Beruflich Dokumente
Kultur Dokumente
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
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
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
q
Defective alternator
q
Clogging of air cleaner
Possible causes
q
Defective air cleaner clogging sensor
BEFORE TROUBLESHOOTING CODE DISPLAY
q
q
WA320-5
q
Overheating of engine coolant
Defective engine coolant temperature
q
q
(high temperature) sensor
WA320-5
Defective engine coolant temperature
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
TESTING AND ADJUSTING
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
q
q
q
q
q
q
Defective relay
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
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
(2)
BEFORE TROUBLESHOOTING CODE DISPLAY
20-303
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
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).
20-304 WA320-5
(2)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
Effect on Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.
WA320-5 20-305
(1)..d
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
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.
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]
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]
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 connectors L41 and T11. 3) Connect T-
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
Wiring harness between L41 Voltage between L41 (Female)
(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.
4) Connect connector. 5) Turn starting switch ON
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]
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.
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 Operates the HST safety relay to output error codes DX19KZ and DX20KZ.
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.
4) Connect connector. 5) Turn starting switch ON
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
1) Turn starting switch OFF. 2) Disconnect connector L42. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON
4 Defective HST controller
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]
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.
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 Operates the HST safety relay to output error codes DX19KZ and DX20KZ.
Related
Information
20-312 WA320-5
(2)
TESTING AND ADJUSTING FAILURE CODE [DW26KZ]
TJW02989
WA320-5 20-313
(2)
TESTING AND ADJUSTING FAILURE CODE [DX19KZ]
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.
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 Operates the HST safety relay to output error codes DX20KZ.
1 Defective motor 1 solenoid Between T06 (Female) (1) and (2) Resistance 15 - 35z
Between T06 (Female) (1), (2) and chassis 1Mz and
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)
3 ity (Disconnection or defec-
tive contact) Wiring harness between L111 (Female) (3) and
Resistance 1z and below
chassis ground
Wiring harness between L111 (Female) (2) and
L23 (Female) (15) Resistance 1z and below
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
Wiring harness between T06 Resistance between T06
4 Wiring harness ground fault (Female) (2) and L111 (Female) (Female) (2), L111 (Female) (6) 1Mz and
above
(6) and chassis ground
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)
TESTING AND ADJUSTING FAILURE CODE [DX19KZ]
WA320-5 20-315
(2)
TESTING AND ADJUSTING FAILURE CODE [DX20KZ]
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.
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 Operates the HST safety relay to output error codes DX19KZ and DX20KZ.
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
Between T05 (Female) (1), (2) and chassis 1Mz and
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, T05 and fuse
Causes and FS1 (12). 3) Connect T-adapter
Standard
Wiring harness between T05 (Female) (1) and
Values L41 (Female) (14) Resistance 1z and below
Wiring harness between T05 (Female) (2) and Resistance 1z and below
Wiring harness discontinu- L111 (Female) (6)
3 ity (Disconnection or defec-
tive contact) Wiring harness between L111 (Female) (3) and
Resistance 1z and below
chassis ground
Wiring harness between L111 (Female) (2) and
L23 (Female) (15) Resistance 1z and below
Wiring harness between fuse FS1 (12) and L111 Resistance 1z and below
(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
Wiring harness between T05 Resistance between T05
1Mz and
(Female) (1) and L41 (Female) (Female) (1), L41 (Female) (14) above
(14) and chassis ground
4 Wiring harness ground fault Wiring harness between T05 Resistance between T05
1Mz and
(Female) (2) and L111 (Female) (Female) (2), L111 (Female) (6) above
(6) and chassis ground
Wiring harness between fuse Resistance between fuse FS1
1Mz and
FS1 (12) and L111 (Female) (12), L111 (Female) (1) and above
(1) * chassis ground
In the above case of marked mark (*), the fuse is blown.
20-316 WA320-5
(2)
TESTING AND ADJUSTING FAILURE CODE [DX20KZ]
WA320-5 20-317
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-1]
Related
Information
Wiring harness between L102 (Female) (2) and Resistance 1z and below
chassis ground
Wiring harness between L41 (Female) (16) and
Resistance 1z and below
chassis ground
1) Turn starting switch OFF. 2) Interchange relay (L102) with normal relay. 3) Turn
starting switch ON. 4) Operate FNR switch
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.
4) Applies impressed voltage between L102 (Male) (1) - (2)
Applies 24V impressed voltage
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
D12 (Male) (2) o (1) Discontinuity
D12 (Male) (2) o (3) Discontinuity
D12 (Male) (3) o (1) Discontinuity
a Connect the (+) pole of the tester to the left side of D12 ( ) o ( ).
20-318 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-1]
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
9JF00531
WA320-5 20-319
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-2]
Related
Information
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,
4) Applies impressed voltage between L103 (Male) (1) - (2)
Applies 24V impressed voltage
Between Resistance 1z and below
between L103 (Male) (1) - (2)
L103 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L103 (Male) (1) - (2) Resistance above
20-320 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-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
Wiring harness between L42 (Female) (12) and
L103 (Female) (5) Resistance 1z and below
Wiring harness between fuse FS1 (12) and L103 Resistance 1z and below
(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)
Wiring harness between L103 (Female) (2) and
Resistance 1z and below
L03 (Female) (4)
Wiring harness between L03 (Female) (3) and
J07 (Female) (1) Resistance 1z and below
Wiring harness between L03 (Female) (1) and 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
Wiring harness between fuse Resistance between fuse FS1
5 Wiring harness ground fault FS1 (12) and L103 (Female) (12), L103 (Female) (3) and 1Mz and
above
(3) chassis ground
Wiring harness between fuse Resistance between fuse FS1
FS1 (12) and L103 (Female) (12), L103 (Female) (1) and 1Mz and
above
(1) chassis ground
a In the above case, the all fuses are blown.
WA320-5 20-321
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-2]
9JF00532
20-322 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-3]
1) Turn starting switch OFF. 2) Disconnect connectors L41 and L56. 3) Connect T-
adapter. 4) Turn starting switch ON.
Hot short-circuiting
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)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-3]
9JF00533
WA320-5 20-325
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-4]
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
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
the above Resistance above
Wiring harness between L41 (Female) (2) and Resistance 1z and below
L54 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L54, L03. 3) Connect T-
adapter
Wiring harness between L41 Resistance between L41
(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
Wiring harness between L41 Resistance between L41
1Mz and
(Female) (2), L54 (Female) (3) (Female) (2) and chassis
and L03 (Female) (3) ground above
20-326 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-4]
9JF00511
WA320-5 20-327
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [HST-5]
Related
Information
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)
Wiring harness between L102 (Female) (3) and
fuse FS1 (3) Resistance 1z and below
1) Turn starting switch OFF. 2) Disconnect Connectors L41, L42, L102 and T09.
3) Connect T-adapter
Wiring harness between T09 Resistance between T09 1Mz and
(Female) (4) and L42 (Female) (Female) (4), L42 (Female) (5)
(5) and chassis ground above
Wiring harness between T09 Resistance between T09
1Mz and
Possible (Female) (3) and L41 (Female) (Female) (3), L41 (Female) (13) above
(13) and chassis ground
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
Wiring harness between L102 Resistance between L102
(Female) (1) and D12 (Female) (Female) (1) and D12 (Female) 1Mz and
above
(2) * (2) and chassis ground
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)
WA320-5 20-351
(2)..
TESTING AND ADJUSTING RELATED ELECTRICAL CIRCUIT DIAGRAM
20-352 WA320-5
(3)
TESTING AND ADJUSTING ECSS-1
WA320-5 20-353
(2)
TESTING AND ADJUSTING ECSS-1
.
Causes Standard value in normal state/Remarks on troubleshooting
1) Turn starting switch OFF.
2) Replace diode (D05) with normal one.
3) Turn starting switch ON.
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 (2) to (3) in diode range. There is continuity.
Check continuity from (1) to (2) in diode range. There is not continuity.
Check continuity from (1) to (3) in diode range. There is not continuity.
Check continuity from (3) 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.
1) Turn starting switch OFF.
2) Disconnect connector L14.
3) Connect T-adapter.
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
1) Turn starting switch OFF.
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)
TESTING AND ADJUSTING ECSS-1
WA320-5 20-355
(2)
TESTING AND ADJUSTING ECSS-1
20-356 WA320-5
(2)
TESTING AND ADJUSTING ECSS-1
WA320-5 20-357
(2)
TROUBLESHOOTING OF MONITOR
SYSTEM (MON MODE)
WA320-5 20-401
(1)..
(3)
TESTING AND ADJUSTING
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
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
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
q
Defective alternator
q
Clogging of air cleaner
Possible causes
q
Defective air cleaner clogging sensor
BEFORE TROUBLESHOOTING CODE DISPLAY
q
q
WA320-5
q
Overheating of engine coolant
Defective engine coolant temperature
q
q
(high temperature) sensor
WA320-5
Defective engine coolant temperature
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
TESTING AND ADJUSTING
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
q
q
q
q
q
q
Defective relay
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
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
(2)
BEFORE TROUBLESHOOTING CODE DISPLAY
20-405
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
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).
20-406 WA320-5
(2)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
Effect on Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.
WA320-5 20-407
(1)..d
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
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.
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]
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
WA320-5 20-409
(1)..d
TESTING AND ADJUSTING FAILURE CODE [2G42ZG]
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
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
3 ity (Disconnection or defec- L23 (Female) (19) Resistance 1z and below
Causes and
Standard tive contact)
Wiring harness between T12 (Female) (2) and Resistance 1z and below
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
(Female) (1) (1) and chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L23. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
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]
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 20-411
(3)
(1)..d
TESTING AND ADJUSTING FAILURE CODE [989FN1]
Machine moni-
tor or control- Activates an alarm.
ler Reaction
Effect on If the machine is driven as it is, HST motor may be broken (seized).
Machine
Related
Information
20-412 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AA1ANX]
20-414 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AA1ANX]
9JF01293
WA320-5 20-415
(1)..d
TESTING AND ADJUSTING FAILURE CODE [AB00L6]
Related
Information
20-416 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [AB00MA]
Description of During engine operation, the input voltage to the alternator terminal R signal is below 5V.
Trouble
Machine moni-
tor or control- Activates an alarm.
ler Reaction
The battery is deteriorated.
Effect on The engine cannot be started.
Machine
The service meter does not work.
Related
Information
WA320-5 20-417
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@BAZG]
20-418 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [B@BAZK]
9JF01296
WA320-5 20-419
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@BCNS]
20-420 WA320-5
(3)
(1)
TESTING AND ADJUSTING FAILURE CODE [B@BCZK]
WA320-5 20-421
(1)..d
TESTING AND ADJUSTING FAILURE CODE [B@C7NS]
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.
20-422 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [B@CRNS]
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.
WA320-5 20-423
(1)..d
TESTING AND ADJUSTING FAILURE CODE [D5ZHL6]
Failure Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure
(L6))
Controller
Action Code Failure Code
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-
tor or control- Activates an alarm.
ler Reaction
Effect on No reaction.
Machine
Related
Information
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
1) Turn starting switch OFF. 2) Disconnect connector L106. 3) Solid part check.
4) Applies impressed voltage between L106 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L106 (Male) (1) - (2) Resistance 1z and below
L106 (Male)
(3) and (5) Does not apply voltage 1Mz and
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.
Wiring harness between L02 (Female) (3) and
Resistance 1z and below
L106 (Female) (3)
Wiring harness discontinu-
Wiring harness between L23 (Female) (3) and
3 ity (Disconnection or defec- Resistance 1z and below
L106 (Female) (5)
tive contact)
Wiring harness between L106 (Female) (2) and Resistance 1z and below
chassis ground
Wiring harness between L106 (Female) (1) and
Resistance 1z and below
L15 (Female) (3)
1) Turn starting switch OFF. 2) Disconnect Connectors L02, L15, L23 and L106.
3) Connect T-adapter.
Wiring harness between L02 Resistance between L02
1Mz and
(Female) (3) and L106 (Female) (3), L106 (Female) (3)
above
(Female) (3) and chassis ground
Wiring harness between L23 Resistance between L23
4 Wiring harness ground fault 1Mz and
(Female) (3) and L106 (Female) (3), L106 (Female) (5) above
(Female) (5) and chassis ground
Wiring harness between L106 Resistance between L106
1Mz and
(Female) (1) and L15 (Female) (Female) (1), L15 (Female) (3) above
(3) and chassis ground
a In the above case, the fuse is blown.
20-424 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [D5ZHL6]
WA320-5 20-425
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DAF0KT]
20-426 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DAJ0KR]
Related
Information
1 Defective wiring harness Wiring harness between L22 Resistance between L22 1Mz and
(Female) (6) and chassis
(Female) (6), L42 (Female) (16) ground above
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-
tor or control- Activates an alarm.
ler Reaction
Effect on The monitor does not work.
Machine
Related
Information
20-430 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DD16LD]
U]
Failure Code [DD16LD] (Monitor panel mode selector switch 1 [U
(Panel switch 2) input error (LD))
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-
tor or control- Activates an alarm.
ler Reaction
Effect on The monitor does not work.
Machine
Related
Information
WA320-5 20-431
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DD17LD]
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-
tor or control- Activates an alarm.
ler Reaction
Effect on The monitor does not work.
Machine
Related
Information
20-432 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DD18LD]
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-
tor or control- Activates an alarm.
ler Reaction
Effect on The monitor does not work.
Machine
Related
Information
WA320-5 20-433
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DDK3KB]
Related
Information
20-434 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DDK3KB]
WA320-5 20-435
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DDS5L6]
20-436 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DGE2KX]
WA320-5 20-437
(1)..d
(3)
TESTING AND ADJUSTING FAILURE CODE [DGE3L6]
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
20-438 WA320-5
(3)
(1)
TESTING AND ADJUSTING FAILURE CODE [DGH1KX]
WA320-5 20-439
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DGR4KA]
20-440 WA320-5
(1)
TESTING AND ADJUSTING FAILURE CODE [DGR4KX]
WA320-5 20-441
(1)..d
TESTING AND ADJUSTING FAILURE CODE [DHE4L6]
20-442 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-1]
Related If the parking brake does not work normally, carry out troubleshooting after carrying out the applicable troubleshoot-
Information ing.
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
1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
4) Applies impressed voltage between L104 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L104 (Male) (1) - (2) Resistance 1z and below
L104 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L104 (Male) (1) - (2) Resistance above
1) Turn starting switch OFF.
2) Replace L101 with normal relay.
3) Turn starting switch ON.
4) Operate parking brake switch.
20-444 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-1]
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
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-1]
20-446 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-1]
TJW02990
WA320-5 20-447
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-2]
20-448 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-3]
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
WA320-5 20-449
(1)..d
(4)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-4]
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
20-450 WA320-5
(1)
(4)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-5]
Troubleshooting Code [MON-5] (The fuel level gauge does not rise
or decrease. )
Controller
Action Code Failure Code
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-
tor or control- No reaction.
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
WA320-5 20-451
(1)..d
(4)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-6]
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
20-452 WA320-5
(1)
(4)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-7]
WA320-5 20-453
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-8]
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
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)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-9]
WA320-5 20-455
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-10]
20-456 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-11]
WA320-5 20-457
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-12]
20-458 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-13]
Controller
Action Code Failure Code
Code
Trouble The alarm buzzer does not sound or stop
- - -
Description of
The alarm buzzer does not sound or stop.
Trouble
Machine moni-
tor or control- No reaction.
ler Reaction
Effect on
The alarm buzzer does not sound or stop.
Machine
Related
Information
1) Turn starting switch OFF. 2) Disconnect Connectors L21, L46. 3) Connect T-adapter.
2 Wiring harness ground fault a In the above case, the fuse is blown.
Alarm buzzer
3 Defective alarm buzzer The alarm buzzer sounds.
is normal.
Between L46 (Female) (2) and
chassis ground
The alarm buzzer does not Defective
sound. alarm buzzer.
20-460 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-13]
WA320-5 20-461
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-14]
20-462 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-15]
20-464 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [MON-15]
WA320-5 20-465
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE
TROUBLESHOOTING [MON-16,
CODE 17]
[MON-16]
20-466 WA320-5
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
WA320-5 20-501
(2)
(1)..
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
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).
20-502 WA320-5
(2)
(1)
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
Effect on Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.
WA320-5 20-503
(1)..d
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
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.
20-504 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-506 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
WA320-5 20-507
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-508 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-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
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-
tor or control- No reaction.
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
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.
Defective directional select When direction select switch is Resistance 1z and below
3 Between MF1 turned N.
switch (Female) (1)
and (3) 1Mz and
Other than above. Resistance
above
1) Turn starting switch OFF. 2) Replace both diodes (D18) with normal diodes.
3) Turn starting switch START.
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
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-510 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
TJW02991
WA320-5 20-511
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]
Related If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Information applicable code.
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)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]
TJW02991
WA320-5 20-513
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
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.
4) Applies impressed voltage between L115 (Male) (1) - (2)
Applies 24V impressed voltage
Between Resistance 1z and below
between L115 (Male) (1) - (2)
L115 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L115 (Male) (1) - (2) Resistance above
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 (2) o (1) with diode range Continuity
Measure between (2) o (3) with diode range Continuity
4 Defective diode (D05)
Measure between (1) o (2) with diode range No continuity
Measure between (1) o (3) with diode range No continuity
Measure between (3) o (2) with diode range No continuity
Measure between (3) o (1) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-514 WA320-5
(3)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
Wiring harness between fuse FS2 (5) and L115 Resistance 1z and below
(Female) (1)
Wiring harness between L115 (Female) (2) and
Resistance 1z and below
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
(1) * chassis ground
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
WA320-5 20-515
(1)..d
(3)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
b) Preheating is constant
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
Between between L115 (Male) (1) - (2) Resistance 1z and below
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) above
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.
3) Connect T-adapter.
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
(2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L22. 3) Insert T-adapter.
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)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
WA320-5 20-517
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
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
1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
4) Applies impressed voltage between L112 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L112 (Male) (1) - (2) Resistance 1z and below
L112 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L112 (Male) (1) - (2) Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect connector D01, L19, L112, T01. 3) Con-
Causes and nect T-adapter.
Standard
Wiring harness between L112 Resistance between L112
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
Wiring harness between L112 Resistance between L112
(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)
Measure between (2) o (1) with diode range Continuity
3 Defective diode (D01)
Measure between (2) o (3) with diode range Continuity
Measure between (1) o (2) with diode range Discontinuity
Measure between (1) o (3) with diode range Discontinuity
Measure between (3) o (2) with diode range Discontinuity
Measure between (3) o (1) with diode range Discontinuity
20-518 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
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
1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
4) Applies impressed voltage between L101 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L101 (Male) (1) - (2) Resistance 1z and below
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L101 (Male) (1) - (2) above
20-520 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
6 Defective junction connec- Carry out inspection, and if any abnormality is found, repair or replace.
tor (J05), (J10) and (J12)
1) Turn starting switch OFF. 2) Disconnect connector L21. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch
WA320-5 20-521
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
20-522 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
WA320-5 20-523
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
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-
tor or control- No reaction.
ler Reaction
Effect on Boom kick-out does not function or cannot be cancelled.
Machine
Related
Information
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.
Wiring harness between F04 (Female) (A) and
Resistance 1z and below
fuse FS1 (13)
Wiring harness between F04 (Female) (B) and
Resistance 1z and below
L113 (Female) (2)
Wiring harness between F04 (Female) (C) and Resistance 1z and below
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L113 (Female) (1) and
Resistance 1z and below
tive contact) fuse FS1 (13)
Wiring harness between L113 (Female) (3) and
Resistance 1z and below
fuse FS1 (13)
Wiring harness between L113 (Female) (5) and Resistance 1z and below
L36 (Female) (1)
Wiring harness between L36 (Female) (2) and
Resistance 1z and below
chassis ground
a With all the above items, the boom kick-out does not function
20-524 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
a In this case, the fuse is blown and no detents function (lever returns to neutral)
WA320-5 20-525
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
20-526 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
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-
tor or control- No reaction.
ler Reaction
Effect on Bucket positioner does not function or cannot be cancelled.
Machine
Related
Information
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.
1) Turn starting switch OFF. 2) Disconnect connector F03, L114, L37 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F03 (Female) (A) and
Resistance 1z and below
fuse FS1 (13)
Wiring harness between F03 (Female) (B) and
Resistance 1z and below
L114 (Female) (2)
Wiring harness between F03 (Female) (C) and Resistance 1z and below
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L114 (Female) (1) and
Resistance 1z and below
tive contact) fuse FS1 (13)
Wiring harness between L114 (Female) (3) and
Resistance 1z and below
fuse FS1 (13)
Wiring harness between L114 (Female) (5) and Resistance 1z and below
L37 (Female) (1)
Wiring harness between L37 (Female) (2) and
Resistance 1z and below
chassis ground
a With all the above items, the bucket positioner does not function
20-528 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
a In this case, the fuse is blown and no detents function (lever returns to neutral)
WA320-5 20-529
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
20-530 WA320-5
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-7]
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-
tor or control- No reaction.
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-
Wiring harness between fuse FS1 (13) and L35
2 ity (Disconnection or defec- (Female) (1) Resistance 1z and below
tive contact)
Wiring harness between L35 (Female) (2) and Resistance 1z and below
chassis ground
WA320-5 20-531
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
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.
1) Turn starting switch OFF.
2) Disconnect connector L112.
2 Defective parking brake 3) Check relay unit.
neutral safety relay (L112)
Between L112 (male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF.
2) Disconnect connector L112.
3) Check relay unit.
4) Apply normal voltage between L112 (male) (1) and (2).
20-532 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
Relay (L108)
No
When forward relay (L108) is replaced, does con- is normal.
dition become normal? Relay (L108)
Yes is defective.
1) Turn starting switch OFF.
2) Disconnect connector L108.
3) Check relay unit.
Defective forward relay
3 (L108) Between L108 (male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF.
2) Disconnect connector L108
3) Check relay unit.
4) Apply normal voltage between L108 (male) (1) and (2).
WA320-5 20-533
(2)
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
20-534 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
WA320-5 20-535
(2)
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
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.
20-536 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
No Relay (L107)
When forward relay (L107) is replaced, does con- is normal.
dition become normal? Relay (L107)
Yes
is defective.
1) Turn starting switch OFF.
2) Disconnect connector L107.
3) Check relay unit.
WA320-5 20-537
(2)
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
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.
20-538 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
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
Standard Wiring harness between L05 Resistance between L05
Values (Female) (2) and L48 (Female) (Female) (2), L48 (Female) (4) 1Mz and
above
(4) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (3) and L48 (Female) (Female) (3), L48 (Female) (5) 1Mz and
above
(5) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (5) and L57 (Female) (Female) (5), L57 (Female) (2) 1Mz and
above
(2) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (4) and L57 (Female) (Female) (4), L57 (Female) (1) 1Mz and
5 Wiring harness ground fault above
(1) and chassis ground
Wiring harness between L48 Resistance between L48
(Female) (6) and L57 (Female) (Female) (6), L57 (Female) (5) 1Mz and
above
(5) and chassis ground
Resistance between L05
Wiring harness between fuse (Female) (7) and chassis 1Mz and
FS1 (14) and L05 (Female) (7) above
ground
Resistance between L48
Wiring harness between fuse (Female) (3) and chassis 1Mz and
FS1 (14) and L48 (Female) (3) above
ground
Resistance between L57
Wiring harness between fuse (Female) (6) and chassis 1Mz and
FS1 (14) and L57 (Female) (6) above
ground
WA320-5 20-539
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
20-540 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
Wiring harness between fuse FS1 (14) and L57 Resistance 1z and below
(Female) (6)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
FS1 terminal. 3) Connect T-adapter.
Wiring harness between L05 Resistance between L05
(Female) (8) and L52 (Female) (Female) (8), L52 (Female) (1) 1Mz and
above
(1) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (9) and L52 (Female) (Female) (9), L52 (Female) (2) 1Mz and
above
(2) and chassis ground
4 Wiring harness ground fault
Resistance between L05
Wiring harness between fuse (Female) (7) and chassis 1Mz and
FS1 (14) and L05 (Female) (7) above
ground
Resistance between L52
Wiring harness between fuse (Female) (6) and chassis 1Mz and
FS1 (14) and L52 (Female) (4) above
ground
a In the all above cases, the fuse is blown.
20-542 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
WA320-5 20-543
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of The window washer does not function due defective window washer motor, switch, timer (Front only) or wiring har-
Trouble ness.
Machine moni-
tor or control- No reaction.
ler Reaction
Effect on The window washer does not function.
Machine
Related
Information
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
20-544 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Wiring harness between L05 (Female) (6) and Resistance 1z and below
L48 (Female) (2)
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L05 (Female) (3) and
Resistance 1z and below
tive contact) L48 (Female) (5)
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
Wiring harness between L05 Resistance between L05
1Mz and
(Female) (6) and B07 (Female) (Female) (6), B07 (Female) (1) above
(1) and chassis ground
Wiring harness between L05 Resistance between L05
1Mz and
(Female) (6) and L48 (Female) (Female) (6), L48 (Female) (2) above
(2) and chassis ground
Wiring harness between L05 Resistance between L05
1Mz and
(Female) (3) and L48 (Female) (Female) (7), L48 (Female) (5) above
5 Wiring harness ground fault (5) and chassis ground
Rear side
WA320-5 20-545
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
20-546 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
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.
20-548 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
WA320-5 20-549
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
20-550 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
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
Carry out the following troubleshooting when the circuits of the other lamp systems are normal.
WA320-5 20-551
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
ler Reaction
Effect on When the lamp switch is set to the 2nd position, headlamp "Hi 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
Carry out the following troubleshooting when the circuits of the other lamp systems are normal.
20-552 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
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
Carry out the following troubleshooting when the circuits of the other lamp systems are normal.
20-554 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
WA320-5 20-555
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
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.
20-556 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
WA320-5 20-557
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
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-
tor or control- None in particular.
ler Reaction
Effect on The working lamp 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 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.
20-558 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
WA320-5 20-559
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
20-560 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
WA320-5 20-561
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
20-562 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
WA320-5 20-563
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
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
(Female) (1) Resistance 1z and below
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)
Wiring harness between C03 (Female) (5) and
Resistance 1z and below
A11 (Female) (2)
Wiring harness between C03 (Female) (6) and
A13 (Female) (2) Resistance 1z and below
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
(Female) (4) Resistance 1z and below
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
Resistance 1z and below
chassis ground
Wiring harness between A11 (Female) (3) and
chassis ground Resistance 1z and below
Wiring harness between A13 (Female) (3) and Resistance 1z and below
chassis ground
Wiring harness between A01 (Female) (1) and
Resistance 1z and below
chassis ground
1) Turn starting switch OFF. 2) Disconnect connector A01, A05, A09, A10, A11, A13
and fuse FS2 terminal. 3) Connect T-adapter.
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A09 (Female) (1) and chas-
FS1 (2) and A09 (Female) (1) * sis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A10 (Female) (1) and chas-
FS1 (2) and A10 (Female) (1) * sis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2) and A11 (Female) (1) and
3 Wiring harness ground fault FS1 (2) and A11 (Female) (1) * chassis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A13 (Female) (1) and chas-
FS1 (2) and A13 (Female) (1) * sis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A12 (Female) (1) and chas-
FS1 (2) and A12 (Female) (1) * sis ground above
Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A15 (Female) (1) and chas-
FS1 (2) and A15 (Female) (1) * above
sis ground
20-564 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
3 Wiring harness ground fault Wiring harness between A09 Resistance between A09 1Mz and
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (6)
above
(6) and chassis ground
Wiring harness between A10 Resistance between A10
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (5) 1Mz and
above
(5) and chassis ground
Wiring harness between A11 Resistance between A11
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (4) 1Mz and
above
(4) and chassis ground
Wiring harness between A13 Resistance between A13
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (3) 1Mz and
above
(3) and chassis ground
Wiring harness between A05 Resistance between A05
(Female) (2) and C03 (Female) (Female) (2), C03 (Female) (3) 1Mz and
above
(3) and chassis ground
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.
1) Turn starting switch OFF. 2) Replace relay A10 with normal relay. 3) Turn starting
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-
mal relay? Condition is abnormal. Relay is
normal.
1) Turn starting switch OFF. 2) Replace relay A11 with normal relay. 3) Turn starting
switch ON. 4) Start air conditioner
Defective blower M2 relay Defective
6 Does condition become normal Condition is normal. relay.
A11
when relay is replaced with nor-
mal relay? Condition is abnormal. Relay is
normal.
1) Turn starting switch OFF. 2) Replace relay A13 with normal relay. 3) Turn starting
switch ON. 4) Start air conditioner
Defective blower M1 relay Defective
7 Does condition become normal Condition is normal. relay.
A13
when relay is replaced with nor-
mal relay? Condition is abnormal. Relay is
normal.
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
switch ON. 4) Start air conditioner
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
Between A01 (Female) (1) and (4) Resistance 4.8z
Between A01 (Female) (1) and (5) Resistance 4.0z
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
10
control panel
WA320-5 20-565
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A12, A15, B04,
C03, C04 and fuse FS2 terminal. 3) Connect T-adapter.
Wiring harness between fuse Resistance between fuse FS1 1Mz and
FS1 (2) and A12 (Female) (1), (2), A12 (Female) (1), (4) and
(4) * chassis ground above
20-566 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
1) Turn starting switch OFF. 2) Replace relay A15 with normal relay. 3) Turn starting
switch ON. 4) Start air conditioner
Defective compressor Defective
4 Does condition become normal Condition is normal. relay.
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.
4) Turn starting switch ON.
1Mz and
5 Defective pressure switch Between A05 Turn air conditioner switch OFF. Resistance above
(Male) (1) and
(2) When air conditioner switch is
Resistance 1z and below
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
switch ON. 4) Start air conditioner
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.
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
10 control panel
WA320-5 20-567
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
20-568 WA320-5
(2)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
A08 (Female) (6) Resistance 1z and below
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
(1) and chassis ground
Resistance between A07
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
(11) and chassis ground
Resistance between A07
Wiring harness between A07 (Female) (8), C03 (Female) 1Mz and
(Female) (8) and C03 (Female) (13) above
(13) and chassis ground
Resistance between A08
Wiring harness between A08 1Mz and
(Female) (1) and C04 (Female) (5) (Female) (1), C04 (Female)
(5) and chassis ground above
2 Wiring harness ground fault
Wiring harness between A08 Resistance between A08
(Female) (2), C04 (Female) 1Mz and
(Female) (2) and C04 (Female) (6) (6) and chassis ground above
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)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
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.
20-570 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
Related infor- Check that water is not leaking from the hot-water circuit
mation Check that air is blowing out of the air outlet.
WA320-5 20-571
(2)
(1)..d
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
20-572 WA320-5
(2)
(1)
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-13]
i) Water leaks
Controller
Action Code Error code Air conditioner is defective
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
WA320-5 20-573
(2)
(1)..d
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
WA320-5 20-601
(2)..
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
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?
20-602 WA320-5
(1)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
WA320-5 20-603
(1)..d
TESTING AND ADJUSTING FAILURE CODE AND CAUSE TABLE
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
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
TESTING AND ADJUSTING
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
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
20-606 WA320-5
(2)
TESTING AND ADJUSTING H-2
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
WA320-5 20-607
(2)
TESTING AND ADJUSTING H-3
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
20-608 WA320-5
(2)
TESTING AND ADJUSTING H-4
WA320-5 20-609
(2)
TESTING AND ADJUSTING H-5
Clutch solenoid
Clutch
Remedy E E E E
No. Diagnosis X X X X
20-610 WA320-5
(2)
TESTING AND ADJUSTING H-6
Priority valve
Obit-roll
Spool
Remedy E E E
No. Diagnosis X X X X X X
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)
TESTING AND ADJUSTING H-7
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?
20-612 WA320-5
(2)
TESTING AND ADJUSTING H-8, H-8
H-9
Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)
Is the steering wheel play correct?
Remedy E E E
No. Diagnosis X X X
WA320-5 20-613
(2)
TESTING AND ADJUSTING H-10
H-10 The brake does not work or does not work well
Ask the operator about the following: Cause
Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Brake linkage
Remedy E E E E E E E
No. Diagnosis X X X X X X X X X
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
20-614 WA320-5
(2)
TESTING AND ADJUSTING H-11
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)
TESTING AND ADJUSTING H-12
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
20-616 WA320-5
(2)
TESTING AND ADJUSTING H-13
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
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
The relief oil pressure from the relief valve of the work
7 Q
equipment valves is too high
WA320-5 20-617
(2)
TESTING AND ADJUSTING H-14
H-14 When rising, the lift arm comes to move slowly at specific
height
Inspection before diagnosis
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."
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
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20-618 WA320-5
(1)
TESTING AND ADJUSTING H-18
Cause
Improper adhesion of lift arm spool check valve of the work equipment valve
WA320-5 20-619
(1)..d
TESTING AND ADJUSTING H-19
The HST charge pump (which is used as PPC pump, too) is defective
Inspection before diagnosis
Is the stroke of the bucket control lever appropriate?
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
20-620 WA320-5
(2)
TESTING AND ADJUSTING H-20
Check of Abnormality
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
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
6 The relief oil pressure from the relief valve of the work Q Q Q
equipment valves is low
The relief oil pressure from the relief valve of the work
7 equipment valves is too high Q
WA320-5 20-621
(2)
TESTING AND ADJUSTING H-21
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."
Cause
Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
Oil leak from bucket cylinder piston seal
Check of Abnormality
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)
TESTING AND ADJUSTING H-24
H-24 The bucket wobbles during travel with cargo (The work
equipment valve is set to "HOLD")
Inspection before diagnosis
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.
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
WA320-5 20-623
(1)..d
TESTING AND ADJUSTING H-27
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
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
20-624 WA320-5
(2)
TROUBLESHOOTING OF ENGINE
(S MODE)
WA320-5 20-701
(1)..
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
[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)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
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
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
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.
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)
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
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
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.
Confirm recent repair history
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
Replace
Correct
Remedy
Clean
Clean
Clean
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
TESTING AND ADJUSTING
t co m
pens
ator
ca n c
el
20-707
(1)..d
S-1
TESTING AND ADJUSTING S-2
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
Confirm recent repair history
Questions
Remedy -
20-708 WA320-5
(1)
TESTING AND ADJUSTING S-2
)
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
Confirm recent repair history
Questions
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
Remedy
WA320-5 20-709
(1)..d
TESTING AND ADJUSTING S-2
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
stuck c.)
lack of rotating force due to defective electrical sys-
er et
tem
)
er lev
Insufficient supply of fuel
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
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
Confirm recent repair history
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
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
There is leakage from fuel piping w
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
When air cleaner element is inspected directly, it is found to be clogged q
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)
TESTING AND ADJUSTING S-3
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
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
Confirm recent repair history
Degree of use of machine Operated for long period EEE E E
Replacement of filters has not been carried out according to Oper- w w w
ation Manual
Questions
Replace
Correct
Correct
Adjust
Remedy
Clean
Clean
Clean
Clean
WA320-5 20-711
(1)..d
TESTING AND ADJUSTING S-4
tc.)
Insufficient supply of fuel
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
Confirm recent repair history
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
Replace
Replace
Replace
Correct
Remedy -
Clean
Clean
Clean
Add
20-712 WA320-5
(1)
TESTING AND ADJUSTING S-5
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
Confirm recent repair history
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
Clean
Clean
Clean
Remedy
Add
WA320-5 20-713
(1)..d
TESTING AND ADJUSTING S-6
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
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
Confirm recent repair history
Degree of use of machine Operated for long period E EEE E
Suddenly w w w
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Remedy
Clean
Clean
Clean
Clean
20-714 WA320-5
(1)
TESTING AND ADJUSTING S-7
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
q
stopped
When check is made using delivery method, injection timing is q
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 outside q
standard value
When muffler is removed, exhaust color returns to normal q
When control rack is pushed, it is found to be heavy, or does not q
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Remedy
Clean
WA320-5 20-715
(1)..d
TESTING AND ADJUSTING S-8
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
Confirm recent repair history
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
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Remedy
Clean
20-716 WA320-5
(1)
TESTING AND ADJUSTING S-9
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
Confirm recent repair history
Degree of use of machine Operated for long period E E E
Questions
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
Replace
Replace
Replace
Remedy -
Clean
Clean
Clean
WA320-5 20-717
(1)..d
TESTING AND ADJUSTING S-10
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
Confirm recent repair history
Degree of use of machine Operated for long period EE E
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
Seal on injection pump has come off w
There is irregular combustion w
Check items
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-718 WA320-5
(1)
TESTING AND ADJUSTING S-11
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
Confirm recent repair history
Questions
Remedy
WA320-5 20-719
(1)..d
TESTING AND ADJUSTING S-12
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
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
Confirm recent repair history
Degree of use of machine Operated for long period EE E
Questions
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)
TESTING AND ADJUSTING S-13
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
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA320-5 20-721
(1)..d
TESTING AND ADJUSTING S-14
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
Confirm recent repair history
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
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy -
Add
20-722 WA320-5
(3)
(1)
TESTING AND ADJUSTING S-15
.)
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
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
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
Confirm recent repair history
Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q Q
Engine oil must be added more frequently w
Black under light load w
Color of exhaust gas
Black w Q Q
Metal particles found in oil filter w w
Blow-by gas excessive w
Noise of interference is heard from around turbocharger w
Check items
stopped
When control rack is pushed, it is found to be heavy, or does not q
return
Injection pump test shows that injection amount is incorrect q
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
TESTING AND ADJUSTING S-16
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
Confirm recent repair history
Degree of use of machine Operated for long period EEE
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified fuel is being used 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
Replace
Correct
Correct
Adjust
Remedy
20-724 WA320-5
(1)