108) Between L108 (male) (1) and (2) Resistance 200 - 400z
2) Disconnect connector L108

Between and (1) and (2)
(2)
2) Disconnect connector T01.
4 Defective forward solenoid
Between T01 (male) (1) and (2) Resistance 30 - 60z
Between T01 (male) (1), (2) and chassis ground Resistance Min. 1 Mz
Possible
causes and 2) Disconnect connectors T01, L15, L108, and L112 and fuse (FS1).
standard 3) Connect T-adapter.
value in nor-
mal state Wiring harness between L15 (female) (2) and Resistance Max. 1 z
L108 (female) (1)
harness (Disconnection in Wiring harness between L108 (female) (2) and
5 Resistance Max. 1 z
wiring harness or defective chassis ground
contact) Wiring harness between fuse FS1 (12) and L108
(female) (3) Resistance Max. 1 z
Wiring harness between L108 (female) (5) and Resistance Max. 1 z

T01 (female) (1)
Wiring harness between T01 (female) (2) and
Resistance Max. 1 z
L112 (female) (5)
2) Disconnect connectors T01, L15, L22, and L108

(female) (2) and L22 (female) (female) (2), L22 (female) (10) Min. 1 Mz
Grounding fault in wiring Wiring harness between L108 Resistance between L108
6 harness (female) (5) and D01 (female) (female) (5), D01 (female) (1) Min. 1 Mz
(female) (5) and T01 (female) (female) (5), T01 (female) (1) Min. 1 Mz
Resistance between fuse (FS1)
Wiring harness between fuse
(FS1) (12) and L15 (female) (12), L15 (female) (1), L108 Min. 1 Mz
(female) (3) and chassis
(1), L108 (female) (3) ground
a In all of these cases, the fuse is broken.
WA320-5 20-533
(2)
(1)..d
20-534 WA320-5
(2)
(1)
WA320-5 20-535
(2)
(1)..d
b) When directional lever is set in "R", machine does not travel in reverse
Action Code Error code Controller
Code Travel direction is not changed normally
Trouble
b) When directional lever is set in "R", machine does not travel in reverse
- - -
Contents of The machine does not travel in reverse since the directional lever system, reverse relay system, or reverse solenoid
trouble valve system is defective.
Action of
machine moni-
tor
Problem that
appears on The machine does not travel in reverse.
machine
If error code "DDK3KB" is displayed to indicate simultaneous input of directional lever FR signals, carry out the trou-
bleshooting for it first.
Related infor- When the parking brake lever is pulled, if the parking brake omission caution lamp goes off and the parking brake indi-
mation
cator lamp does not light up, carry out the troubleshooting for "MON-1 Parking brake indicator lamp does not light up"
before carry out the following troubleshooting.

1 Defective directional lever When direc-

tional lever is Resistance Max. 1 z
Between L15 (female) (1) and in "R".
(4) When direc-
tional lever is Resistance Min. 1 Mz
not in "R".
1. Turn starting switch OFF.
2. Replace L112 with normal relay.
3. Turn starting switch ON.
4. Operate parking brake.
Possible Relay (L112)

causes and No
When parking brake neutral safety relay (L112) is is normal.
standard value replaced, does condition become normal?
in normal state Relay (L112)
Yes
is defective.
Defective parking brake
2 neutral safety relay (L112) 3) Check relay unit.


Between
(2)
20-536 WA320-5
(2)

No Relay (L107)
When forward relay (L107) is replaced, does con- is normal.
dition become normal? Relay (L107)
Yes
is defective.
Defective reverse relay 1) Turn starting switch OFF.

3
(L107) 2) Disconnect connector L107

Between
L107(male) When normal voltage is not
(6)
Between and (5) and (6)
L107(male) When normal voltage is not
(6)
2) Disconnect connector T01.
4 Defective reverse solenoid
Possible
causes and Between T01 (male) (3) and (4) Resistance 30~60z
standard
value in nor- Between T01 (male) (3), (4) and chassis ground Resistance Min. 1 Mz
mal state
2) Disconnect connectors T01, L15, L107, and L112 and fuse (FS1).

L107 (female) (5)
harness (Disconnection in Wiring harness between L107 (female) (6) and
5 Resistance Max. 1 z
wiring harness or defective chassis ground
contact) Wiring harness between fuse FS1 (12) and L107
(female) (3) Resistance Max. 1 z

T01 (female) (3)
Wiring harness between T01 (female) (4) and
Resistance Max. 1 z
L112 (female) (5)
2) Disconnect connectors T01, L15, L22, and L107

Grounding fault in wiring (5) and chassis ground
6 harness
(female) (4) and D01 (female) (female) (4), D01 (female) (3) Min. 1 Mz
Resistance between fuse (FS1)
Wiring harness between fuse
(FS1) (12) and L15 (female) (12), L15 (female) (1), L107 Min. 1 Mz
(female) (1) and chassis
(1), L107 (female) (1) ground
a In all of these cases, the fuse is broken.
a For the related circuit diagram, see a).
WA320-5 20-537
(2)
(1)..d
Troubleshooting Code [E-9] (The wiper does not function)

a) The rear wiper does not function
Controller
Action Code Failure Code The wiper does not function
Code Trouble a) The rear wiper does not function
- - -
Description of The rear wiper does not function due defective rear wiper, switch, timer or wiring harness.
Trouble
Machine moni-
ler Reaction
Effect on The rear wiper does not function.
Machine
Related
Information

Between L57 (6) and chassis ground Voltage 20 - 30V
Between L57 (2) and chassis Turn wiper
Voltage 20 - 30V
ground switch Lo.
1 Defective rear wiper motor
ground switch Hi. Voltage 20 - 30V
When the wiper switch is turned OFF during running of the wiper, the voltage is
applied between the L57 (Female) (5) and chassis ground until the wiper motor
stops.

ground switch INT Voltage 20 - 30V
2 Defective wiper timer Turn wiper
Possible Between L48 (2) and chassis
Causes and switch Voltage 20 - 30V
ground WASHER
Standard
Values 20 - 30V o
Between L48 (5) and chassis ground
0V OV o
(The voltage is output intermittently by wiper Voltage 20 - 30V
switch INT)
(Repeated)
Between L05 Turn wiper switch Lo. Resistance 1z and below

(Male) (7) and 1Mz and
(5) Other than above. Resistance above
Between L05 Turn wiper switch Hi. Resistance 1z and below

Def7ective rear wiper (Male) (7) and 1Mz and
3 switch (4) Other than above. Resistance above
Between L05 Turn wiper switch INT Resistance 1z and below

Between L05 Turn wiper switch INT Resistance 1z and below

20-538 WA320-5
(2)
(1)

1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L57 and fuse FS1
Wiring harness between L05 (Female) (2) and Resistance 1V and below
L48 (Female) (4)
Resistance 1V and below
L48 (Female) (5)
L57 (Female) (2) Resistance 1V and below
4 ity (Disconnection or defec- Wiring harness between L05 (Female) (4) and Resistance 1V and below
L57 (Female) (1)
tive contact)
L57 (Female) (5)
(Female) (7)
(Female) (3) Resistance 1V and below
Wiring harness between fuse FS1 (14) and L57 Resistance 1V and below
(Female) (6)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
Possible FS1 terminal. 3) Connect T-adapter.
Causes and
Values (Female) (2) and L48 (Female) (Female) (2), L48 (Female) (4) 1Mz and
above
above
above
5 Wiring harness ground fault above
above
Wiring harness between fuse (Female) (7) and chassis 1Mz and
ground
ground
ground
WA320-5 20-539
(2)
20-540 WA320-5
(2)
b) The rear wiper does not function

Controller
Action Code Failure Code The wiper does not function
Code Trouble b) The rear wiper does not function
- - -
Description of The rear wiper does not function due defective rear wiper, switch, timer or wiring harness.
Trouble
Machine moni-
ler Reaction
Effect on The rear wiper does not function.
Machine
Related
Information

1 Defective rear wiper motor Voltage 20 - 30V
ground switch Lo.
When the wiper switch is turned OFF during running of the wiper, the voltage is
applied between the L52 (Female) (1) and chassis ground until the wiper motor
stops.

Between L05 Turn wiper switch Lo. Resistance 1z and below

2 Defective rear wiper switch (9) Other than above. Resistance
above
Between L05 Turn wiper switch OFF. Resistance 1z and below

(9) Other than above. Resistance
above
1) Turn starting switch OFF. 2) Disconnect connector L05, L52 and fuse FS1 termi-
Possible
Causes and Wiring harness between L05 (Female) (8) and Resistance 1z and below
Standard L52 (Female) (1)
Values Wiring harness discontinu- Wiring harness between L05 (Female) (9) and
(Female) (6)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
FS1 terminal. 3) Connect T-adapter.
above
above
ground
ground
a In the all above cases, the fuse is blown.
20-542 WA320-5
(2)
WA320-5 20-543
(2)
Troubleshooting Code [E-10] (The window washer does not function)

Controller
Action Code Failure Code Code Trouble The window washer does not function
- - -
Description of The window washer does not function due defective window washer motor, switch, timer (Front only) or wiring har-
Trouble ness.
Machine moni-
ler Reaction
Effect on The window washer does not function.
Machine
Related

Information

1) Turn starting switch OFF. 2) Disconnect connector B07, B06. 3) Insert T-adapter.
Front washer motor
Defective window washer
1 motor Between B07 (1) and chassis ground Voltage 20 - 30V
Rear washer motor
Between B06 (1) and chassis ground Voltage 20 - 30V

Common to front switch and rear switch.
Between L05 (Male) (7) and chassis ground Voltage 20 - 30V

Front switch
Possible Between L05 Turn washer switch ON. Resistance 1z and below
Causes and 2 Defective wiper switch (Male) (7) and
Standard Turn washer switch OFF. Resistance 1Mz and
(6) above
Values
Rear switch
Between L05 Turn washer switch ON. Resistance 1z and below

(10) Turn washer switch OFF. Resistance
above
Turn washer
Between L05 (Male) (7) and
(9), (10) and wiper low Resistance 1z and below
switch ON.
Wiring harness between L48 (3) and chassis
3 Defective wiper timer Wiring harness between L48 Turn washer

(Relay) Voltage 20 - 30V
(2) and chassis ground switch ON.
Wiring harness between L48 (5) and chassis
(0.2 to 0.8 sec. after the washer switch was
turned ON)
20-544 WA320-5
(2)
(1)

1) Turn starting switch OFF. 2) Disconnect connector L05, L48, B06, B07 and fuse
Front side

B07 (Female) (1) Resistance 1z and below
L48 (Female) (2)
Rear side

Common to front and rear side.

Possible 1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57, D10, D13
Causes and and fuse FS1 terminal. 3) Connect T-adapter.
Standard
Front side
Values
1Mz and
(Female) (6) and B07 (Female) (Female) (6), B07 (Female) (1) above
1Mz and
1Mz and
5 Wiring harness ground fault (5) and chassis ground
Rear side

1Mz and
(Female) (10) and B06 (Female) (10), B06 (Female) above
Common to front and rear side.

Wiring harness between fuse 1Mz and
FS1 (14) and L05 (Female) (7) (Female) (7) and chassis above
ground
a In the all above cases, the fuse is blown.
WA320-5 20-545
(2)
20-546 WA320-5
(2)
Troubleshooting Code [E-11] (Lamps do not work properly)

a) Either of headlamps "Hi" and "Lo" does not light up
Controller
Action Code Failure Code Night light is abnormal
Code Trouble a) Either of headlamps "Hi" and "Lo" does not light up
- - -
Description of Either of headlamps "Hi" and "Lo" does not light up because of disconnection (grounding fault) of a switch, lamp, or
Trouble wiring harness of the headlamp system.
Machine moni-
ler Reaction
Effect on When the lamp switch is set to the 2nd position, either of headlamps "Hi" and "Lo" does not light up.
Machine
If the fuse is broken, there is a grounding fault. Accordingly, check the related wiring harnesses (between the fuse
Related and relay and between the fuse and lamp).
Information
Carry out the following troubleshooting when the circuits of the other lamp systems are normal.

2) Disconnect connectors HEAD (on left side and right side).
3) Insert T-adapter.
Between
HEAD (Left) Set lamp switch to "2nd posi-
(2) and chas- tion" and dimmer switch to "Lo". Voltage 20 - 30V
sis ground
Between
1 Defective lamps HEAD (Left) Set lamp switch to "2nd posi-
Voltage 20 - 30V
(2) and chas- tion" and dimmer switch to "Hi".
sis ground
Between
HEAD (Right) Set lamp switch to "2nd posi- Voltage 20 - 30V
(2) and chas- tion" and dimmer switch to "Lo".
sis ground
Possible
Causes and Between
Standard HEAD (Right) Set lamp switch to "2nd posi-
(2) and chas- tion" and dimmer switch to "Hi". Voltage 20 - 30V
Values
sis ground
Turn lamp switch OFF. Resistance Min. 1 Mz
Between L04 Set lamp switch to "1st posi-
(male) (2) and tion". Resistance Min. 1 Mz
Defective lamp/dimmer
2 (3)
switch Set lamp switch to "2nd posi- Resistance Max. 1 z
tion".
Between L04 Set dimmer switch to "Lo". Resistance Max. 1 z
(male) (4) and
(3) Set dimmer switch to "Hi". Resistance Min. 1 Mz
Between L04 Set dimmer switch to "Lo". Resistance Min. 1 Mz
(male) (5) and
(3) Set dimmer switch to "Hi". Resistance Max. 1 z
20-548 WA320-5
(2)
(1)

Condition does not become Relay (L120)
When headlamp relay (L119) is normal. is normal.
become normal? Relay (L120)
Condition becomes normal. is defective.
3 Defective right headlamp 3) Check relay L119.
relay (L119)
3) Check relay L119.
4) Apply test voltage between L119 (male) (1) and (2).
Between (1) and (2)
L119 (male)
(3) and (5) When 24 V is not applied
between (1) and (2)
When headlamp relay (L120) is normal. is normal.
become normal? Condition becomes normal. Relay (L120)
Possible is defective.
Causes and
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connector L120.
Defective left headlamp 3) Check relay L120.
4
relay (L120)
Between (1) and (2) Resistance Max. 1 z
L120 (male)
(3) and (5) When 24 V is not applied Resistance Min. 1 Mz
between (1) and (2)
2) Disconnect connectors L04, L119, L120, HEAD (Left), and HEAD (Right) and fuse
terminals FS1 (8) and (9).
chassis ground
Wiring harness between L120 (female) (5) and
Resistance Max. 1 z
Disconnection in wiring HEAD (Left) (female) (2)
5 harness (Disconnection or
defective contact) HEAD (Right) (female) (2) Resistance Max. 1 z
Wiring harness between fuse (FS1) (8) terminal Resistance Max. 1 z

and L120 (female) (1), (3)
Wiring harness between fuse (FS1) (9) terminal
Resistance Max. 1 z
and L119 (female) (1), (3)
Wiring harness between L119 (female) (2), L120
(female) (2) and L04 (female) (2) Resistance Max. 1 z
WA320-5 20-549
(2)
20-550 WA320-5
(2)
b) Headlamp "Lo beam" does not light up

Controller
Code Trouble b) Headlamp "Lo beam" does not light up
- - -
Description of Headlamp "Lo beam" does not light up because of disconnection (grounding fault) of a switch, lamp, or wiring harness
Trouble of the headlamp system.
Machine moni-
ler Reaction
Effect on When the lamp switch is set to the 2nd position, headlamp "Lo beam" does not light up.
Machine
If the fuse is broken, there is a grounding fault. Accordingly, check the related wiring harness (between the fuse and
Related lamp).
Information

Between
1 Defective lamps HEAD (Left) Set lamp switch to "2nd posi-
(2) and chas- tion" and dimmer switch to "Lo". Voltage 20 - 30V
sis ground
Between
HEAD (Right) Set lamp switch to "2nd posi-
Voltage 20 - 30V
(2) and chas- tion" and dimmer switch to "Lo".
sis ground
Possible 4) Connect connector.
Causes and 5) Turn starting switch ON.
Standard
Values Turn lamp switch OFF. Resistance Min. 1 Mz
Between L04 Set lamp switch to "1st posi-
Defective lamp/dimmer (male) (2) and tion".
2 (3)
switch Set lamp switch to "2nd posi-
tion". Resistance Max. 1 z

(male) (4) and
(3) dimmer switch to "Hi". Resistance Min. 1 Mz
(male) (5) and
(3) dimmer switch to "Hi". Resistance Max. 1 z
2) Disconnect connectors L04, HEAD (Left), and HEAD (Right).
Disconnection in wiring 3) Connect T-adapter.
defective contact) Wiring harness between L04 (female) (4) and
HEAD (Left) (female) (1), HAED (Right) (female) Resistance Max. 1 z
(1)
WA320-5 20-551
(2)
c) Headlamp "Hi beam" does not light up

Controller
Code Trouble c) Headlamp "Hi beam" does not light up
- - -
Description of Headlamp "Hi beam" does not light up because of disconnection (grounding fault) of a switch, lamp, or wiring harness
Trouble of the headlamp system.
Machine moni-
ler Reaction
Effect on When the lamp switch is set to the 2nd position, headlamp "Hi beam" does not light up.
Machine
Related lamp).
Information

Between
1 Defective lamps HEAD (Left) Set lamp switch to "2nd posi- Voltage 20 - 30V
(3) and chas- tion" and dimmer switch to "Hi".
sis ground
Between
HEAD (Right) Set lamp switch to "2nd posi-
(3) and chas- tion" and dimmer switch to "Hi". Voltage 20 - 30V
sis ground
Possible 4) Turn starting switch ON.
Causes and
Standard Turn lamp switch OFF. Resistance Min. 1 Mz
Values Between L04 Set lamp switch to "1st posi- Resistance Min. 1 Mz
(male) (2) and tion".
2 Defective lamp/dimmer (3)
switch Set lamp switch to "2nd posi-
Resistance Max. 1 z
tion".
(male) (4) and
(3) Set dimmer switch to "Hi". Resistance Min. 1 Mz
(male) (5) and
(3) Set dimmer switch to "Hi". Resistance Max. 1 z
2) Disconnect connectors L04, HEAD (Left), and HEAD (Right).
Disconnection in wiring 3) Connect T-adapter.
defective contact) Wiring harness between L04 (female) (5) and
J03 (4), (2) and HEAD (Left) (female) (3), HAED Resistance Max. 1 z
(Right) (female) (3)
20-552 WA320-5
(2)
d) Clearance lamp (Small lamp) does not light up

Controller
Code Trouble d) Clearance lamp (Small lamp) does not light up
- - -
Description of The clearance lamp (Small lamp) does not light up because of disconnection (grounding fault) of a switch, lamp, or
Trouble wiring harness of the clearance lamp system.
Machine moni-
ler Reaction
Effect on When the lamp switch is set to the 1st position, clearance lamp (small lamp) does not light up.
Machine
If the fuse is broken, there is a grounding fault. Accordingly, check the related wiring harnesses (between the fuse
Related and relay and between the fuse and lamp).
Information

2) Disconnect connectors COMBI (on left side and right side).
Between
COMBI (Left) Set lamp switch to "1st posi-
1 Defective lamps (5) and chas- tion". Voltage 20 - 30V
sis ground
Between
COMBI
Set lamp switch to "1st posi-
(Right) (5) tion". Voltage 20 - 30V
and chassis
ground
2 Defective lamp switch Turn lamp switch OFF. Resistance Min. 1 Mz
Possible Between L04 Set lamp switch to "1st posi- Resistance Max. 1 z
Causes and (male) (2) and tion".
Standard (3)
Values Set lamp switch to "2nd posi-
tion".
When small lamp relay (L117) normal. is normal.
is replaced, does condition
become normal? Condition becomes normal. Relay (L117)
is defective.
Defective left small lamp 3) Check relay L117.
3
relay (L119)
Between (1) and (2) Resistance Max. 1 z
L117 (male)
(3) and (5) When 24 V is not applied Resistance Min. 1 Mz
between (1) and (2)
20-554 WA320-5
(2)

When small lamp relay (L118) normal. is normal.
is replaced, does condition
become normal? Relay (L118)
4 Defective right small lamp 3) Check relay L118.
relay (L118)
Between L118 (male) (1) and (2) Resistance 200 - 400 z
Between (1) and (2)
L118 (male)
Possible Resistance Min. 1 Mz
between (1) and (2)
Causes and
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connectors L04, L117, L118, L26, COMBI (Left), and COMBI (Right)
and fuse terminals FS2 (10) and (11).
Resistance Max. 1 z
chassis ground
Wiring harness between L117 (female) (5), J10
(9), (10), L26 (female) (12), and COMBI (Left) Resistance Max. 1 z
(female) (1)
Wiring harness between L118 (female) (5), R23
Disconnection in wiring (female) (4), and COMBI (Right) (female) (1) Resistance Max. 1 z
defective contact) Wiring harness between fuse (FS2) (10) terminal Resistance Max. 1 z
and L117 (female) (1), (3)
Resistance Max. 1 z
and L118 (female) (1), (3)
Wiring harness between L117 (female) (2), L118
(female) (2), and L04 (female) (1) Resistance Max. 1 z
Wiring harness between COMBI (Left) (female) Resistance Max. 1 z

Wiring harness between COMBI (Right) (female)
Resistance Max. 1 z
WA320-5 20-555
(2)
e) Turn signal lamp does not flash

Controller
Code Trouble Turn signal lamp does not flash
- - -
Description of The turn signal lamp does not flash because of disconnection (grounding fault) of a switch, lamp, or wiring harness of
Trouble the turn signal lamp system.
Machine moni-
ler Reaction
Effect on The turn signal lamp does not flash.
Machine
Related If the fuse is broken, there is a grounding fault. Accordingly, check the related wiring harness.
Information Carry out the following troubleshooting when the circuits of the other lamp systems are normal.

1 Defective winker switch Between L04 Set winker switch to "right". Resistance Max. 1 z
(male) (6) and
(7) Set winker switch to "left". Resistance Min. 1 Mz
Between L04 Set winker switch to "left". Resistance Max. 1 z
(male) (6) and
(8) Set winker switch to "right". Resistance Min. 1 Mz
Possible
Causes and 1) Turn starting switch OFF.
Standard 2) Disconnect connector L06.
Values 3) Connect T-adapter.
Between L06 Turn hazard switch OFF. Resistance Max. 1 z
(male) (1) and
2 Defective hazard switch (2) or
between (4) Turn hazard switch ON. Resistance Min. 1 Mz
and (5)
Between L06 Turn hazard switch OFF. Resistance Min. 1 Mz
(male) (3) and
(2) or
between (6) Turn hazard switch ON. Resistance Max. 1 z
and (5)
20-556 WA320-5
(2)

2) Disconnect connectors L04, R22, R23, COMBI (Left), COMBI (Right), R22, R23,
D11, and D14 and fuse terminals FS1 (2) and (10).
a When the turn signals on both sides are defective (The headlamp does not light
up either, in this case)

Resistance Max. 1 z
chassis ground
a When the turn signal on the left side is defective
Wiring harness between L04 (female) (8), J03

(10), (6), and COMBI (Left) (female) (3) Resistance Max. 1 z
Wiring harness between COMBI (Left) (4) and Resistance Max. 1 z

chassis ground
Wiring harness between L04 (female) (8), J03 Resistance Max. 1 z
(10), (9), and R22 (female) (1)
Wiring harness between R22 (female) (6) and
Resistance Max. 1 z
chassis ground
Wiring harness between J01 (female) (17), D14
(2), (1), and J03 (7) Resistance Max. 1 z
a When the turn signal on the right side is defective
Wiring harness between L04 (female) (7), J03 Resistance Max. 1 z

(20), (16), and COMBI (Right) (female) (3)
Possible Wiring harness between COMBI (Right) (2) and
Causes and Disconnection in wiring Resistance Max. 1 z
Standard chassis ground
Values defective contact) Wiring harness between L04 (female) (7), J03
(20), (19), and R23 (female) (1) Resistance Max. 1 z
Wiring harness between R23 (female) (6) and Resistance Max. 1 z

chassis ground
Wiring harness between J01 (female) (20), D11
Resistance Max. 1 z
(2), (1), and J03 (17)
a When the turn signals on both sides are defective
Wiring harness between fuse (FS1) (10) terminal,

J10 (4), (1), and L06 (female) (1) Resistance Max. 1 z
Wiring harness between fuse (FS1) (2) terminal Resistance Max. 1 z

and L06 (female) (3)
Resistance Max. 1 z
L49 (female) B
Wiring harness between L49 (female) (E) and
chassis ground Resistance Max. 1 z
Wiring harness between L49 (female) (L) and Resistance Max. 1 z

J01 (female) (6)
Resistance Max. 1 z
J01 (female) (4)
a When hazard lamp does not function

J01 (female) (5) Resistance Max. 1 z

J01 (female) (18)
WA320-5 20-557
(2)
f) Working lamp does not light up

Controller
Code Trouble f) Working lamp does not light up
- - -
Description of The working lamp does not light up because of disconnection (grounding fault) of a switch, lamp, or wiring harness of
Trouble the working lamp system.
Machine moni-
ler Reaction
Effect on The working lamp does not light up.
Machine
Related lamp).
Information Carry out the following troubleshooting when the circuits of the other lamp systems are normal.
If the small lamp (LH) does not light up, carry out the troubleshooting for the small lamp (LH) system first.

2) Disconnect connectors C05, C06, and B01 or B02.
6) Turn small lamp switch ON (Small lamp must light up).
Turn front working lamp switch Voltage 20 - 30V
Between C05 ON.
(1) and chas-
sis ground Turn front working lamp switch
Voltage Max. 1 V
OFF.
Turn front working lamp switch
Between C06 ON. Voltage 20 - 30V
1 Defective lamps
(1) and chas-
sis ground Turn front working lamp switch Voltage Max. 1 V
OFF.
Turn rear working lamp switch
Possible Between B01 Voltage 20 - 30V
ON.
Causes and (1) and chas-
Standard sis ground Turn rear working lamp switch
Values OFF. Voltage Max. 1 V
Turn rear working lamp switch Voltage 20 - 30V

Between B02 ON.
(1) and chas-
sis ground Turn rear working lamp switch
Voltage Max. 1 V
OFF.
2) Disconnect connectors L07 and L08.
Turn front working lamp switch
Between L07 ON. Resistance Max. 1 z
Defective working lamp (male) (2) and
2 switch (3) Turn front working lamp switch Resistance Min. 1 Mz
OFF.
Turn rear working lamp switch
Between L08 Resistance Max. 1 z
ON.
(male) (2) and
(3) Turn rear working lamp switch
OFF. Resistance Min. 1 Mz
20-558 WA320-5
(2)

When working lamp relay normal. is normal.
(L122) is replaced, does condi-
tion become normal? Relay (L122)
3 Defective working lamp 3) Check relay L122.
relay (L122)
Between (5) and (6)
L122 (male)
between (5) and (6)
2) Disconnect connectors L04, L120, L119, HEAD L, and HEAD R, and fuse termi-
nals (8) and (9).
Possible 4) When small lamp (LH) is normal
Causes and
Standard a When all the lamps are defective
Values
L122 (female) (5)
Resistance Max. 1 z
chassis ground
a When the working lamps on the front side are defective

L07 (female) (2) Resistance Max. 1 z
Disconnection in wiring Wiring harness between fuse (FS2) (12) terminal
4 harness (Disconnection or Resistance Max. 1 z
defective contact)
Resistance Max. 1 z
C05 (female) (1), C06 (female) (1)
Wiring harness between C05 (female) (2), C06
(female) (2) and chassis ground Resistance Max. 1 z
a When the working lamps on the rear side are defective

L08 (female) (2)
Resistance Max. 1 z
B01 (female) (1), B02 (female) (1) Resistance Max. 1 z
Wiring harness between B01 (female) (2), B02 Resistance Max. 1 z

(female) (2) and chassis ground
WA320-5 20-559
(2)
Troubleshooting Code [E-12] (The horn does not sound)

Controller
Action Code Failure Code Code Trouble The horn does not sound
- - -
Description of Horn does not sound due to defective switch, relay, horn or wiring harness in the horn system.
Trouble
Machine moni-
ler Reaction
Effect on The horn does not sound.
Machine
Related

Information

1) Turn starting switch OFF. 2) Disconnect connector L13. 3) Connect connector.
Between L13 Push horn switch ON Resistance 1z and below
1 Defective horn switch (Male) (1) and
chassis 1Mz and
Horn switch OFF Resistance above
ground
Between L116 (1), (3) and chassis ground Voltage 20 - 30V
Between L116 (2) and chassis
Voltage 20 - 30V
ground
Between L116 (2) and chassis
ground Voltage 1V and below
Between L116 (5) and chassis Voltage 20 - 30V

ground
switch ON.
Possible
2 Defective horn relay (L116) Relay L116 is
Causes and Does condition become normal Condition is abnormal. normal.
Standard when horn and lamp relay L116
Values is replaced with normal relay? Defective
Condition is normal.
relay L116.
Between L116 (Male) (1) and (2) Resistance 200 - 400z
Applies 24V impressed voltage Resistance 1z and below
Between between L116 (Male) (1) - (2)
L116 (Male)
Resistance
1) Turn starting switch OFF. 2) Disconnect connector F01, F02. 3) Insert T-adapter.
4) Connect T-adapter. 5) Turn starting switch ON.
Between F01 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
3 Defective horn (2) Horn switch OFF Voltage 1V and below
Between F02 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
(2) Horn switch OFF Voltage 1V and below
20-560 WA320-5
(2)
(1)

1) Turn starting switch OFF. 2) Disconnect connector L13, L116 and fuse FS2 (9) ter-
minal. 3) Connect T-adapter.
(Female) (1), (3) Resistance 1z and below
4 ity (Disconnection or defec- Wiring harness between L116 (Female) (5) and Resistance 1z and below
L13 (Female) (1)
tive contact)
F02 (Female) (1)
Wiring harness between F01 (Female) (2), F02
(Female) (2) and chassis ground Resistance 1z and below
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector L116, F01, F02 and fuse FS2
Standard (9) terminal. 3) Connect T-adapter.
Values
1Mz and
FS2 (9) and L116 (Female) (1), (9), L116 (Female) (1), (3) and above
(3) *1 chassis ground
5 Wiring harness ground fault (1) *2 and chassis ground above

(Female) (5), F01 (Female) (1), 1Mz and
(Female) (5) and F01 (Female) F02 (Female) (1) and chassis above
(1), F02 (Female) (1)
ground
a In case of *1 above, fuse is blown
a In case of *2 above, horn does not stop sounding
WA320-5 20-561
(2)
Troubleshooting Code [E-13] (Defective the air conditioner)

a) The air conditioner does not work
Controller
Action Code Failure Code Defective the air conditioner
Code Trouble a) The air conditioner does not work
- - -
Description of The air conditioner does not work.
Trouble
Machine moni-
ler Reaction
Effect on The air conditioner does not work.
Machine
Related If fuse FS2 (2) is blown, check wiring harness between fuse FS2 (2) - C03 (Female) (8) for short circuit with ground.
Information

1) Turn starting switch OFF. 2) Disconnect connector C03, fuse FS2 terminal.
Possible Wiring harness discontinu-
Wiring harness between fuse FS2 (2) and C03
Causes and 1 ity (Disconnection or defec- (Female) (8) Resistance 1z and below
Standard tive contact)
Values Wiring harness between C03 (Female) (11) and Resistance 1z and below
chassis ground
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
2
control panel
20-562 WA320-5
(2)
(1)
WA320-5 20-563
(2)
b) Air does not flow out or amount of air cannot be adjusted.

Code Defective air conditioner
Trouble
b) Air does not flow out or amount of air cannot be adjusted.
- - -
Description of Air does not flow out or amount of air cannot be adjusted.
Trouble
Machine moni-
ler Reaction
Effect on Air does not flow out or amount of air cannot be adjusted.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector A09, A10, A11, A13 and fuse
Wiring harness between fuse FS2 (2) and A09
Power supply wiring har- Wiring harness between fuse FS2 (2) and A10 Resistance 1z and below
ness discontinuity (Discon- (Female) (1)
1
nection or defective Wiring harness between fuse FS2 (2) and A11
contact) Resistance 1z and below
(Female) (1)
Wiring harness between fuse FS2 (2) and A13
Wiring harness between fuse FS2 (1) and A09 Resistance 1z and below
(Female) (3)
1) Turn starting switch OFF. 2) Disconnect connector C03, A09, A10, A11, A12 and
fuse FS2 terminal. 3) Connect T-adapter.
Wiring harness between C03 (Female) (7) and
A09 (Female) (2) Resistance 1z and below
Wiring harness between C03 (Female) (4) and Resistance 1z and below
A10 (Female) (2)
A11 (Female) (2)
Wiring harness between A09 (Female) (4) and Resistance 1z and below
A01 (Female) (6)
Wiring harness discontinuity Wiring harness between A10 (Female) (4) and
2 (Disconnection or defective Resistance 1z and below
A01 (Female) (5)
contact)
Possible Wiring harness between A11 (Female) (4) and A01
Causes and
Standard Wiring harness between A13 (Female) (4) and
Values Resistance 1z and below
A01 (Female) (3)
Wiring harness between A10 (Female) (3) and
chassis ground
chassis ground
chassis ground
1) Turn starting switch OFF. 2) Disconnect connector A01, A05, A09, A10, A11, A13
and fuse FS2 terminal. 3) Connect T-adapter.
(2), A09 (Female) (1) and chas-
FS1 (2) and A09 (Female) (1) * sis ground above
(2) and A11 (Female) (1) and
3 Wiring harness ground fault FS1 (2) and A11 (Female) (1) * chassis ground above
FS1 (2) and A15 (Female) (1) * above
sis ground
20-564 WA320-5
(2)

Wiring harness between C03 Resistance between C03 1Mz and
(Female) (7) and A09 (Female) (Female) (7), A09 (Female) (2)
3 Wiring harness ground fault Wiring harness between A09 Resistance between A09 1Mz and
above
Wiring harness between A10 Resistance between A10
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (5) 1Mz and
above
above
above
(Female) (2) and C03 (Female) (Female) (2), C03 (Female) (3) 1Mz and
above
a If marked * above, fuse is blown
1) Turn starting switch OFF. 2) Replace relay A09 with normal relay. 3) Turn starting
Possible switch ON. 4) Start air conditioner
Causes and Defective blower main relay Defective
Standard 4 Does condition become normal Condition is normal. relay.
A09
Values when relay is replaced with nor-
mal relay? Condition is abnormal. Relay is
normal.
switch ON. 4) Start air conditioner
Defective blower Hi relay Defective
5 Does condition become normal Condition is normal. relay.
A10
when relay is replaced with nor-
normal.
Defective blower M2 relay Defective
A11
normal.
Defective blower M1 relay Defective
A13
normal.
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
Defective
8 Defective blower motor Does condition become normal Condition is normal. motor.
when motor is replaced with nor-
mal motor? Condition is abnormal. Relay is
motor.
1) Turn starting switch OFF. 2) Disconnect connector A01. 3) Solid part check.
Between A01 (Female) (1) and (3) Resistance 2.8z
9 Defective blower resister
10
control panel

a See "TROUBLESHOOTING CODE [E-12.(a)]".
WA320-5 20-565
(2)
c) Does not cool or temperature cannot be adjusted.

Trouble
c) Does not cool or temperature cannot be adjusted.
- - -
Description of Does not cool or temperature cannot be adjusted.
Trouble
Machine moni-
ler Reaction
Effect on Does not cool or temperature cannot be adjusted.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector A12, A15 and fuse FS2 termi-
Power supply wiring har-
ness discontinuity (Discon- Wiring harness between fuse FS2 (2) and A12
1 Resistance 1z and below
nection or defective (Female) (1), (4)
contact) Wiring harness between fuse FS2 (2) and A15 Resistance 1z and below
(Female) (1), (4)
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A07, A08, A12,
A15, B04, C03, C04 and J06. 3) Connect T-adapter.
chassis ground
C03 (Female) (4)
A12 (Female) (2), A15 (Female) (2)
B04 (Female) (1)
E16 (Female) (1) Resistance 1z and below
Wiring harness between B04 (Female) (3) and
chassis ground
tive contact) Wiring harness between compressor magnet Resistance 1z and below
clutch (-) terminal and chassis ground
Possible
Causes and A03 (Female) (2) Resistance 1z and below
Standard
Values Wiring harness between A03 (Female) (1) and
J06 (16), (15) and C03 (Female) (12)
J06 (16), (15) and A02 (Female) (4)
C03 (Female) (9) Resistance 1z and below
C04 (Female) (4)
C03 (Female) (15)
C04 (Female) (3) Resistance 1z and below
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A12, A15, B04,
C03, C04 and fuse FS2 terminal. 3) Connect T-adapter.
FS1 (2) and A12 (Female) (1), (2), A12 (Female) (1), (4) and
(4) * chassis ground above

1Mz and
FS1 (2) and A15 (Female) (1), (2), A15 (Female) (1), (4) and above
3 Wiring harness ground fault (4) * chassis ground
(Female) (3) and B04 (Female) (Female) (3), B04 (Female) (2) 1Mz and
above
(2) * and chassis ground

(Female) (4), A12 (Female) (2), 1Mz and
(Female) (4) and A12 (Female) A15 (Female) (2) and chassis above
(2), A15 (Female) (2)
ground
20-566 WA320-5
(2)

(Female) (3) and B04 (Female) (Female) (3), B04 (Female) (1) 1Mz and
above
Wiring harness between A15 Resistance between A15 1Mz and
(Female) (3) and E16 (Female) (Female) (3), E16 (Female) (1)
Wiring harness between C03 Resistance between C03

1Mz and
(Female) (16) and A03 (Female) (16), A03 (Female) above
(Female) (1) and J06 (16), (15) (Female) (1), C03 (Female) 1Mz and
above
and C03 (Female) (12) (12) and chassis ground
(Female) (1) and J06 (16), (15) (Female) (1), A02 (Female) (4)
and A02 (Female) (4) and chassis ground above
1Mz and
(Female) (1) and C03 (Female) (Female) (1), C03 (Female) (9)
1Mz and
(Female) (3) and C04 (Female) (Female) (3), C04 (Female) (4) above
(Female) (5) and C03 (Female) (Female) (5), C03 (Female) 1Mz and
above
(15) (15) and chassis ground
(Female) (6) and C04 (Female) (Female) (6), C04 (Female) (3)
a If marked * above, fuse is blown
Defective compressor Defective
Possible clutch relay A15
when relay is interchanged with
Causes and normal relay? Relay is
Standard Condition is abnormal.
normal.
Values
1) Turn starting switch OFF. 2) Disconnect connector A05. 3) Connect T-adapter.
1Mz and
5 Defective pressure switch Between A05 Turn air conditioner switch OFF. Resistance above
(Male) (1) and
(2) When air conditioner switch is
ON and cooling is in operation
1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch
ON. 4) Start air conditioner.
6 Defective thermister Temperature: 25C 37 - 50kz
Between A03 (Male) (1) and (2)
Temperature: 100C 3.5 - 4.0kz
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
Defective temperature con- Defective
7 Does condition become normal Condition is normal.
trol servo motor motor.
when servo motor is inter-
changed with normal motor? Condition is abnormal. Motor is
normal.
1) Turn starting switch OFF. 2) Replace compressor with normal compressor. 3) Turn
starting switch ON. 4) Start air conditioner
Defective air
Condition is normal. conditioner
Defective air conditioner Does condition become normal compressor.
8 compressor when air conditioner compres-
sor is replaced with normal Air condi-
compressor? tioner com-
Condition is abnormal.
pressor is
normal.
Turn starting switch OFF. 2) Replace diode D06 with normal diode.
Defective
Condition is normal. diode D06.
9 Defective diode (D06) Replace diode D06 with normal
diode Diode D06 is
Condition is abnormal.
normal.
10 control panel

WA320-5 20-567
(2)
d) Impossible to switch between recirculated air and fresh air

Trouble
d) Impossible to switch between recirculated air and fresh air
- - -
Description of Air conditioner system is defective, so it is impossible to switch between recirculated air and fresh air
Trouble
Machine moni-
ler Reaction
Effect on Impossible to switch between recirculated air and fresh air
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
adapter.
tive contact)
Wiring harness between C04 (Female) (2) and Resistance 1z and below
L51 (Female) (1)
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
Standard adapter.
Values
2 Wiring harness ground fault above
above
3 control panel

20-568 WA320-5
(2)
e) Impossible to switch vents

Controller
Action Code Failure Code Defective air conditioner
Code Trouble e) Impossible to switch vents
- - -
Description of Impossible to switch vents
Trouble
Machine moni-
ler Reaction
Effect on Impossible to switch vents
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector A03, A07, A08, C03, C04, J06.
Wiring harness between A07 (Female) (1) and C03 (Female) (1) Resistance 1z and below
Wiring harness discontinuity
1 (Disconnection or defective Wiring harness between A08 (Female) (1) and C04 (Female) (5) Resistance 1z and below
contact) Wiring harness between A08 (Female) (2) and C04 (Female) (6) Resistance 1z and below
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
1) Turn starting switch OFF. 2) Disconnect connector ACP1, ACP2, ACM2. 3) Connect
T-adapter.
Resistance between A07
Wiring harness between A07 (Female) (1), C03 (Female) 1Mz and
(Female) (1) and C03 (Female) (1) above
Wiring harness between A07 1Mz and
(Female) (2) and C03 (Female) (2) (Female) (2), C03 (Female)
Possible (2) and chassis ground above
Causes and
Standard Wiring harness between A07 Resistance between A07
(Female) (3), C03 (Female) 1Mz and
Values (Female) (3) and C03 (Female) (11) above
(Female) (2), C04 (Female) 1Mz and
(Female) (2) and C04 (Female) (6) (6) and chassis ground above


(Female) (1), J06 (16), (14), 1Mz and
(Female) (1) and J06 (16), (14) and A07 (Female) (6) and chassis
A07 (Female) (6) above
ground
Wiring harness between A03
(Female) (1) and J06 (16), (14) and (Female) (1), J06 (16), (14), 1Mz and
A08 (Female) (6) and chassis above
A08 (Female) (6) ground
3 Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

WA320-5 20-569
(2)
f) Defective cooling (Mechanical system)

Controller
Action Code Error code Air conditioner is defective
Code Trouble f) Defective cooling (Mechanical system)
- - -
Contents of Cooling is defective because of abnormality in the mechanical system.
trouble
Action of
machine moni-
tor
Problem that
appears on Cooling is defective because of abnormality in the mechanical system.
machine
Related infor-
mation

Gas leakage from pipe joint Check. If abnormality is detected, repair or replace.
1
or piping part
Natural leakage from hoses,
2 etc. (Refrigerant has not Check quantity of refrigerant. If insufficient, add proper amount of refrigerant.
been added for long period)
Insufficient charge with Charge with refrigerant to proper level.
3 refrigerant
Check. If abnormality is detected, repair or replace.
4 Defective expansion valve a Check that the valve is not opened too wide. Check thermometer tube for defec-
tive contact.
5 Clogging of low-pressure cir- Check. If any part is clogged, repair or replace.

cuit or evaporator
6 Clogging of evaporator fins Check. If evaporator fins are clogged, clean them.
Possible
causes and 7 Clogging of filter Check, then clean or replace.
standard
value in Defective installation of ther-
normal state 8 Check. If abnormality is detected, repair or replace.
mistor
Air leakage from air condi- Check. If leakage is detected, repair or replace.
9
tioner unit or duct joint
10 Insufficient set air flow Increase the set air flow.
11 Overcharging with refriger- Check quantity of refrigerant. If it is too much, reduce it to proper level.
ant
Evacuate the system, then charge it with proper quantity of refrigerant and replace
12 Air in system
receiver drier.
13 Clogging of condenser fins Check. If condenser fins are clogged, clean them.
Defective compression by Check. If abnormality is detected, repair or replace.

14
compressor
Evacuate the system, then charge it with proper quantity of refrigerant and replace
15 Water in refrigerant circuit
receiver drier.
20-570 WA320-5
(2)
(1)
g) Defective heating (Defective hot-water circuit)

Controller
Code Trouble g) Defective heating (Defective hot-water circuit)
- - -
Contents of Heating is defective (The hot-water circuit is defective).
trouble
Action of
machine moni-
tor
Problem that
appears on Heating is defective (The hot-water circuit is defective).
machine
Related infor- Check that water is not leaking from the hot-water circuit
mation Check that air is blowing out of the air outlet.

Check. If heater core fins are clogged, clean them.
1 Clogging of heater core fins a If this item is the cause, both temperatures at the heater core hot-water inlet and
outlet are high.
Check. If leakage is detected, repair or replace.

Air leakage from air condi- a If this item is the cause, both temperatures at the heater core hot-water inlet and
2 tioner unit
Possible outlet are high.
causes and
standard Check. If clogging or defect is detected, repair or replace.
value in normal Defective waste valve (Clog- a If this item is the cause, the temperatures at the heater core hot-water inlet is high
state 3 ging or defect in valve)
and that at the heater core hot-water outlet is low.
Check. If clogging is detected, repair or replace.

4 Clogging in heater core a If this item is the cause, the temperatures at the heater core hot-water inlet is high
and that at the heater core hot-water outlet is low.
Clogging up to heater core Check. If clogging is detected, repair or replace.

5
hot-water inlet a If this item is the cause, the temperatures at the heater core hot-water inlet is low.
WA320-5 20-571
(2)
(1)..d
h) Abnormal sound comes out

Controller
Code Trouble h) Abnormal sound comes out
- - -
Contents of Abnormal sound comes out.
trouble
Action of
machine moni-
tor
Problem that
appears on Abnormal sound comes out.
machine
Related infor-
mation

Defective installation of Check. If abnormality is detected, repair.
1
case bolts (screws)
Interference of fan case or Check. If abnormality is detected, repair or replace.
2 breakage of fan
Possible Foreign matter in blower
causes and 3 motor or defective blower Check. If abnormality is detected, remove foreign matter and repair or replace.
standard motor
value in normal
state 4 Defective expansion valve Check. If abnormal sound (blowing or leaking sound) comes out, replace valve.
Looseness or wear of com- Check. If looseness or wear is detected, repair or replace.

5
pressor V-belt
Improper quantity of refriger- Check quantity of refrigerant, then adjust it properly, if necessary.
6 ant
7 Defective compressor Check. If abnormality is detected, repair or replace.
20-572 WA320-5
(2)
(1)
i) Water leaks
Controller
Code Trouble i) Water leaks
- - -
Contents of Water leaks.
trouble
Action of
machine moni-
tor
Problem that
appears on AWater leaks.
machine
Related infor-
mation

Clogging of water drain
1 opening in air conditioner Check. If abnormality is detected, repair.
unit
Clogging, bend, defective
2 installation, or hole of drain Check. If abnormality is detected, repair or replace.
Possible hose of air conditioner unit
causes and Breakage (Cracking) of air
standard 3 Check. If breakage (cracking) is detected, repair or replace.
conditioner unit case
value in normal Defective mounting bolt
state 4 (screw) of air conditioner Check. If abnormality is detected, repair or replace.
unit case
Defective joint of hot-water Check. If abnormality is detected, repair or replace.
5 circuit piping
6 Defective heater core Check. If abnormality is detected, repair or replace.
7 Defective water valve Check. If abnormality is detected, repair or replace.
WA320-5 20-573
(2)
(1)..d
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Method of using troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602

Failure code and cause table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-604
H-1 The machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
H-2 The travel speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-607
H-3 The thrusting force is weak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
H-4 Engine stalls when traveling or engine speed drops excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H-5 The gear is not shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
H-6 The steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H-7 The steering wheel is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
H-8 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-9 Machine deviates naturally to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
H-10 The brake does not work or does not work well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H-11 The brake is not released or is dragged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H-12 The lift arm does not rise or lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H-13 The lift arm moves slowly or the lift arm rising force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . 20-617
H-14 When rising, the lift arm comes to move slowly at specific height . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) . . . . . . . . . . . . . . . . 20-618
H-16 Hydraulic drifts of the lift arm occur often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-17 The lift arm wobbles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily . . . . . . . . 20-619
H-19 The bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-20 The bucket moves slowly or the tilting-back force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-21 The bucket comes to operate slowly in he midst of tilting-back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-22 The bucket cylinder cannot hold down the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-23 Hydraulic drifts of the bucket occur often. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD") . . . . . . 20-623
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily. . . . . . . . . . 20-623
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy . . . . . . . . . . . . . . . . 20-623
H-27 The travel damper does not operate and machine pitches and bounces . . . . . . . . . . . . . . . . . . . . . 20-624
WA320-5 20-601
(2)..
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHART

This troubleshooting chart, like the other troubleshooting charts (YES/NO type), determines the location from the
problem of occurring on the machine and categorizes the problem under one of the main components, such as the
steering system or work equipment hydraulic system. Use the following procedure to carry out accurate trouble-
shooting swiftly.
Step 1. Ask operator questions 2) Find the matching cause in the Causes col-
The questions to ask the operator are given umn.
under the problem. If the answer to the question If a problem is found, the Q marks on the
matches the content given, the cause given after same line as the troubleshooting are the
the arrow is the probable cause. causes. (In Troubleshooting item 2 in the
Keeping the content of the questions in mind, same diagram on the right the cause is c or
read the matrix and proceed with Step 2 and e.)
Step 3 to pinpoint the correct cause. When there is one Q mark
Carry out troubleshooting for the other items
Example: Steering wheel will not turn marked with Q in the same Causes column
Ask the operator and check the following points. to check if the problem occurs, then make
Did the problem suddenly start? repairs.
o Broken part in steering equipment When there are two Q marks
Go to Step 3) to narrow down the cause.
Was the steering wheel heavy before?
o Internal wear, defective seal in steering 1. Steering wheel does not turn i Problem
related equipment (example)
Ask the operator the following questions.
Step 2. Checks before troubleshooting Did the problem suddenly start?
Before measuring the oil pressure or starting the Yes = Equipment related to steering broken
troubleshooting, confirm the checks before start- Was there previously any symptom, such as heaviness of
the steering wheel?
ing items, check for leakage of oil, or for loose Yes = Wear of equipment related to steering, defective seal
bolts.
This will prevent wasting time when trouble-
Checks before troubleshooting (example)
shooting.
Is the oil level in the hydraulic tank correct? Is the type of oil
The items given under Checks before trouble-
correct?
shooting are checks that are particularly impor- Is there any leakage of oil from the steering valve or Orbit-
tant to make about the condition of the machine roll?
before starting the actual troubleshooting. Has the safety bar been removed from the frame?
Example: Checks before starting troubleshooting <Example 1>

Is oil level and type of oil in hydraulic tank Remedy
correct? No.
Problems
Is there any oil leakage from steering valve
Steering wheel does not turn in either direction (left and
or demand valve? 1
right)
Is steering linkage adjusted properly? 2 In Item 1, movement of work equipment is abnormal
3 Steering wheel turns only in one direction (left or right)
Step 3. Method of reading matrix 4 Steering wheel is heavy and does not turn
1) Operate the machine when carrying out trou-
bleshooting of the items in the Troubleshoot-
<Example 2>
ing column. If any problems occur as the
Cause
result of the troubleshooting, put a check
against the item. a b c d e
a When carrying out the troubleshooting, Remedy E
X C A X
check the easier items first. It is not nec- Problems X
essary to follow the number order. 1 Q Q Q Q
2 q q
3 Q Q
4 Q Q
5 Q Q
20-602 WA320-5
(1)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
3) Operate the machine and carry out trouble-

shooting of the items not checked in Step 1).
Operate the machine in the same way as in Cause
Step 1), and if any problem occurs, put a a b c d e
check against the item. (In Troubleshooting E
Remedy
item 5 in the diagram on the right, the prob- X C A X
lem was re-enacted.) Problems X
4) Find the matching cause in the cause col- 1 Q Q Q Q
umn. o 2 q q
In the same way as in Step 2), if a problem is 3 Q Q
found, the Q marks on the same line for the 4 Q Q
troubleshooting item are the causes. (In
o 5 q q
Troubleshooting item 5 in the diagram on the
right, the cause is b or e.) Applicable items found in Step 3)
Applicable items found in Step 1)
5) Narrow down the causes. Causes to eliminate Common causes

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the Cause
line for each troubleshooting item and in the a b c d e
same Cause column as each other) that Remedy E
have causes common with the problem X C A X
Problems X
items found in the troubleshooting in Step 1)
1 Q Q Q Q
and Step 3).
a The items that are not common (items o 2 q q
that do not have Q marks in the same 3 Q Q
cause common as each other) are prob- 4 Q Q
ably not the cause, so they can be elimi- o 5 q q
nated.
(The causes for Troubleshooting item 2 Nature of remedy
in the diagram on the right are c or e,
and the causes in Troubleshooting item Cause
5 are b or e, so Cause e is the common a b c d e
cause.)
Remedy E
6) Repeat the operation in Steps 3), 4), and 5) X C A X
until the cause is narrowed down to 1 item (1 Problems X
common item). 1 Q Q Q Q
a If cause items are 2 or more, continue o 2 q q
until number of items becomes mini- 3 Q Q
mum.
4 Q Q
o 5 Q q
7) Remedy
After narrowing down the common causes,
taken the action given in the remedy line.
X: Replace E: Repair A: Adjust C: Clean
WA320-5 20-603
(1)..d
TESTING AND ADJUSTING FAILURE CODE AND CAUSE TABLE
FAILURE CODE AND CAUSE TABLE
Part causing problem HST HST

HST pump
motor 2 motor 1
Low pressure relief valve (Charge relief valve)
Mode selector solenoid valve (SOL a)
Angle stopper solenoid valve (SOL b)
Angle stopper control solenoid valve

forward and reverse solenoid valve
Pump body (Charge pump end)
Pump body (Piston pump end)
High pressure cut-off valve

High pressure relief valve
Inching valve linkage

Inching valve
Motor body
Motor body
DA valve
Damper
Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q
Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
Rimpull is weak in both forward and reverse Q Q Q Q Q Q
The thrusting force is weak at forward (Reverse is normal) Q
The thrusting force is weak at reverse (Forward is normal) Q
Engine stalls when traveling or engine speed drops excessively Q Q Q
The gear is not shifted Q Q
The steering wheel does not turn
Brake Steering wheel
The steering wheel is heavy

There is play in steering wheel or excessive shock
Machine deviates naturally to one side when traveling
The brake does not work or does not work well
The brake is not released or is dragged
The lift arm does not rise or lower Q Q
The lift arm moves slowly or the lift arm rising force is insufficient Q
When the lift arm rising, the lift arm comes to move slowly at
specific height
The lift arm cylinder cannot be hold down the bucket
(The bucket rises in the air)
Hydraulic drift of the lift arm occur often
Work equipment system
The lift arm wobbles during operation

When the control lever is switched from "HOLD" to "RAISE", the
lift arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in he midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occur often
The bucket wobbles during travel with cargo
(The work equipment valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT", the
bucket falls temporarily
The control levers of the lift arm and bucket do not move
smoothly and heavy
20-604 WA320-5
(2)
Q
Q
Q
Q
Clutch solenoid
Q
Q
Q
Q
Clutch
Q
Q
Transfer
WA320-5
Q
Q
Q
Q
Q
Q
Q
Work equipment and steering pump
Q
Brake pump
Q
Q
Q
Orbit-roll
Q
Q
Q
Q
Q
Q
Q
Priority valve
Q
Q
Relief valve
Steering valve
Q
Safty valve
Q
Q
Q
Q
Steering cylinder
Q
Tire inflation pressure
Q
Accumulator charge valve
Q
Brake valve
Q
Q
Slack adjuster
Q
Q
Brake disc and plate
Axle
Q
Q
Brake piston
Q
Wheel brake linkage
Q
Q
Q
Q
Cut-off relief valve
Q
Q
Q
Q
Unload valve
valve
Cut-off
Q
Q
Q
Q
Check valve
Q
Q
Q
Q
Q
Q
Main relief valve
Q
Q
Q
Lift arm spool
Q
Q
Q
Q
Q
Bucket spool
Q
Q
Q
Q
Suction and safety valve
control valve
Work equipment
Suction valve
Q
Q
Q
Q
Lift arm cylinder
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Lift arm PPC valve
Q
Q
Q
Q
Bucket PPC valve
Q
Cushion valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
(2)
Work equipment system Brake Steering wheel HST related
FAILURE CODE AND CAUSE TABLE
20-605
TESTING AND ADJUSTING H-1
H-1 The machine does not start

Ask the operator about the following: Cause
Has the machine come not start suddenly? HST HST
o Breakage of HST pump and motor related equipment HST pump motor 2 motor 1 Others
Was there any problem of not traveling before? a b c d e f g h i j k l m n o
o Internal wear of HST pump and motor related equip-

ment, defective seal
Inspection before diagnosis

Are the oil level in the hydraulic tank and the oil type appro-
priate?

Is inching valve linkage properly adjusted?

Is the any external oil leak found around the hydraulic piping,
pump and motor?


Clutch solenoid
Inching valve
Motor body
Motor body
DA valve
Transfer
Damper
Clutch
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 The machine does not start at reverse (Forward is normal) Q Q

Does not travel forward or in reverse, motor makes sound
4 Q Q Q
of rotation
20-606 WA320-5
(2)
H-2 The travel speed is slow

Did the travel speed suddenly becomes slower? HST
o Breakage of HST pump and motor related equipment HST pump HST motor 2 motor 1 Others
Was there any problem of travel speed becoming slower a b c d e f g h i j k l m n o
before?

o Internal wear of HST pump and motor related equip-
ment, defective seal
Mode selector solenoid valve (SOL a)

Angle stopper solenoid valve (SOL b)
Angle stopper control solenoid valve

priate?
Is the inching valve linkage adjusting appropriate?

Is inching valve linkage properly adjusted?

pump and motor?
Clutch solenoid
Inching valve
Motor body
Motor body
DA valve
Clutch
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The travel speed is slow at forward (Reverse is normal) Q Q
3 The travel speed is slow at reverse (Forward is normal) Q Q

Maximum travel speed in both forward and reverse is
4 Q
approx. 4 km/h
5 Maximum travel speed in both forward and reverse is Q

approx. 18 km/h
Abnormal sound comes from motor in both forward and
6 reverse when travel speed is 10 km/h or more Q Q
WA320-5 20-607
(2)
H-3 The thrusting force is weak

a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
pump motor 2 motor 1 Others
a b c d e f g h i j
Inclination control solenoid valve


Clutch solenoid
Inching valve
Motor body
Motor body
Transfer
Clutch
Remedy E E E E E E E E E E
No. Diagnosis X X X X X X X X X X
A
1 Rimpull is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
2 The thrusting force is weak at forward (Reverse is normal) Q
3 The thrusting force is weak at reverse (Forward is normal) Q

Rimpull is weak in both forward and reverse, but maximum
4 Q Q Q
travel speed is reached the linee.
20-608 WA320-5
(2)
H-4 Engine stalls when traveling or engine speed drops excessively

Was there any problem before? HST HST
o Dirt in HST pump, motor related equipment pump motor 2 Others
a b c
Inclination stopper solenoid valve (SOLb)

pump and motor?

DA valve
Remedy E E E
No. Diagnosis X X X
Engine stalls when traveling or engine speed drops exces-

1 sively Q Q Q
Machine moves when the direction the lever is at F or R
2 Q
and engine is at Li
WA320-5 20-609
(2)
H-5 The gear is not shifted

a If the speed range switch and the monitor display do not Cause
match, check the electrical wiring. HST HST
a When the travel speed is slow, carry out troubleshooting for motor 2 motor 1 Others
H-2 first. a b c d
Inclination stopper solenoid valve (SOLb)
Clutch solenoid
Clutch
Remedy E E E E
No. Diagnosis X X X X
1 The gear is not shifted Q Q Q Q
20-610 WA320-5
(2)
H-6 The steering wheel does not turn

Did the problem suddenly start? Hydraulic
o Breakage of steering related equipment pump Others
Was there previously any symptom, such as heavy steering? a b c d e
o Internal wear of steering related equipment, defective
Internal defective steering cylinder (Defective piston seal)

Defective hydraulic pump or PTO
seal
Steering pump and switch pump

priate?
Has the safety bar been removed from frame?
Priority valve
Emergency steering valve (*1)

Relief valve
Steering
Obit-roll
Spool
Remedy E E E
No. Diagnosis X X X X X X
1 Steering wheel does not turn in both directions (left and Q Q Q Q Q

right)
In condition in Item 1, movement of work equipment is
2 abnormal Q
In condition in Item 1, movement of work equipment is nor-
3 Q
mal
4 Steering wheel turns only in one direction (left or right) Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q
7 Emergency steering does not function in both directions Q

(left and right)
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is
felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
WA320-5 20-611
(2)
H-7 The steering wheel is heavy

Did the problem suddenly start? Hydraulic
o Breakage of steering related equipment pump Valve Others
Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
The steering pump is defective The hydraulic pump is defective

seal
Clogging of hydraulic oil return filter, defective bypass valve

Internal defective steering cylinder (Defective piston seal)

priate?
Are the serrated parts of the orbit roll and steering column
connected normally?
Priority valve
valve and cylinder?
Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
Is the tire inflation pressure correct?
Check for abnormalities

Measure operating effort of steering wheel and time taken to
turn steering, and check standard judgment value table to
see if there is any abnormality.
Obit-roll internal defect
Clogging of oil cooler

Relief valve
Spool
Remedy E E E E E E E
No. Diagnosis X X X X X X X
A C C
Steering wheel is heavy when turned in both directions (left
1 Q Q Q Q Q
and right)
2 Steering wheel is heavy when turned in one direction (left Q Q
and right)
Steering wheel is heavy particularly when engine is running
3 at low speed Q Q Q Q
Lift arm lifting speed is slow when engine is running at full
4 Q Q
speed
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
20-612 WA320-5
(2)
TESTING AND ADJUSTING H-8, H-8
H-9
H-8 Steering wheel shakes or jerks

Checks before troubleshooting Cause
Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves
Is there any play in the center hinge pin bearing or steering
a b c
cylinder pin or bushing?
Is there any variation in the tire inflation pressure?
Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)
Is the steering wheel play correct?
Check for abnormalities

Operate at a safe place and check how the steering wheel
shakes and under what conditions.
a In cases where the steering wheel is heavy but does not
shake, go to "H-7 The steering wheel is heavy".
Defective cushion valve

Defect inside drbitrol
Remedy E E E
No. Diagnosis X X X
1 Chassis shakes when traveling on rough road surface Q Q Q

Shakes when steering is suddenly turned during operation
2 or travel Q Q Q
3 Chassis shakes when accelerating during travel operations Q Q Q
4 Chassis shakes when engine is started Q
5 Excessive shock when steering wheel is turned back Q
H-9 Machine deviates naturally to one side when traveling

Causes: Defective steering
Defective operation of safety valve
: Oil leakage inside steering cylinder
: Variation in tire inflation pressure
WA320-5 20-613
(2)
H-10 The brake does not work or does not work well
Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Defective seal of accumulator piston, insufficient gas pressure

Has the brake come not to work gradually?
o Wear of lining and disc, defective seal
Metal contact due to complete wear of brake lining in axle

Is the oil level in the hydraulic tank appropriate?
Defective operation of accumulator charge valve

Is the play of brake pedal appropriate?
Oil leak from brake tube and connector, deformation of tube.
Tire air pressure and state of tire tread.
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
Measure the braking force and check referring to the stan-
Defective brake pump (For charge)

Defective brake piston seal in axle
dard value table if the brake does not work practically.
Mixing of air in brake circuit

Defect inside brake valve
Defective slack adjuster
Brake linkage
Remedy E E E E E E E
No. Diagnosis X X X X X X X X X
1 When the brake pedal is stepped on, only a little resistance Q Q Q Q Q

is felt
2 When the brake pedal is stepped on, a strong resistance is Q Q

felt
3 When the brake works, an abnormal noise occurs from the Q Q

axle brake
When the four wheels are jacked up, the axle is placed on a
4 table and the brake is applied at the first forward speed, Q Q Q Q
only a specific wheel rotates
5 An airflow is observed in bleeding air from brake circuit, and Q

the brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
8 The brake pedal leg-power and stroke are normal, but the Q Q Q Q Q Q Q Q Q
brake does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
20-614 WA320-5
(2)
H-11 The brake is not released or is dragged

Has the brake pedal returned completely? a b c d
Is the parking brake released completely?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
Abnormal heat of brake.
Defective brake piston seal in axle

Does the machine travel smoothly inertia on a level ground?
Defective slack adjuster

Remedy E E E E
No. Diagnosis X X X X
1 The brake pedal is released, but the brake is still applied Q Q Q Q
When the brake pedal is released, oil is drained from the air
2 bleeder, the circuit oil pressure drops and the brake is Q Q
released
When the four wheels are jacked up, the axle is placed on a
3 table, the engine is stopped, the parking brake is released Q Q Q
and the tires are rotated by hand but a specific tire hardly
rotates
WA320-5 20-615
(2)
H-12 The lift arm does not rise or lower

Has the lift arm come not to work suddenly? Priority Cut-off HST PPC Work equip-
o Seizure or breakage of each equipment Tank to Pump valve valve pump valve ment valve Cylinder
Did any abnormal noise occur at the time (And where)? a b c d e f g h i j k l m
Was there the phenomenon that the lift arm worked slowly?
Clogging of pump suction port or mixing of much air in oil

o Wear of parts or deformation of spring

Is the oil level in the hydraulic tank appropriate?
Is the stroke of the lift arm control lever appropriate?
Is the engine speed appropriate?
Breakage inside valve body (Lift arm spool)

Defective operation of main relief valve
Damage of lift arm cylinder piston seal

Defective low-pressure relief valve
Defective work equipment pump
Defective HST charge pump
Defective operation of spool

Defective cut-off relief valve
Defective steering pump
Defective unload valve

Defective check valve
Remedy C E E E E E E E E E
No. Diagnosis E X X X X X X X X X X X X
1 The bucket cannot operate and the lift arm cannot rise Q Q Q Q Q Q Q Q Q Q Q
2 The bucket operates but the lift arm cannot rise Q Q
3 The lift arm can rise without load but cannot rise when Q Q Q Q
loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q

When the engine is at full throttle, the steering operation is
6 Q Q
heavy and slow
20-616 WA320-5
(2)
H-13 The lift arm moves slowly or the lift arm rising force is
insufficient
Inspection before diagnosis Cause
Is the stroke of the lift arm control lever appropriate? Tank to Priority Cut-off HST PPC Work equipment
Cylinder
Pump valve valve pump valve valve
Check of Abnormality
Rising force and speed problem are closely related, and this a b c d e f g h i j k
problem occurs as insufficient rising speed at first. Measure
Defective operation or improper adjustment of main relief valve

the lift arm rising speed when the lift arm is loaded and make
sure referring to the criterion table that the speed is abnor-

mal.
Wear or breakage inside valve body (Lift arm spool)

Defective work equipment pump and steering pump
Damage of lift arm cylinder piston seal

Defective low-pressure relief valve

Remedy C E E E E E E E A E
No. Diagnosis E X X X X X X X X X X
1 The bucket tilting force and speed are abnormal, and the lift Q Q Q Q Q Q Q Q
arm rising speed is slow
The bucket tilting force and speed are normal, and the lift
2 arm rising speed is slow Q Q Q
When the oil temperature rises in No. 1, the lift arm speed
3 Q Q
becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
5 Large hydraulic drift of lift arm cylinder Q Q

The relief oil pressure from the relief valve of the work
6 equipment valves is low Q
7 Q
equipment valves is too high
WA320-5 20-617
(2)
H-14 When rising, the lift arm comes to move slowly at specific
height
Deformation of lift arm cylinder in appearance
Cause
Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see "H-13. The lift arm moves slowly or the lift arm rising force is insufficient."
H-15 The lift arm cylinder cannot hold down the bucket
(The bucket rises in the air)
See "H-13. The lift arm moves slowly or the lift arm rising force is insufficient."

Is the stroke of the lift arm control lever appropriate?
Cause
Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
Oil leak from lift arm cylinder piston seal
H-16 Hydraulic drifts of the lift arm occur often

Ask the operator about the following:
Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
Have hydraulic drifts come to occur often gradually? o Wear of parts

Is the lift arm spool at the neutral position? o The spool detent is defective
Diagnosis and Cause

Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective
H-17 The lift arm wobbles during operation

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm control lever in the "HOLD" posi-
tion.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-15. Hydraulic drifts of the lift arm occur often."
2. When the lift arm cylinder cannot lift the machine, see "H-15. The lift arm cylinder cannot hold down the bucket."
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with the normal hydraulic drift and
after the lift arm cylinder operates to full stroke o The cause is vacuum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20-618 WA320-5
(1)
H-18 When the control lever is switched from "HOLD" to

"RAISE," the lift arm falls temporarily
Check of Phenomenon
When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the lift arm falls temporarily due to its own
weight. When the control lever is completely set to "RAISE," the lift arm returns to normal.
Cause
Improper adhesion of lift arm spool check valve of the work equipment valve
WA320-5 20-619
(1)..d
H-19 The bucket does not tilt back

Has the bucket come not to work suddenly o Seizure or
breakage of each equipment Tank to Pump Priority Cut-off HST PPC Work Equip- Cylinder
Valve valve pump Valve ment Valve
Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j k l m
Was there the phenomenon that the bucket worked slowly?
o Wear of parts or deformation of spring
The HST charge pump (which is used as PPC pump, too) is defective
Is the stroke of the bucket control lever appropriate?
The hydraulic pump and the switch pump are defective
Breakage inside valve body (Bucket spool)

The low-pressure relief valve is defective
Defective operation of main relief valve
Damage of bucket cylinder piston seal

The steering pump is defective

The spool is defective

Remedy C E E E E E Defective check valve E E A
No. Diagnosis E X X X X X X X X X X X
1 The lift arm cannot operate and the bucket cannot tilt back Q Q Q Q Q Q Q Q Q Q
2 The bucket can lift the machine but cannot tilt back, or the
lift arm operates but the lift arm cannot tilt back Q Q Q
3 The bucket can tilt back without load but cannot in digging Q Q Q
or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
6 When the engine is at full throttle, the steering operation is Q Q

heavy and slow
20-620 WA320-5
(2)
H-20 The bucket moves slowly or the tilting-back force is

insufficient
Inspection before diagnosis Cause
Is the stroke of the bucket control lever appropriate? Tank to Priority Cut-off HST PPC Work equipment
Cylinder
Seizure of work equipment linkage bushing (Does any Pump valve valve pump valve valve
abnormal noise occur?) a b c d e f g h i j k l
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Make sure in an actual operation that the tilting-back force is
insufficient.
Measure the operating speed of the bucket, and make sure
referring to the criterion value table that the speed is abnor-
mal
Defective operation or improper adjustment of main relief valve

The hydraulic pump and the switch pump are defective
Wear or breakage inside valve body (Bucket spool)

Defective operation of low-pressure relief valve
Damage of bucket cylinder piston seal


Remedy C E E E E E E E A E
No. Diagnosis E X X X X X X X X X X X
The lift arm rising force and speed are abnormal, and the
1 Q Q Q Q Q Q Q Q
bucket tilting force and speed are abnormal
2 The lift arm rising force and speed are normal, and the Q Q Q Q
bucket tilting force and speed are abnormal
When the oil temperature rises in No. 1, the bucket speed
3 becomes worse Q Q
4 The hydraulic pump is causing an abnormal noise Q Q
5 Large hydraulic drift of bucket cylinder Q Q Q
6 The relief oil pressure from the relief valve of the work Q Q Q
equipment valves is low
7 equipment valves is too high Q
WA320-5 20-621
(2)
H-21 The bucket comes to operate slowly in he midst of tilting-

back
Deformation of bucket cylinder in appearance
Cause
Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-20. The bucket moves slowly or the tilting-back force is insufficient."
H-22 The bucket cylinder cannot hold down the bucket

See "H-20. The bucket moves slowly or the tilting-back force is insufficient."

Is the stroke of the bucket control lever appropriate?
Cause
Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
Oil leak from bucket cylinder piston seal
H-23 Hydraulic drifts of the bucket occur often

Ask the operator about the following:
Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
Have hydraulic drifts come to occur often gradually? o Wear of parts

Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is defective
Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
Oil leak in bucket cylinder
Improper adhesion of safety valve (With suction valve) on the bottom side
Improper oil tight of bucket spool
20-622 WA320-5
(1)
H-24 The bucket wobbles during travel with cargo (The work
equipment valve is set to "HOLD")
Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
Defective seal of bucket cylinder piston
Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to diagnoses for
relevant abnormal phenomena.
H-25 When the control lever is switched from "HOLD" to "TILT,"

the bucket falls temporarily
Check of Phenomenon
When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due to its own
weight. When the control lever is completely set to "TILT," the bucket returns to normal.
Cause
Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move
smoothly and heavy
Check of Abnormality Cause
Refer to the criterion value table and check if the lever oper- PPC
ating efforts are large practically. valve
a
Defective operation of relief valve
Remedy C
No. Diagnosis E
1 Becomes heavy in some places during operation regard- Q

less of oil pressure and oil temperature
Becomes heavy overall during operation regardless of oil
2 pressure and oil temperature Q
WA320-5 20-623
(1)..d
H-27 The travel damper does not operate and machine pitches
and bounces
Check the following points with the operator. Cause
Did the machine starts pitching and bouncing suddenly? o Solenoid
Accumulator Controller Sensor
Breakage of related device valve
Did abnormal sound come out when the machine started a b c d
pitching and bouncing? From what part did the abnormal
Gas leakage from accumulator or defective seal

sound come out?
Did the machine starts pitching and bouncing gradually? o
Wear of related device or defective seal
Check before troubleshooting

Check that the hydraulic tank is filled with oil of a proper type
up to a proper level.
Defective travel speed sensor

Malfunction of solenoid valve
Check that the travel damper switch is set properly.
Malfunction of controller
No. Remedy X X X X
Troubleshooting
Travel speed to start operation of travel damper (6 km/h) is
1 changes largely Q Q
2 Travel damper does not work while machine is loaded Q Q

3 Travel damper does not work while machine is empty Q Q
4 Boom lowers more than 30 cm at maximum when travel Q

damper operated while machine is loaded
5 Travel damper does not work at all Q Q Q Q
20-624 WA320-5
(2)
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702

S-1 Starting performance is poor (Starting always takes time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706
S-2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
(1) Engine does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) . . . . . . . . . . . . . . . . 20-709
(3) Exhaust smoke comes out but engine does not start(Fuel is being injected) . . . . . . . . . . . . . . . 20-710
S-3 Engine does not pick up smoothly (Follow-up is poor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
S-4 Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
S-5 Engine does not rotate smoothly (Hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
S-6 Engine lacks output (or lacks power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
S-7 Exhaust smoke is black (Incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
S-8 Oil consumption is excessive (or exhaust smoke is blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
S-9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
S-10 Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
S-11 Oil is in cooling water, or water spurts back, or water level goes down . . . . . . . . . . . . . . . . . . . . . . 20-719
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
S-13 Oil level rises (Water, fuel in oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
S-14 Water temperature becomes too high (Overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
S-15 Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-723
S-16 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
WA320-5 20-701
(1)..
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in B are items that can be
obtained from the user, depending on the users
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from infor-
mation (A) that he has obtained from the user and
the results of (C) that he has obtained from his own Causes
inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
(b) (2) (3)
(a) w
Questions
(A) (b) w
(c) w
(d) Q
(e) Q
(B)
(C)
Check items
i q
shooting
Trouble-
ii q
iii q
20-702 WA320-5
(1)
The basic method of using the troubleshooting chart is as follows.

Items listed for [Questions] and [Check items] that have a relationship
with the Cause items are marked with !, and these, causes that have a
high probability are marked with T.
Check each of [Questions] and [Check items] in turn, and marked the ! Causes
or T in the chart for items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points is the most probable
n)
cause, so start troubleshooting for that item to make final confirmation of
jectio
the causes.
ive in
*1. For [Confirm recent repair history] in the [Questions] Section, ask
the user, and mark the Cause column with # to use as reference
ce ss
renc
zzle
for locating the cause of the failure. However, do not use this
p (ex
ent
n no
terfe
when making calculations to narrow down the causes.
r
elem
e
g
jectio
d
pum
er, in
timin
*2. Use the # in the Cause column as reference for [Degree of use
n
, cyli
aner
(Operated for long period)] in the [Questions] section as refer-
ed in
harg
tion
io n
g
ence. As a rule, do not use it when calculating the points for locat-
n rin
ir cle
t
injec
injec
rboc
iz
ing the causes, but it can be included if necessary to determine
e
pisto
s
a
e d tu
ctive
ged,
oper
the order for troubleshooting.
ged
Worn
Defe
Clog
Clog
Impr
Seiz
*1 Confirm recent repair history
*2 Degree of use of machine Operated for long period EEE
w
WA320-5 20-703
(1)..d
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have
causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and
[Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
Insufficient intake of air Causes
Improper condition of fuel injection
head
ed)
Excessive injection fuel
tion)
r seiz
r and
injec
y
seat
spra
lunge
arge
valve
ssive
ctive
ce
ck, p
boch
eren
(exce
, defe
and
ent
p (ra
n tur
air cle er, interf
valve
nder
e
r
elem
ing
p
ozzle
uffle
c
pum
pum
n
e
leara
n tim
e
li
ed m
g, cy
ct of
betw
aner
tion n
harg
ction
tion
Defe r injectio
lve c
conta
n rin
logg
injec
of air
Legend
rboc
injec
je
a
in
Q : Possible causes (judging from Questions and check items)
c
per v
pisto
ed tu
ctive
ctive
ctive
hed,
w
age
: Most probable causes (judging from Questions and Check items)
ged
ged
ope
t : Possible causes due to length of use (used for a long period)
Impro
Worn
Leak
Defe
Defe
Crus
Clog
Clog
Impr
Seiz
q : Items to confirm the causes.
Confirm recent repair history

Degree of use Operated for long period EEE E
Suddenly became black w Q Q
Color of exhaust gas Gradually became black w Q Q
Questions
Black under light load w

Engine oil must be added more frequently w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Non-specified fuel is being used Q Q
Noise of interference is heard from around turbocharger w
Dust indicator lamp is red w
Blow-by gas excessive w
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
When exhaust manifold is touched immediately after start- w Q
Check items
ing engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment w
Seal on injection pump has come off w
Clanging sound is heard from around cylinder head w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
When turbocharger is rotated by hand, it is found to be heavy q

When air cleaner element is inspected directly, it is found to be clogged q
When compression pressure is measured, it is found to be low q q
Speed does not change when operation of certain cylin-
q
Troubleshooting
ders is stopped
When check is made using delivery method, injection tim- q
ing is found to be incorrect
Injection pump test shows that injection amount is incorrect q
When valve clearance is checked directly, it is found to be q
outside standard value
When muffler is removed, exhaust color returns to normal q
When control rack is pushed, it is found to be heavy, or q
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-704 WA320-5
(1)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of Q and w marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element: wQw
(2) Air leakage between turbocharger
and head QQ
(3) Clogged, seized injection nozzle: Q
(4) Defective contact of valve, valve seat: Q
(5) Worn position ring, cylinder: Q
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked q. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA320-5 20-705
(1)..d
TESTING AND ADJUSTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but engine takes time
to start
Defective electrical system
Insufficient supply of fuel
Insufficient intake of air Causes
Improper selection of fuel
(At ambient temperature of -10C or below, ASTM D975 No. 2 die-
sel fuel is used)
a Battery charging rate
eat
Charging rate
lve s
Ambient 100% 90% 80% 75% 70%
ilter
temperature
e, va
t
u ze f
men
20C 1.28 1.26 1.24 1.23 1.22
ater
raine
r
linde
f valv
0C 1.29 1.27 1.25 1.24 1.23
er ele
p ga
ir he
t
g, c y
s
a ct o
-10C 1.30 1.28 1.26 1.25 1.24
pum
ilter,
ke a
clean
n rin
The specific gravity should exceed the valve for the charging rate
co n t
fuel f
feed
l inta
ir
of 70% in the above table.
pisto
a
ctive
trica
ged
ged
ged
In cold areas the specific gravity must exceed the value for the
Worn
Defe
Clog
Clog
Clog
Elec
charging rate of 75% in the above table.
Degree of use of machine Operated for long period EEE
Gradually became worse w w Q Q Q
Ease of starting
Starts when warm w
Questions
Indicator lamp does not light up w

Replacement of filters has not been carried out according to operation Manual w w w
Non-specified fuel has being used Q Q
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular Q Q
Blow-by gas is excessive w
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When Engine is cranked with starting motor,
w w
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular) Q Q
When fuel filter, strainer are inspected directly, they are found to be clogged q
When feed pump strainer is inspected directly, it is found to be clogged q
Troubleshooting
Heater mount does not become warm q

Is voltage 26 - 30V between alternator terminal B and termi- Yes
nal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Remedy
Clean
Clean
Clean
* Use a test stand
20-706 WA320-5
(1)
q
Replace D e fe
ctive
q
w w
Replace Defe
ctive
regu
lator
q
w
w
Replace alter
E
D e fe
ctive n ator
WA320-5
q
w
w
Q
Q
Replace D e fe or de
t erior
ctive ated
w
*Adjust D e fe injec
t io batte
ctive n no
zzle ry
q
w
w
Q
Q
Replace D e fe injec
tion t
ctive
in im
q
Q w
Correct D e fe jectio ing
ctive n pu
q
w Q
Q
Clean Clog Leak
a
mp (
rack
ged ge, c
w
Replace D e fe air b
r e a th e
loggin , plunge
g r stu
ctive r hole , air in fu ck)
w
Replace Defe feed
p in e l pipin
Causes
ctive
boos
ump fuel t
ank g
t co m
pens
ator
ca n c
el
20-707
(1)..d
S-1
S-2 Engine does not start

(1) Engine does not turn
General causes why engine does not turn

Causes
Internal parts of engine seized
a If internal parts of the engine are seized, carry
out troubleshooting for "Engine stops during
operations".
Defective electrical system
witch
ion
n e ct
Failure in power train
ircuit
y rela r safety s
ry
batte
l con
ng c
oid
a
rated
witch
starti
in
o to r
solen
y
term
ctive fety relay
ing m
terio
ing s
g of
l cu t
ttery
ar
atter
or de
g ge
wirin
start
start
e
a
sa
u
b
b
f
en rin
ctive
ctive
ctive
ctive
ctive
ctive
ctive
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions
Degree of use of machine Operated for long period E E

Condition of horn when start- Horn sounds w Q Q
ing switch is turned ON Horn volume is low w
Speed of rotation is low w
When starting switch is Makes grating noise w w
turned to START, pinion
moves out, but Soon disengages pinion again w
Makes rattling noise and does not turn Q Q Q
When starting switch is turned to START, pinion does not move w Q Q
out
Check items
When starting switch is turned to ON, there is no clicking sound Q w

Battery terminal is loose w
When starting switch is turned ON, linkage is not actuated w
Troubleshooting of defective wiring in starting circuit
When battery is checked, battery electrolyte is found to be low w
Specific gravity of electrolyte, voltage of battery is low q

For the following conditions 1) - 5), turn the starting switch OFF,
connect the cord, and carry out troubleshooting
q
1) When terminal B and terminal C of starting switch are con-
nected, engine starts
2) When terminal B and terminal C of starting motor are con- q
nected, engine starts
Troubleshooting
3) When terminal B and terminal C of starting safety relay are

q
connected, engine starts
4) When terminal of safety switch and terminal B of starting
q
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and termi-
q
nal E
When ring gear is inspected directly, tooth surface is found to be
q
chipped
Cannot be moved by hand even when linkage of fuel cut solenoid
q
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy -
20-708 WA320-5
(1)
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke

Causes
comes out
Supply of fuel impossible
)
eized
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
ger s
ke y
a Standards for use of fuel
ank
n
haft,
, plu
fuel t
AMBIENT TEMPERATURE
strain iston
KIND OF
rive s
n fee mp (rack
FLUID -22 -4 14 32 50 68 86 104 122F
iner
le in
p
g
r
oid
-30 -20 -10 0 10 20 30 40 50C
pipin
p
e
mp d
er ho
olen
tr
u
leakin tank
s
u
p
fu e l
p
n pu
um p
d
ASTM D975 No. 2
cu t s
u se d
reath
n
ilter,
in
jectio
g
Diesel fuel
jectio
p
fuel
uel f
fu e l
feed
air b
fu e l
r o ke
(*1)
in
t
en, in
n
f
ctive
ctive
oper
fficie
ed b
ged
ged
ged
ged
Defe
Defe
Clog
Clog
Clog
Clog
Brok
Impr
Seiz
I n su
Questions
Degree of use of machine Operated for long period EE E

Exhaust smoke suddenly stops coming out (when starting again) w w w
Replacement of filters has not been carried out according to Oper- w w
ation Manual
Fuel tank is found to be empty w
There is leakage from fuel piping w
Mud is stuck to fuel tank cap w
When starting switch is turned ON, linkage is not actuated w
When fuel filter is drained, fuel does not come out w
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is w Q Q Q
Check items
loosened
2) No fuel spurts out even when injection pump piping sleeve w w w
nut is loosened
Rust and water are found when fuel tank is drained Q Q Q
Inspect injection pump directly q
When control rack is pushed, it is found to be heavy, or does not
return q
Troubleshooting
Inspect feed pump directly q

When fuel filter, strainer are inspected directly, they are found to
q q
be clogged
When feed pump strainer is inspected directly, it is found to be
clogged q
When fuel cap is inspected directly, it is found to be clogged q

Cannot be moved by hand even when linkage of fuel cut solenoid
q
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA320-5 20-709
(1)..d
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
General causes why exhaust smoke comes out but

Causes
engine not start
stuck c.)
lack of rotating force due to defective electrical sys-
er et
tem
)
er lev
k ca p
y
spra
, rock
nger
Insufficient intake of air
stem
l tan
r
heate
ctive
, plu
Improper selection of fuel and oil
valve
in fue
e l sy
atter
r
(rack
reath zle, defe

e
tem (
ir
n
t
er ele er
men
a
li
u
ed b
er
in
f
a ke
r
r hole
e sys
linde
ump
air in
strain
ra
iorat
t
al int
oz
s
p
n valv
g , cy
e
um p
ion n
ing,
se d
tion
lter,
r
clean
Defe e electric
Leak e or dete
ed p
clogg
n rin
fu e l u
broke
injec
fi
t
injec
air b
fuel
ir
fe
pisto
a
ctive
age,
tive,
oper
ged
ged
ged
ged
ged
ctiv
ctiv
Worn
Defec
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Impr
Degree of use of machine Operated for long period EEE E
Suddenly failed to start w w
When engine is cranked, abnormal noise is heard from around w
cylinder head
Questions

Replacement of filters has not been carried out according to Oper- w w w
ation Manual
Rust and water are found when fuel tank is drained w w
Indicator lamp does not light up w
Starting motor cranks engine slowly w
Mud is stuck to fuel tank cap Q
When fuel lever is placed at FULL position, it does not contact stopper Q
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when fuel filter air bleed plug is w
loosened
2) No fuel comes out even when fuel filter air bleed plug is w w Q
loosened
When exhaust manifold is touched immediately after starting w
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out w
Remove head cover and check directly q
When control rack is pushed, it is found to be heavy, or does not q
return
When compression pressure is measured, it is found to be low q
When fuel filter, strainer are inspected directly, they are found to q q
Troubleshooting
be clogged
When feed pump strainer is inspected directly, it is found to be q
clogged
Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
When feed pump is operated, there is no response, or operation q
is too heavy
Speed does not change when operation of certain cylinders is stopped q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
Clean
Clean
Clean
Clean
Clean
20-710 WA320-5
(1)
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly

Causes
ca p
Improper fuel used
pray
eat
lve s
l pipin uel tank
tive s
d va
e fe c
er
nger
a ce
e an
n
ent
leakin er hole in
g
aine
li
zle, d
valve er, interf

er
p plu
r
reath nce
elem
f valv
train
d
p str
ed tu ring, cylin
a
ed in ction noz
pum
g fu e
clear
er, s
aner
a ct o
pum
rg
ocha
ction
t
air cle
il
co n t
f
feed
air b
fuel
inje
n
b
je
pisto
r
ctive
ged,
oper
ged
ged
ged
ged
ged
Worn
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Impr
Seiz
Seiz
Degree of use of machine Operated for long period EEE E E
ation Manual
Questions
Non-specified fuel is being used w w w w

Engine pick-up suddenly became poor Q w Q Q
Rust and water are found when oil is drained w w
Blue under light load Q w
Color of exhaust gas
Black w w w Q
Check items

High idling speed under no load is normal, but speed suddenly
drops when load is applied w w Q
There is hunting from engine (rotation is irregular) Q w Q Q

When exhaust manifold is touched immediately after starting w Q
When air cleaner element is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
clogged
Troubleshooting
Speed does not change when operation of certain cylinders is q

stopped
When control rack is pushed, it is found to be heavy, or does not return q
When valve clearance is checked directly, it is found to be outside q
standard value
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean
WA320-5 20-711
(1)..d
S-4 Engine stops during operations
General causes why engine stop during operations

Causes
Seized parts inside engine
tc.)
ver, e
c k)
Overheating
r st u
ker le
a If there is overheating and the engine stops,
lunge
od
carry out troubleshooting for overheating.
nk
e, roc
ting r
e l ta
ring
Failure in power train
ke y
t
m en
ck, p
(valv
pisto
t bea
in fu
nnec
a If the engine stops because of a failure in the
haft,
quip
p (ra
r
reath piping
aine
stem
iner
leakin d pump
power train, carry out troubleshooting for the
le
sh a f
n, c o
train
s
e
er ho
pum
e
p st r
a
y
chassis.
tank
p driv
s
r
r
l
rank
r train
t
g fue
ia
pisto
gear
s
valve
fe e
auxil
pum
ction
filter,
uel in
Broke seized c
pum
powe
eized
ized
eized
amic
je
ump
eed
air b
fuel
f
in
e l
t
e
n dyn
f
en fu
en, s
en, s
en, s
ctive
re in
ged,
en p
fficie
ged
ged
ged
en,
Failu
Defe
Clog
Clog
Clog
Clog
Brok
Brok
Brok
Brok
Brok
Brok
I n su
Degree of use of machine Operated for long period EE
Abnormal noise was heard and w w w w w w Q Q w
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q
Replacement of filters has not been carried out according to Oper- w w
ation Manual
Non-specified fuel is being used Q Q Q Q
Fuel level lamp lights up w
When feed pump is operated, operation is too light or too heavy Q Q w
w
Check items
Engine rotates, but stops when power train is operated

Does not turn at all w w
When it is attempted to turn Turns in opposite direction w
by hand using barring tool Moves amount of backlash w w
Shaft does not turn w
Rust and water are found when tank is drained w w
Troubleshooting of chassis
Metal particles are found when oil is drained w w Q Q
Remove oil pan and inspect directly q q

Remove head cover and inspect directly q
When gear train is inspected, it does not turn q
Troubleshooting
Rotates when pump auxiliary equipment is removed q

When fuel filter, strainer are inspected directly, they are found to
q
be clogged
When feed pump strainer is inspected directly, it is found to be
q
clogged
Inspect feed pump directly q
When control rack is pushed, it is found to be heavy, or does not
q
return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy -
Clean
Clean
Clean
Add
20-712 WA320-5
(1)
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly

Causes
Air in fuel system
um p
ozzle
Defective governor mechanism
eed p nd feed p
and n
Defective electric governor mechanism
(engine with electric governor)
ump
a If hunting stops when electric governor rod is dis-
ank
l t ank
ficien eed is too trol rack
connected, carry out troubleshooting for the
fuel t
r
erno
rnor
n fue
chassis.
een f
strain r
v
le in
adjus n of gove
e
low
o
er
twee
co n
strain
t of g
betw
er ho
nk
n of
uit be
tmen
l in ta
um p
ircuit
reath
ilter,
o
io
Defe e operati
c
a t
ir
p
ir in c
c
t fue
oper
fuel f
feed
air b
sp
ir in
idling
ged a
ged a
ctive
ctive
ged
ged
ged
ctiv
Insuf
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Low
Degree of use of machine Operated for long period EE
Occurs at a certain speed range w w w Q
Occurs at low idling Q w Q Q Q Q
Questions
Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Oper-
ation Manual w w

Rust and water are found when tank is drained Q Q
Leakage from fuel piping w w
When feed pump is operated,
w
Check items
1) No response, light, return is quick

2) No response, light, return is normal w
Engine speed sometimes rises too far w w
Engine is sometimes difficult to stop w w
Seal on injection pump has come off w w
When governor level is moved it is found to be stiff q q
When injection pump is tested, governor is found to be improperly q
adjusted
Troubleshooting

return
When fuel tank cap is inspected directly, it is found to be clogged q q
clogged
be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
WA320-5 20-713
(1)..d
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output

Causes
t
m en
Improper fuel used
ray
tive a eat
ragm
djust
lve s
e sp
(if non-specified fuel is used, output drops)
ank
iaph
Lack of output due to overtaking
fectiv
n ce
t
d va
e l
tor d
fu
m
r
rfere
a If there is overheating and lack of output, carry
aking ge, defec

e an
hrag
ent
e
g
r
in
ing
aine
jectio nozzle, d
n
ensa
er
out troubleshooting for overheating.
p plu
r
le
e
e
elem
linde
el pip
f valv
strain
c
t
diap
o
er, in
aran
p st r
h
omp
pum
ther
g , cy
linka
aner
fu
a ct o
g a te
le
pum
harg
lter,
ost c
brea
c
io
n
n rin
air cle
valve
west
fi
lever
t
co n t
rboc
c
feed
fuel
je
o
ir
le
b
pisto
in
a
ed tu
ctive
ctive
ctive
ed in
ged,
oper
fu e l
ged
ged
ged
ged
ged
Worn
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Bent
Impr
Seiz
Seiz
Degree of use of machine Operated for long period E EEE E
Suddenly w w w
Questions
Power was lost

Gradually Q Q Q Q Q Q
ation Manual
Non-specified fuel is being used w w w w
Black w w
Blow-by gas excessive w Q
Check items
Engine pickup is poor and combustion is irregular w Q Q Q

High idling speed under no load is normal, but speed suddenly w w Q
drops when load is applied
There is hunting from engines (rotation is irregular) Q Q Q Q
High idling speed of engine is low Q w
Leakage from fuel piping w
clogged
be clogged
Troubleshooting

clogged
stopped
return
standard value
When level is placed at FULL position, it does not contact stopper q
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 WA320-5
(1)
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black

Causes
head
)
eized
n)
Excessive injection of fuel
jectio
r and
y
, plun at
ger s
spra
se
ive in
arge
valve
ctive
e
cess
renc
b o ch
(rack
d e fe
and
x
ent
terfe
n tu r
(
valve
der
n ce
r
zzle,
elem
g
ump
ump
uffle
er, in
timin
n
twee
leara
li
n no
ion p
tion p
ed m
g , cy
ct of
aner
harg
tion
e
c
b
jectio
conta
t
n rin
clogg
ir cle
valve
injec
injec
injec
of air
rboc
pisto
in
a
e d tu
ctive
ctive
ctive
hed,
oper
oper
age
ged
ged
Worn
Leak
Crus
Defe
Defe
Defe
Clog
Clog
Impr
Impr
Confirm recent repair history Seiz
Degree of use of machine Operated for long period EEE E
Suddenly became black w Q Q
Color of exhaust gas Gradually became black w Q Q
Questions

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Engine pickup is poor and combustion is irregular Q w Q Q Q Q
Check items

Timing lock on fuel injection pump does not match w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
clogged
Speed does not change when operation of certain cylinders is
Troubleshooting
q
stopped
When check is made using delivery method, injection timing is q
found to be incorrect
standard value
When muffler is removed, exhaust color returns to normal q
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Remedy
Clean
WA320-5 20-715
(1)..d
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 min-

Causes
utes continuously. (Both low and high idling)
General causes why oil consumption is excessive
rger
Abnormal combustion of oil
ocha
)
gine
External leakage of oil
Turb
ss e n
l
d
Wear of lubrication system
n se a
r hea
ce
hose
stem
su r f a
r
er le
coole
roke
linde
y
r (lin
ther
se a l
s
e), b
g
r oil
il coo pan or cy
take
lu
brea
linde
d
nd
ain p
seal,
o
ing
, guid
m in
e
wer e
e r
il pip
e
r
g , cy
t
o
oil dr
oil fil
in
ring
rear
in fro
(stem
th e r
Worn al at turb
r
oil
at blo
le
om o
n rin
iston
rom
from
m
brea
ken
d
o
valve
e
pisto
seal
f
f
, bro
su ck
en p
en o
age
age
age
age
ged
se
Worn
Worn
Worn
Worn
Leak
Leak
Leak
Leak
Clog
Brok
Brok
Dust
Degree of use of machine Operated for long period E EE E
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Questions
Engine oil becomes contaminated quickly Q w Q

Exhaust smoke is blue under light load w w
Excessive w w Q Q
Amount of blow-by gas
None w
Area around engine is dirty with oil w w w w
There is oil in engine cooling water w
When exhaust pipe is removed, inside is found to be dirty with oil w Q
Check items
When turbocharger air supply pipe is removed, inside is found to w

be dirty with oil
Oil level in clutch or TOROFLOW transmission damper chamber w
rises
Clamps for intake system are loose w
When breather element is inspected, it is found to be clogged with q
dirty oil
Troubleshooting
There is external leakage of oil from engine q q q q

Pressure-tightness test of oil cooler shows there is leakage q
Excessive play of turbocharger shaft q q
Inspect rear seal directly q
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty with q
oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
20-716 WA320-5
(1)
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

Causes
Entry of exhaust gas due to internal wear
Clogging of lubrication passage
Improper fuel
nd
Improper oil used
e
rbine
Operation under excessive load
tube
se
e r tu
reath er
drain
er ho
r lin
harg
er oil
linde
rboc
lack
id
e gu
g , cy
er , b
harg
e is b
at tu
turbo r
le
, valv
er
il coo
eath
c
n rin
oil filt
seal
mok
valve
r
pisto
b
u st s
ctive
ged
ged
ged
ged
Worn
Worn
Exha
D e fe
Clog
Clog
Clog
Clog
Degree of use of machine Operated for long period E E E
Questions

Non-specified fuel is being used Q
Black w
Excessive w Q Q Q
Carry out troubleshooting for "Exhaust smoke is black".

Amount of blow-by gas
Check items
None w
When oil filter is inspected, metal particles are found Q w Q
When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w

When breather element is inspected directly, hose is broken or is q
Troubleshooting
found to be clogged with dirty oil

When oil filter is inspected directly, it is found to be clogged q
When oil cooler is inspected directly, it is found to be clogged q
Turbocharger oil drain tube is clogged q
Excessive play of turbocharger shaft q
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Remedy -
Clean
Clean
Clean
WA320-5 20-717
(1)..d
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

Causes
Leakage of fuel
n)
Excessive injection of fuel
jectio
ka g e
n)
al ins ead cove el filter
pisto
ive in
rol lin
mp (
u
ing, f
r
ce ss
nger
cont
d pu
el pip
y
g
sp r a
p ( ex
p plu
timin
fuel
e fee
m fu
eh
nt of
lder
pum
m
n
id
u
jectio
insid
tion p
e fro
le ho
st m e
tion
fuel in
a ka g
l
oil se
e
nozz
injec
injec
adju
o f fu
le
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
D e fe
D e fe
D e fe
D e fe
D e fe
Defe
Exte
More than for other machines of
Questions
w Q
Condition of fuel same model
consumption Gradually increased Q Q
Suddenly increased Q Q
Black w Q Q Q
Exhaust smoke color
White Q
There is irregular combustion w
Check items

Match mark on injection pump is misaligned w
There is external leakage of fuel from engine w
Engine oil level rises and smells of diesel fuel Q w w
Engine low idling and high idling speeds are high Q w
Injection pump measurement shows that injection amount is q
excessive
stopped
Troubleshooting

return
When check is made using delivery method, injection timing is q
found to be incorrect
Remove feed cover and inspect directly q
When engine speed is measured, low and high idling speeds are q
found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 WA320-5
(1)
S-11 Oil is in cooling water, or water spurts back,

or water level goes down
General causes why oil is in cooling water

Causes
Internal leakage in lubrication system
Internal leakage in cooling system
oil co gasket
ck
-ring
r blo
ler
ad
o
d, he
re, O
linde
ting
in cy
r hea
ler co
by pit
train
linde
racks
il coo
ower
se d
e n cy
s cau
nal c
en o
en p
Hole
Brok
Brok
Brok
Inter
Questions
Degree of use of machine Operated for long period E E

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as cooling water Q Q
Engine oil level has risen, oil is cloudy white w Q Q
Check items
Excessive air bubbles inside radiator spurts back w

Hydraulic oil, transmission oil is cloudy white w
When hydraulic oil transmission oil is drained, water is found w
Pressure-tightness test of oil cooler shows there is leakage q q

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage q

Remove oil pan and inspect directly q q
Replace
Replace
Replace
Replace
Replace
Remedy
WA320-5 20-719
(1)..d
S-12 Oil pressure caution lamp lights up

(Drop in oil pressure)
General causes why oil pressure lamp lights up

Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper oil used (improper viscosity) Causes
Deterioration of oil due to overheating
a Standards for engine oil selection
Selection of SAE No. according to
Type of oil ambient temperature
-30 -20 -10 0 10 20 30 40 50C
sens ing
ip
n
SAE0W-30
or
oil pa
tion p ide oil pa
ulic p
g
razin
SAE5W-40
n so r
e
r valv
yd r a
side
ipe b
sure
strain rnal
e
SAE10W
an
e ins
f valv
ve l s
ed h
er in
mp
Defe e regulato
Engine oil
Defe e oil pres

p
ing, jo
er
il
oil pu
il
SAE10W-30
l in o
oil pip
rush
oil le
o
relie
oil filt
in
c
SAE 15W-40 bear
r, fue
c
of oil
u
ctive
ctive
ctive
en s
ing,
ged
ged
ged
ctiv
ctiv
Worn
W a te
SAE 30
Leak
L a ck
Defe
Defe
Defe
Clog
Clog
Clog
Brok
Questions
Replacement of filters has not been carried out according to Oper- w

ation Manual
Caution lamp lights up w Q
Lights up at low idling w Q
Condition when oil pressure Lights up at low, high idling w w w w Q Q Q
lamp lights up Lights up on slopes w
Sometimes lights up w w Q Q
Check items
There is crushing, leakage from hydraulic piping (external) w

Oil level sensor lamp lights up w w
When oil level in oil pan is inspected, it is found to be low w
Metal particles are found when oil is drained w
Metal particles are stuck to oil filter element w Q
Oil is cloudy white or smells of diesel oil w
When oil filter is inspected, it is found to be clogged q q

Carry out troubleshooting for
Remove oil pan and inspect directly q q q

Troubleshooting
Oil pump rotation is heavy, there is play q

There is catching of relief valve or regulator valve, spring or valve q q
"Oil level rises".
guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out q
When oil pressure is measured, it is found to be within standard q
valve
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
-
Add
20-720 WA320-5
(1)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trouble-

Causes
shooting for "Oil is in cooling water".
General causes why oil level rises
Water in oil (milky white)
r
cove
Fuel in oil (diluted, and smells of diesel fuel)
al
head
nt se
Entry of oil from other component
p
et
pum
ipme
ide in g inside
ce
gask
surfa
eve
ction
le ho O-ring
y equ
lock
head
er sle
pipin
seal
je
der b
xiliar
re ,
, dam er head,
g
ld
rear
stat
rom
in
ler co
p au
t
cylin
it
Defe e part ins
o
p
fuel f
aged
m
y
nozz
pum
il coo
de b
r
lind
side
h e
f
t
o
en cy
s ma
ctive
ctive
ctive
ks in
en o
age
ctiv
Worn
Leak
Defe
Defe
Defe
Crac
Brok
Brok
Hole
Questions
Degree of use of machine Operated for long period E EE E

There is oil in radiator cooling water w Q Q Q Q
Fuel must be added more frequently w w w
Exhaust smoke is white w Q Q
When engine is first started, drops of water come from muffler w
Leave radiator cap open. When engine is run at idling, an abnor- w Q
mal number of bubbles appear, or water spurts back
Check items
Oil level goes down in clutch, TORQFLOW transmission, or w

damper chamber
Oil level goes down in hydraulic tank w
Engine oil smells of diesel fuel w w w
Water temperature is low w
Pressure-tightness test of oil cooler shows there is leakage q
Pressure-tightness test of cylinder head shows there is leakage q
Troubleshooting
Inspect rear seal directly q

When pump auxiliary equipment is removed, seal is found to be q
damaged
Remove injection pump and inspect directly q
Defective contact with thermostat seal valve q
Remove oil pan and check directly q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA320-5 20-721
(1)..d
S-14 Water temperature becomes too high

(Overheating)
General causes why water temperature becomes too

Causes
high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Defective cooling circulation system
e
ratur
Rise in oil temperature in power train
)
open
uge
t
aske
a Carry out troubleshooting for chassis.
mpe
il coo pulley
e ga
s not
r fins
ad g
oil te
ratur
fan
ler
(doe
diato
d, he
valve
erter
wo rn
e
e
ing
ater
e mp
ostat
r
e d ra
r hea
o
crush p
conv
sure
y pitt
tor c
en o
pum
ling w
,
Lack e water t
g
therm
lippin
linde
pres
radia
brok
de b
que
ater
o
of c o
in tor
en cy
belt s
s ma
en w
ctive
ctive
ged,
ged,
ged
ctiv
De fe
De fe
De fe
B ro k
B ro k
Clog
Clog
Clog
Hole
Rise
Fan
Degree of use of machine Operated for long period EE EE
Suddenly overheated w Q Q
Questions
Condition of overheating
Always tends to overheat w w Q Q
Rise quickly w Q
Water temperature gauge
Does not go down from red range w
Radiator water level sensor lights up w
Fan belt whines under sudden load w
Cloudy white oil is floating on cooling water w
Cooling water flows out from overflow hose w
Excessive air bubbles inside radiator, water spurts back w
Engine oil level has risen, oil is cloudy white Q w
Check items
There is play when fan pulley is rotated w

Radiator shroud, inside of underguard are clogged with dirt or mud w w
When light bulb is held behind radiator, no light passes through w
Water is leaking because of cracks in hose or loose clamps w
When belt tension is inspected, it is found to be loose w
Power train oil temperature enters red range faster than engine w
coolant temperature
Temperature difference between top and bottom radiator tanks is q

excessive
Carry out troubleshooting for chassis.
Temperature difference between top and bottom radiator tanks is q

slight
Troubleshooting
When water filler port is inspected, core is found to be clogged q

When function test is carried out on thermostat, it does not open q
When water temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When measurement is made with radiator cap tester, set pressure q
is found to be low
Remove oil pan and inspect directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy -
Add
20-722 WA320-5
(3)
(1)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external

Causes
noise.
.)
head
ine)
ition)
General causes why abnormal noise is made
er, etc
s eng
)
eized
Abnormality due to defective parts
f pos
tion)
nder
er lev
er les
Abnormal combustion
d cyli
injec
out o
ger s
m (va rance
, rock
Air sucked in from intake system
r, inte ylinder (lin
er an
sive
, plun
oard
e
a
e
renc
nce
e cle
lv
ozzle
f a n b p ( e xce s
charg
ing b
(rack
rfere
terfe
h
f valv
ing, c
cklas
n
ide m een turbo

(divid
syste
n
in
um p
shing
io
um
ton r
ent o
lt
a
c t
b
valve
d inje
tion p
p
uffler
arge
of pis
train
d bu
tion
tw
justm
air be
b o ch
amic
seize
injec
injec
fan,
seize
gear
wear
a d
n dyn
f
r
rmed
ct ins
age o
e d tu
ctive
ctive
ctive
ssive
ged,
oper
ing,
Broke
Defe
Defe
Defo
Defe
Defe
Clog
Miss
Im p r
Ex c e
Leak
Seiz
Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Black w Q Q
Metal particles found in oil filter w w
Check items
Engine pickup is poor and combustion is abnormal w

Abnormal noise is loud when accelerating engine Q Q Q Q Q Q
Clanging sound is heard from around cylinder head w w
Leakage of air between turbocharger and cylinder head, loose w
clamp
Vibrating noise is heard from around muffler w
Remove gear cover and inspect directly q q
Troubleshooting
stopped
return
Fan is deformed, belt is loose q
When valve clearance is checked, it is found to be outside q
standard value
Remove cylinder head cover and inspect directly q
When muffler is removed, abnormal noise disappears q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA320-5 20-723
(1)..d
S-16 Vibration is excessive
a If there are abnormal noise together with the vibra-

Causes
tion, carry out troubleshooting also for "Abnormal
ck)
noise is made".
)
ction
tc. stu
General causes why vibration is excessive
ion
l inje
ver, e
ligne
cu sh
Defective parts (abnormal wear, breakage)
r)
e fu e
ker le
m pe
misa
Improper combustion
ke n
aring
e, roc
essiv
a
Abnormal combustion
, bro
aft (d
a in
(valv
in be
( e xc
t
bolts
sh
u t sh
e r
ackla
w
m
, ma
um p
syste
o
nting
outp
d p
ain b
g rod
tion p
e an
alve
ing
mou
side
mic v
r
bush
ectin
t
ngin
injec
r
art in
gine
e a
dyna
e
co n n
g
ca m
ctive
er of
e en
oper
en p
ctive
Worn
Worn
Loos
Defe
Cent
Br ok
Im p r
Defe
Degree of use of machine Operated for long period EEE
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idling 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
Remove oil pan and inspect directly q
Remove side cover and inspect directly q
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion q

Inspect inside of output shaft (damper) directly q
When face runout and radial runout are inspected, they are found q
to be incorrect
Remove front cover and inspect directly q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-724 WA320-5
(1)

Wa320 5

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TROUBLESHOOTING OF HST CONTROLLER

SYSTEM (HST MODE)

Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302

(Codes related to monitor)

(Codes related to HST controller)

Defective fuse/fusible link

Defective engine speed sensor

Defective HST motor 2 solenoid

Defective HST motor 1 solenoid

q Defective clutch solenoid

Lowering of engine oil pressure

Defective engine oil pressure sensor

Lowering of engine oil level

Defective engine oil level sensor

Defective boom angle sensor

Defective boom pressure sensor (bottom side)

Defective boom pressure sensor (head side)

Defective subtotal switch

Defective cancel switch

Defective alarm buzzer

Disconnection in wiring harness

Grounding fault in wiring harness

Short circuit with power source in wiring harness

BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM

Category Fuse No. Fuse capacity Power supply destination

Switch power source 11 10A Back lamp, stop lamp

INFORMATION CONTAINED IN TROUBULESHOOTING TABLE

Related Information related to troubleshooting or error that occurred.

Causes Standard Value in Normal State and Remarks on Troubleshooting

<Data to fill in>

<Condition when wiring harness is defective>

Related circuit diagram

Phenomena code table

Failure Code [989F00] (HST motor protection caution (00))

Failure Code [DHH1KX] (HST oil pressure sensor input signal

Causes Standard Value in Normal State and Remarks on Troubleshooting

Related circuit diagram

Failure Code [DLE2LC] (Engine revolution sensor revolution

Effect on Travels but drive power is low

Causes Standard Value in Normal State and Remarks on Troubleshooting

Related circuit diagram

Failure Code [DW26KZ] (Motor 2 solenoid system discontinuity or

Effect on Travel speed does not increase.

Causes Standard Value in Normal State and Remarks on Troubleshooting

1) Turn starting switch OFF. 2) Disconnect connector L41. 3) Insert T-adapter.

Related circuit diagram

Failure Code [DX19KZ] (Motor 1 solenoid system discontinuity or

Effect on Travels but drive power is low

Causes Standard Value in Normal State and Remarks on Troubleshooting

Causes Standard Value in Normal State and Remarks on Troubleshooting

Turn travel speed selector

Related circuit diagram

Failure Code [DX20KZ] (Clutch solenoid system discontinuity or

Effect on Travel speed does not switch.

Causes Standard Value in Normal State and Remarks on Troubleshooting

Causes Standard Value in Normal State and Remarks on Troubleshooting

Related circuit diagram

Troubleshooting Code [HST-1] (Defective HST controller power

Effect on Travels but drive power is low

Causes Standard Value in Normal State and Remarks on Troubleshooting

Does condition become normal The condition Relay (L102) is normal

Causes Standard Value in Normal State and Remarks on Troubleshooting

a In the above case, the all fuses are blown.