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TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)

Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602


Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
Troubleshooting Code [E-1] (The engine does not start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
Troubleshooting Code [E-2] (The engine does not stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
Troubleshooting Code [E-3] (Preheating is impossible or constant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function) . . . . . . . . . . . . . 20-630
Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation). . . . . . . . . . . . . . . . . 20-642
Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation) . . . . . . . . . . . . . . 20-646
Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and cancellation). . . . . . . 20-649
Troubleshooting Code [E-8] (The wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-650
Troubleshooting Code [E-9] (The window washer does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-656
Troubleshooting Code [E-10] (Lamps do not work properly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-660
Troubleshooting Code [E-11] (The horn does not sound) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-672
Troubleshooting Code [E-12] (Defective the air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-674

WA320-5H 20-601
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM

BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM


FUSE BOX CONNECTION TABLE

a This connection chart shows the equipment that each fuse box power source supplies power directly to
("switch power source" means the power supplied when the starting switch is ON; "permanent power source"
means the power supplied when the starting switch is OFF).

Category Fuse No. Fuse capacity Power supply destination


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

Switch power source 11 10A Back lamp, stop lamp


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

20-602 WA320-5H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE

INFORMATION CONTAINED IN TROUBULESHOOTING TABLE


a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
Controller
Action Code Failure Code
Code Trouble Trouble displayed in trouble data
Panel display Panel display Panel display
Description of • Condition when machine monitor or controller detected trouble.
Trouble
Machine moni-
tor or control- • Action to take to protect system or equipment when machine monitor or controller detected trouble.
ler Reaction

Effect on • Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.

Related • Information related to troubleshooting or error that occurred.


Information

Causes Standard Value in Normal State and Remarks on Troubleshooting

<Data to fill in>


1 • Normal standard values used to judge probable cause
• Remarks regarding decision-making

<Condition when wiring harness is defective>


• Disconnection
There is defective connection of connector or disconnection in wiring harness
2 • Short circuit with ground
Wiring harness not wired to ground (GND) circuit is in contact with ground (GND)
circuit
• Short circuit with power source
Wiring harness not wired to power supply (24 V) circuit is in contact with power
Possible Probable cause when
trouble occurred supply (24 V) circuit
Causes and
Standard (the numbers are index
3 <Points to remember when troubleshooting>
Values numbers and do not
indicate the order of pri- 1) Method of displaying connector No. and handling T-adapter
ority) Unless there is special instruction, insert or connect the T-adapter as follows
• If there is no indication for the male or female terminal of the connector No.,
disconnect the connector and insert the T-adapter in both the male and
female terminals
• If there is indication for the male or female terminal of the connector No., dis-
4
connect the connector and connect the T-adapter to only the terminal indi-
cated (either the male terminal or female terminal)
<Points to remember when troubleshooting>
2) Given order for pin numbers and handling tester lead
Unless there is a special instruction, connect tester (+) lead and (-) lead as fol-
lows to carry out troubleshooting
• Connect the (+) lead to the wiring harness for the pin No. given first
5
• Connect the (-) lead to the wiring harness for the pin No. given last

WA320-5H 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE

Related circuit diagram

This is part of electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow: Roughly indicates the location in the machine where it is installed.

20-604 WA320-5H
white 20-605
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Troubleshooting Code [E-1] (The engine does not start)


Speed meter specification (STD)
a) - 1 Defective starting motor system (When direction selector actuation switch is turned OFF)
Controller
Action Code Failure Code The engine does not start
Code Trouble
a) Defective starting motor system
- - -
Description of • The engine does not start due to defective starting motor system.
Trouble
Machine moni-
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
Related applicable code.
Information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

Causes Standard Value in Normal State and Remarks on Troubleshooting


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

20-606 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Interchange relay (one of L133, L136, or L137) with
normal relay. 3) Turn starting switch ON.
Relay (L133,
Does condition become normal The condition is abnormal. L136, L137)
when neutral safety relay (one is normal.
of L133, L136, or L137) is inter- Defective
changed with normal relay? The condition is normal. relay (L133,
L136, L137)
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
Defective multi-function
5 related relay (L133, L136, 3) Solid part check.
L137) Between (Male) (1) - (2) of one of L133, L136, or
Resistance 200 - 400z
L137
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
3) Solid part check. 4) Applies impressed voltage between (Male) (1) - (2) of one of
L133, L136, or L137
Between Applies 24V impressed voltage
Resistance 1zandbelow
(Male) (3) - between L106 (Male) (1) - (2)
(5) of one of
L133, L136, Does not apply voltage Resistance 1Mz and
or L137 between L106 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace both diodes (D08, D15) with normal diodes.
3) Turn starting switch START.

a Only when defect


Defective diode (D08, D15)
The condition is abnormal. Diode (D08, D15) is normal.
6
occurs in both at the The condition is normal. Defective diode (D08, D15)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
1) Turn starting switch OFF. 2) Replace diode (D07) with normal diode. 3) Turn start-
ing switch START.
Possible The condition is abnormal. Diode (D07) is normal.
Causes and

Measure between (1) o (2) with diode range


Standard The condition is normal. Defective diode (D07)
Values
Measure between (3) o (2) with diode range
Continuity

Measure between (2) o (3) with diode range


Continuity
7 Defective diode (D07)

Measure between (2) o (1) with diode range


Discontinuity

Measure between (1) o (3) with diode range


Discontinuity

Measure between (3) o (1) with diode range


Discontinuity
Discontinuity
a Put (+) pole of tester in contact with left side.
1) Turn starting switch OFF. 2) Disconnect connector L106, D08, D15, terminal E01,
R01 and E10. 3) Connect T-adapter.
Wiring harness between L106 (Female) (5) and
D08 (Female) (2) Resistance 1zandbelow
Wiring harness discontinu- Wiring harness between L106 (Female) (5) and
ity (Disconnection or defec- Resistance 1zandbelow
D15 (Female) (2)
a Starting motor related
8 tive contact)
Wiring harness between D08 (Female) (1) and Resistance 1zandbelow
harness E01 (Female) (1)
Wiring harness between D15 (Female) (1) and
Resistance 1zandbelow
E01 (Female) (1)
Wiring harness between R01 and starting motor
Resistance 1zandbelow
terminal B (E10)
1) Turn starting switch OFF. 2) Disconnect connector D07, E02, terminal R16, R15,
R07, R04, R02 and R05. 3) Connect T-adapter.
Wiring harness between R16 and chassis ground Resistance 1zandbelow
Wiring harness discontinu-
ity (Disconnection or defec- Wiring harness between R15 and D07 (Female) (2) Resistance 1zandbelow

a Battery relay related


9 tive contact) Wiring harness between E02 (Female) (2) and
Resistance 1zandbelow
R15
harness Wiring harness between R04 and R02 Resistance 1zandbelow
Wiring harness between R01 and R05 Resistance 1zandbelow
Wiring harness between battery and R04 Resistance 1zandbelow

WA320-5H 20-607
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L02, D07, terminal R03 and
fuse FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L02 (Female) (1), FS1
ity (Disconnection or defec- Resistance 1zandbelow
(1) and R03
a Starting switch related
10 tive contact)
Wiring harness between L02 (Female) (2) and Resistance 1zandbelow
harness D07 (Female) (1)
Wiring harness between L02 (Female) (2) and
Resistance 1zandbelow
L23 (Female) (1)
1) Turn starting switch OFF. 2) Disconnect connector L15, terminal R06 and fuse
FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L15 (Female) (1), FS1
ity (Disconnection or defec- Resistance 1zandbelow
(2) and R06
a Directional lever
11 tive contact)
Wiring harness between L15 (Female) (3) and
Resistance 1zandbelow
related harness L106 (Female) (1)
Wiring harness between L106 (Female) (2) and
chassis ground Resistance 1zandbelow
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector E01, E02, D07. 3) Connect T-
Standard adapter. 4) Turn starting switch ON.
Values Hot short-circuiting
12 Wiring harness between E01 Voltage between E01 (Female)
between harnesses
(Female) (2), E02 (Female) (1) (2), E02 (Female) (1) and chas- 1V and below
and D07 (Female) (3) sis ground
1) Disconnect starting switch terminal. 2) Solid part check.
13 Defective starting switch
Turn starting switch START. Between terminal B and C 1zandbelow
1) Solid part check.
14 Defective starting motor • If the check of the individual part shows that it is normal, the starting motor is
normal.
Between Engine started (Throttle 1/2 and
alternator ter- above) Voltage 26.5 - 29V
15 Defective alternator minal R [E02
(1)] and chas- Engine stopped Voltage 1V and below
sis ground
1) Turn starting switch OFF. 2) Disconnect connector TEL. 3) Connect T-adapter.
Defective short connector
16 TEL Wiring harness between TEL (Female) (7) and Resistance 1zandbelow
(8)

20-608 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

a Perform the inspection and troubleshooting in this section in addition to a) -1.


a) - 2 Defective starting motor system (When the directional selector actuation switch is turned ON)

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.

Causes Standard Value in Normal State and Remarks on Troubleshooting


Specific gravity 1.26V and above
1 Defective battery
Voltage 24V and above
1) Turn starting switch OFF. 2) Interchange relay (L132, L133, L134) with normal
relay. 3) Turn starting switch ON.
Relay (L132,
Does condition become normal The condition is abnormal. L133, L134)
when neutral safety relay is normal.
(L132, L133, L134) is inter- Defective
changed with normal relay? The condition is normal. relay (L132,
L133, L134)
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Defective neutral safety check.
2
relay (L132, L133, L134)
Between L132, L133, L134 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Possible check. 4) Applies impressed voltage between L132, L133, L134 (Male) (1) - (2)
Causes and
Standard Applies 24V impressed voltage
Values Between between L132, L133, L134 Resistance 1zandbelow
L132, L133, (Male) (1) - (2)
L134 (Male) Does not apply voltage
(3) and (5) between L132, L133, L134 Resistance 1Mz and
above
(Male) (1) - (2)
1) Turn starting switch OFF. 2) Disconnect connector MF1. 3) Connect T-adapter.

Defective directional select When direction select switch is


3 Between MF1 turned N. Resistance 1zandbelow
switch (Female) (1)
and (3) Other than above. Resistance 1Mz and
above
1) Turn starting switch OFF. 2) Replace both diodes (D18) with normal diodes.
3) Turn starting switch START.

a Only when defect


Defective diode (D18)
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

WA320-5H 20-609
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

b) Defective fuel cut solenoid system


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

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Interchange relay (R13) with normal relay. 3) Turn
starting switch ON.
Relay (R13)
Does condition become normal The condition is abnormal.
is normal.
when pull relay (R13) is inter-
changed with normal relay? Defective
The condition is normal.
relay (R13)
Defective fuel cut solenoid 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1
pull relay (R13) Between R13 (Male) (1) and (2) Resistance 50 - 90z
1) Turn starting switch OFF. 2) Disconnect connector R13. 3) Solid part check.
4) Applies impressed voltage between R13 (Male) (1) - (2)
Applies 24V impressed voltage
Between R13 between R13 (Male) (1) - (2) Resistance 1zandbelow
(Male) (3) and
(5) Does not apply voltage Resistance 1Mz and
between R13 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
2 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
4) Connect connector.
Between R08 Turn starting switch ON. Voltage 20 - 30V
Defective fuel cut solenoid (1) and (2)
3 timer Turn starting switch OFF. Voltage 1V and below
2 - 4 sec after turning starting 16V and
Possible Between R08 Voltage
switch ON above
Causes and (3) and (4)
Standard Other than above. Voltage 1V and below
Values 1) Turn starting switch OFF. 2) Replace diode (D03 or D04) with a normal diode.
3) Turn starting switch START.
Defective diode
4
(D03 or D04) The condition is abnormal. Diode (D03 or D04) is normal.
The condition is normal. Defective diode (D03 or D04)
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D04, D08, D15, terminal
E01, E03, E11, E23, E24, R05, R08, R09, R10, R12 and R13. 3) Connect T-adapter.
Wiring harness between E24 and chassis ground Resistance 1zandbelow
Wiring harness between D03 (Female) (2) and
chassis ground Resistance 1zandbelow

Wiring harness between E03 and R09 Resistance 1zandbelow


Wiring harness between D04 (Female) (2) and
chassis ground Resistance 1zandbelow
Wiring harness discontinu- Wiring harness between E23 and L02 (Female) (4) Resistance 1zandbelow
5 ity (Disconnection or defec-
tive contact) Wiring harness between E23 and R08 (Female) (1) Resistance 1zandbelow
Wiring harness between R08 (Female) (2) and Resistance 1zandbelow
chassis ground
Wiring harness between R08 (Female) (3) and
Resistance 1zandbelow
R13 (Female) (1)
Wiring harness between R08 (Female) (4) and
R13 (Female) (2) Resistance 1zandbelow

Wiring harness between R10 and R12 Resistance 1zandbelow


Wiring harness between R11 and R06 Resistance 1zandbelow
1) Disconnect starting switch terminal. 2) Solid part check.
6 Defective starting switch
Turn starting switch START. Between terminal B and ACC 1zandbelow

20-610 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Related circuit diagram

WA320-5H 20-611
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Load meter specification (If equipped)


a) - 1 Defective starting motor system (When direction selector actuation switch is turned OFF)
Controller
Action Code Failure Code The engine does not start
Code Trouble a) Defective starting motor system
- - -
Description of • The engine does not start due to defective starting motor system.
Trouble
Machine moni-
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
Related applicable code.
Information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

Causes Standard Value in Normal State and Remarks on Troubleshooting


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

20-612 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Interchange relay (one of L133, L136, or L137) with
normal relay. 3) Turn starting switch ON.
Relay (L133,
Does condition become normal The condition is abnormal. L136, L137)
when neutral safety relay (one is normal.
of L133, L136, or L137) is inter- Defective
changed with normal relay? The condition is normal. relay (L133,
L136, L137)
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
Defective multi-function
5 related relay (L133, L136, 3) Solid part check.
L137) Between (Male) (1) - (2) of one of L133, L136, or
Resistance 200 - 400z
L137
1) Turn starting switch OFF. 2) Disconnect one of connectors L133, L136, or L137.
3) Solid part check. 4) Applies impressed voltage between (Male) (1) - (2) of one of
L133, L136, or L137
Between Applies 24V impressed voltage
Resistance 1zandbelow
(Male) (3) - between L106 (Male) (1) - (2)
(5) of one of
L133, L136, Does not apply voltage Resistance 1Mz and
or L137 between L106 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace both diodes (D08, D15) with normal diodes.
3) Turn starting switch START.

a Only when defect


Defective diode (D08, D15)
The condition is abnormal. Diode (D08, D15) is normal.
6
occurs in both at the The condition is normal. Defective diode (D08, D15)
same time Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
1) Turn starting switch OFF. 2) Replace diode (D07) with normal diode. 3) Turn start-
ing switch START.
Possible The condition is abnormal. Diode (D07) is normal.
Causes and

Measure between (1) o (2) with diode range


Standard The condition is normal. Defective diode (D07)
Values
Measure between (3) o (2) with diode range
Continuity

Measure between (2) o (3) with diode range


Continuity
7 Defective diode (D07)

Measure between (2) o (1) with diode range


Discontinuity

Measure between (1) o (3) with diode range


Discontinuity

Measure between (3) o (1) with diode range


Discontinuity
Discontinuity
a Put (+) pole of tester in contact with left side.
1) Turn starting switch OFF. 2) Disconnect connector L106, D08, D15, terminal E01,
R01 and E10. 3) Connect T-adapter.
Wiring harness between L106 (Female) (5) and
D08 (Female) (2) Resistance 1zandbelow
Wiring harness discontinu- Wiring harness between L106 (Female) (5) and
ity (Disconnection or defec- Resistance 1zandbelow
D15 (Female) (2)
a Starting motor related
8 tive contact)
Wiring harness between D08 (Female) (1) and Resistance 1zandbelow
harness E01 (Female) (1)
Wiring harness between D15 (Female) (1) and
Resistance 1zandbelow
E01 (Female) (1)
Wiring harness between R01 and starting motor
Resistance 1zandbelow
terminal B (E10)
1) Turn starting switch OFF. 2) Disconnect connector D07, E02, terminal R16, R15,
R07, R04, R02 and R05. 3) Connect T-adapter.
Wiring harness between R16 and chassis ground Resistance 1zandbelow
Wiring harness discontinu-
ity (Disconnection or defec- Wiring harness between R15 and D07 (Female) (2) Resistance 1zandbelow

a Battery relay related


9 tive contact) Wiring harness between E02 (Female) (2) and
Resistance 1zandbelow
R15
harness Wiring harness between R04 and R02 Resistance 1zandbelow
Wiring harness between R01 and R05 Resistance 1zandbelow
Wiring harness between battery and R04 Resistance 1zandbelow

WA320-5H 20-613
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L02, D07, terminal R03 L25
and fuse FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L02 (Female) (1), FS1
ity (Disconnection or defec- Resistance 1zandbelow
(1) and R03
a Starting switch related
10 tive contact)
Wiring harness between L02 (Female) (2) and Resistance 1zandbelow
harness D07 (Female) (1)
Wiring harness between L02 (Female) (2) and
Resistance 1zandbelow
L25 (Female) (10)
1) Turn starting switch OFF. 2) Disconnect connector L15, terminal R06 and fuse
FS1. 3) Connect T-adapter.
Wiring harness discontinu- Wiring harness between L15 (Female) (1), FS1
ity (Disconnection or defec- Resistance 1zandbelow
(2) and R06
a Directional lever
11 tive contact)
Wiring harness between L15 (Female) (3) and
Resistance 1zandbelow
related harness L106 (Female) (1)
Wiring harness between L106 (Female) (2) and
chassis ground Resistance 1zandbelow
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector E01, E02, D07. 3) Connect T-
Standard adapter. 4) Turn starting switch ON.
Values Hot short-circuiting
12 Wiring harness between E01 Voltage between E01 (Female)
between harnesses
(Female) (2), E02 (Female) (1) (2), E02 (Female) (1) and chas- 1V and below
and D07 (Female) (3) sis ground
1) Disconnect starting switch terminal. 2) Solid part check.
13 Defective starting switch
Turn starting switch START. Between terminal B and C 1zandbelow
1) Solid part check.
14 Defective starting motor • If the check of the individual part shows that it is normal, the starting motor is
normal.
Between Engine started (Throttle 1/2 and
alternator ter- above) Voltage 26.5 - 29V
15 Defective alternator minal R [E02
(1)] and chas- Engine stopped Voltage 1V and below
sis ground
1) Turn starting switch OFF. 2) Disconnect connector TEL. 3) Connect T-adapter.
Defective short connector
16 TEL Wiring harness between TEL (Female) (7) and Resistance 1zandbelow
(8)

20-614 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

a Perform the inspection and troubleshooting in this section in addition to a) -1.


a) - 2 Defective starting motor system (When the directional selector actuation switch is turned ON)

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.

Causes Standard Value in Normal State and Remarks on Troubleshooting


Specific gravity 1.26V and above
1 Defective battery
Voltage 24V and above
1) Turn starting switch OFF. 2) Interchange relay (L132, L133, L134) with normal
relay. 3) Turn starting switch ON.
Relay (L132,
Does condition become normal The condition is abnormal. L133, L134)
when neutral safety relay is normal.
(L132, L133, L134) is inter- Defective
changed with normal relay? The condition is normal. relay (L132,
L133, L134)
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Defective neutral safety check.
2
relay (L132, L133, L134)
Between L132, L133, L134 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L132, L133, L134. 3) Solid part
Possible check. 4) Applies impressed voltage between L132, L133, L134 (Male) (1) - (2)
Causes and
Standard Applies 24V impressed voltage
Values Between between L132, L133, L134 Resistance 1zandbelow
L132, L133, (Male) (1) - (2)
L134 (Male) Does not apply voltage
(3) and (5) between L132, L133, L134 Resistance 1Mz and
above
(Male) (1) - (2)
1) Turn starting switch OFF. 2) Disconnect connector MF1. 3) Connect T-adapter.

Defective directional select When direction select switch is


3 Between MF1 turned N. Resistance 1zandbelow
switch (Female) (1)
and (3) Other than above. Resistance 1Mz and
above
1) Turn starting switch OFF. 2) Replace both diodes (D18) with normal diodes.
3) Turn starting switch START.

a Only when defect


Defective diode (D18)
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

WA320-5H 20-615
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

b) Defective fuel cut solenoid system


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

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Interchange relay (R13) with normal relay. 3) Turn
starting switch ON.
Relay (R13)
Does condition become normal The condition is abnormal.
is normal.
when pull relay (R13) is inter-
changed with normal relay? Defective
The condition is normal.
relay (R13)
Defective fuel cut solenoid 1) Turn starting switch OFF. 2) Disconnect connector L104. 3) Solid part check.
1
pull relay (R13) Between R13 (Male) (1) and (2) Resistance 50 - 90z
1) Turn starting switch OFF. 2) Disconnect connector R13. 3) Solid part check.
4) Applies impressed voltage between R13 (Male) (1) - (2)
Applies 24V impressed voltage
Between R13 between R13 (Male) (1) - (2) Resistance 1zandbelow
(Male) (3) and
(5) Does not apply voltage Resistance 1Mz and
between R13 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
2 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
4) Connect connector.
Between R08 Turn starting switch ON. Voltage 20 - 30V
Defective fuel cut solenoid (1) and (2)
3 timer Turn starting switch OFF. Voltage 1V and below
2 - 4 sec after turning starting 16V and
Possible Between R08 Voltage
switch ON above
Causes and (3) and (4)
Standard Other than above. Voltage 1V and below
Values 1) Turn starting switch OFF. 2) Replace diode (D03 or D04) with a normal diode.
3) Turn starting switch START.
Defective diode
4
(D03 or D04) The condition is abnormal. Diode (D03 or D04) is normal.
The condition is normal. Defective diode (D03 or D04)
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D04, D08, D15, terminal
E01, E03, E11, E23, E24, R05, R08, R09, R10, R12 and R13. 3) Connect T-adapter.
Wiring harness between E24 and chassis ground Resistance 1zandbelow
Wiring harness between D03 (Female) (2) and
chassis ground Resistance 1zandbelow

Wiring harness between E03 and R09 Resistance 1zandbelow


Wiring harness between D04 (Female) (2) and
chassis ground Resistance 1zandbelow
Wiring harness discontinu- Wiring harness between E23 and L02 (Female) (4) Resistance 1zandbelow
5 ity (Disconnection or defec-
tive contact) Wiring harness between E23 and R08 (Female) (1) Resistance 1zandbelow
Wiring harness between R08 (Female) (2) and Resistance 1zandbelow
chassis ground
Wiring harness between R08 (Female) (3) and
Resistance 1zandbelow
R13 (Female) (1)
Wiring harness between R08 (Female) (4) and
R13 (Female) (2) Resistance 1zandbelow

Wiring harness between R10 and R12 Resistance 1zandbelow


Wiring harness between R11 and R06 Resistance 1zandbelow
1) Disconnect starting switch terminal. 2) Solid part check.
6 Defective starting switch
Turn starting switch START. Between terminal B and ACC 1zandbelow

20-616 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]

Related circuit diagram

WA320-5H 20-617
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]

Troubleshooting Code [E-2] (The engine does not stop)


Controller
Action Code Failure Code Code Trouble The engine does not stop
- - -
Description of • The engine does not stop.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The engine does not stop.
Machine

Related • If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Information applicable code.

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24. 3) Connect T-
adapter. 4) Solid part check.
1 Defective fuel cut solenoid
Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
1) Turn starting switch OFF. 2) Disconnect connector R08. 3) Insert T-adapter.
Possible 4) Connect connector.
Defective fuel cut solenoid
Causes and 2
timer Between R08 Turn starting switch ON. Voltage 20 - 30V
Standard
Values (1) and (2) Turn starting switch OFF. Voltage 1V and below
1) Turn starting switch OFF. 2) Disconnect connector L02, D03, D08, terminal E03,
E23 and R09. 3) Connect T-adapter. 4) Turn starting switch OFF.

Hot short-circuiting Wiring harness between E03, Voltage between E03 (Harness 1V and below
3 R09 and D03 (Female) (1) side) and chassis ground
between harnesses
Wiring harness between E23,
Voltage between E23 (Harness
L02 (Female) (4) and R08 side) and chassis ground 1V and below
(Female) (1)

20-618 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]

Related circuit diagram


Speed meter specification (STD)

WA320-5H 20-619
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]

Related circuit diagram


Load meter specification (If equipped)

20-620 WA320-5H
white 20-621
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Troubleshooting Code [E-3] (Preheating is impossible or constant)


Speed meter specification (STD)
a) Preheating is impossible
Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble
a) Preheating is impossible
- - -
Description of • Preheating is impossible. (The engine water temperature at 0°C and below.)
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is impossible.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
3) Solid part check.
Between E06 and chassis ground Resistance 19 - 25z
1 Defective intake air heater When relay is ON (impressed
relay voltage 24V between E06 - Resistance 1zandbelow
Between E07 chassis ground).
and E08
When the relay OFF (Other Resistance 1Mz and
than above). above

Defective intake air heater 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2
(Ribbon heater) Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.

Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
Causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
4) Applies impressed voltage between L115 (Male) (1) - (2)
Applies 24V impressed voltage
Between Resistance 1zandbelow
between L115 (Male) (1) - (2)
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) 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
Measure between (1) o (2) with diode range
4 Defective diode (D05)
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.

20-622 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter.
Wiring harness between E08 and E09 Resistance 1zandbelow
Wiring harness between R07 and E07 Resistance 1zandbelow

Wiring harness discontinu- Wiring harness between E06, J08 and L115 Resistance 1zandbelow
(Female) (5)
5 ity (Disconnection or defec-
tive contact) Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (3)
Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (1)
Wiring harness between L115 (Female) (2) and Resistance 1zandbelow
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
Standard FS2 (5) and L115 (Female) (5), L115 (Female) (3) and 1Mz and
above
Values (3) * chassis ground

6 Wiring harness ground fault Wiring harness between fuse Resistance between fuse FS2
FS2 (5) and L115 (Female) 1Mz and
(5), L115 (Female) (1) and above
(1) * chassis ground
Wiring harness between J08 Resistance between J08
(Female) (12) and D05 (Female) (12), D05 (Female) 1Mz and
above
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to intake air heater (ribbon heater)
a If it is marked * , the fuse is blown

Wiring harness between L21 Resistance between L21 1Mz and


(Female) (6), E13 (A) and
(Female) (6) and E13 (A) above
chassis ground
a The above is wiring harness related to the engine water temperature (low tem-
perature) sensor

1) Turn starting switch OFF. 2) Disconnect connector E13. 3) Connect T-adapter.


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

WA320-5H 20-623
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

b) Preheating is constant

Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble
b) Preheating is constant
- - -
Description of • Preheating is constant.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is constant.
Machine
• If the failure code DGE3L6 for abnormality in engine water temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
Information
• The engine water temperature (low temperature) is displayed by real-time monitoring code 04103.

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
3) Solid part check.
Between E06 and chassis ground Resistance 19 - 25z
Defective intake air heater When relay is ON (impressed
1 relay voltage 24V between E06 - Resistance 1zandbelow
Between E07 chassis ground).
and E08
When the relay OFF (Other 1Mz and
than above). Resistance above
1) Turn starting switch OFF. 2) Replace relay L115 with normal relay. 3) Turn starting
switch ON.
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.
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 Resistance 1zandbelow
Between between L115 (Male) (1) - (2)
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.

Hot short-circuiting Wiring harness between E08 Voltage between E08, E09 and
3 1V and below
and E09 chassis ground
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.
Short circuit with chassis
4 Wiring harness between L22 Resistance between L22
ground in wiring harness 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

20-624 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Related circuit diagram

WA320-5H 20-625
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Load meter specification (If equipped)


a) Preheating is impossible
Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble a) Preheating is impossible
- - -
Description of • Preheating is impossible. (The engine water temperature at 0°C and below.)
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is impossible.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
3) Solid part check.
Between E06 and chassis ground Resistance 19 - 25z
Defective intake air heater When relay is ON (impressed
1
relay voltage 24V between E06 - Resistance 1zandbelow
Between E07 chassis ground).
and E08
When the relay OFF (Other 1Mz and
than above). Resistance above

Defective intake air heater 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2 (Ribbon heater) Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.

Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
Causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
4) Applies impressed voltage between L115 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L115 (Male) (1) - (2) Resistance 1zandbelow
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) 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
Measure between (1) o (2) with diode range
4 Defective diode (D05)
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.

20-626 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L115, L24, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter.
Wiring harness between E08 and E09 Resistance 1zandbelow
Wiring harness between R07 and E07 Resistance 1zandbelow

Wiring harness discontinu- Wiring harness between E06, J08 and L115 Resistance 1zandbelow
(Female) (5)
5 ity (Disconnection or defec-
tive contact) Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (3)
Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (1)
Wiring harness between L115 (Female) (2) and Resistance 1zandbelow
L24 (Female) (12)
1) Turn starting switch OFF. 2) Disconnect connector D05, L115, L28, 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
Standard FS2 (5) and L115 (Female) (5), L115 (Female) (3) and 1Mz and
above
Values (3) * chassis ground

6 Wiring harness ground fault Wiring harness between fuse Resistance between fuse FS2
FS2 (5) and L115 (Female) 1Mz and
(5), L115 (Female) (1) and above
(1) * chassis ground
Wiring harness between J08 Resistance between J08
(Female) (12) and D05 (Female) (12), D05 (Female) 1Mz and
above
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to intake air heater (ribbon heater)
a If it is marked * , the fuse is blown

Wiring harness between L28 Resistance between L28 1Mz and


(Female) (3), E13 (A) and
(Female) (3) and E13 (A) above
chassis ground
a The above is wiring harness related to the engine water temperature (low tem-
perature) sensor

1) Turn starting switch OFF. 2) Disconnect connector E13. 3) Connect T-adapter.


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

WA320-5H 20-627
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

b) Preheating is constant

Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble
b) Preheating is constant
- - -
Description of • Preheating is constant.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is constant.
Machine
• If the failure code DGE3L6 for abnormality in engine water temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
Information
• The engine water temperature (low temperature) is displayed by real-time monitoring code 04103.

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect heater relay terminal E06, E07, E08.
3) Solid part check.
Between E06 and chassis ground Resistance 19 - 25z
Defective intake air heater When relay is ON (impressed
1 relay voltage 24V between E06 - Resistance 1zandbelow
Between E07 chassis ground).
and E08
When the relay OFF (Other 1Mz and
than above). Resistance above
1) Turn starting switch OFF. 2) Replace relay L115 with normal relay. 3) Turn starting
switch ON.
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.
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 Resistance 1zandbelow
Between between L115 (Male) (1) - (2)
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, L24, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter. 4) 1 minute after starting switch is turned ON.

Hot short-circuiting Wiring harness between E08 Voltage between E08, E09 and
3 1V and below
and E09 chassis ground
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 L24 and L115.
3) Connect T-adapter.
Short circuit with chassis
4 Wiring harness between L24 Resistance between L24
ground in wiring harness 1Mz and
(female) (12) and L115 (female) (female) (12), L115 (female) (2)
above
(2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L24. 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 L24 (12) and chassis ground
above

20-628 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]

Related circuit diagram

WA320-5H 20-629
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Troubleshooting Code [E-4] (The parking brake (Mechanical type)


does not function)
Speed meter specification (STD)
a) Parking brake dragging prevention does not function (mechanical type)
Controller The parking brake (Mechanical type) does not function
Action Code Failure Code
Code Trouble a) Parking brake dragging prevention does not function (mechanical
- - - type)

Description of • Parking brake dragging prevention does not function


Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Parking brake dragging prevention does not function
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Replace relay L112 with normal relay. 3) Turn starting
switch ON. 4) Operate parking brake switch.
Condition is Relay L112 is
Does condition become normal when parking abnormal. normal.
brake neutral safety relay L112 is replaced with
normal relay? Condition is Defective
normal. relay L112.

Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1 neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
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 1zandbelow
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
1Mz and
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2)
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
Measure between (2) o (3) with diode range
3 Defective diode (D01)
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

20-630 WA320-5H
white 20-631
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

b) Parking brake "non-applied" indicator does not light up (mechanical type)


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

Description of • Parking brake "non-applied" indicator does not light up


Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Parking brake "non-applied" indicator does not light up
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L53. 3) Connect T-adapter.
Place parking brake lever 1Mz and
Defective parking brake Between L53 Resistance
1 LOCK. above
lowest switch (Male) (3) and
(2) Place parking brake lever
Resistance 1zandbelow
FREE.
1) Turn starting switch OFF. 2) Disconnect connector L47. 3) Connect T-adapter.
Place parking brake lever 1Mz and
Defective parking brake Between L47 Resistance
2 middle switch LOCK to MIDDLE. above
(Male) (3) and
(1) Place parking brake lever MID- Resistance 1zandbelow
DLE to FREE.
Possible
Causes and 1) Turn starting switch OFF. 2) Replace relay L101 with normal relay. 3) Turn starting
switch ON. 4) Operate parking brake switch.
Standard
Values Relay L101 is
Does condition become normal Condition is abnormal. normal.
when parking brake relay L101
is replaced with normal relay? Condition is normal. Defective
relay L101.

Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
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 Resistance 1zandbelow
Between between L101 (Male) (1) - (2)
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L101 (Male) (1) - (2) above

20-632 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L47, L53, fuse FS1 terminal.
3) Connect T-adapter.
Wiring harness between fuse FS1 (4) and L47 Resistance 1zandbelow
(Female) (1)
Wiring harness between L47 (Female) (2) and
Resistance 1zandbelow
J12 (6), (7) and L53 (Female) (1)
Wiring harness between L53 (Female) (2) and
J10 (19), (18) and L21 (Female) (13) Resistance 1zandbelow
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L53 (Female) (2) and
tive contact) J10 (Female) (19), (20) and J05 (14), (16) and Resistance 1zandbelow
L101 (Female) (1)
Wiring harness between L53 (Female) (2) and
J10 (Female) (19), (20) and J05 (14), (17) and Resistance 1zandbelow
L101 (Female) (5)
Wiring harness between L101 (Female) (2) and
Resistance 1zandbelow
chassis ground
Wiring harness between L47 (Female) (2) and
Resistance 1zandbelow
Possible J12 (Female) (6), (4) and L101 (Female) (3)
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L101, L47, L53, both ends of
Values fuse FS1 terminal. 3) Connect T-adapter.
Resistance between L47
Wiring harness between fuse (Female) (1) and chassis 1Mz and
FS1 (4) and L47 (Female) (1) ground above

Wiring harness between L47 Resistance between L47 1Mz and


5 Wiring harness ground fault (Female) (2) and J12 (6), (5) (Female) (2), L53 (Female) (1)
above
and L53 (Female) (1) and chassis ground
Wiring harness between L47 Resistance between L47
(Female) (2) and J12 (6), (4) (Female) (2), L101 (Female) (3) 1Mz and
and L101 (Female) (3) and chassis ground above

a In the above case, the fuse is blown.

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

Between L21 Place parking brake lever


7 Defective machine monitor Voltage 1V and below
(13) and LOCK to MIDDLE.
chassis Place parking brake lever
ground FREE. Voltage 20 - 30V

WA320-5H 20-633
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Related circuit diagram

20-634 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

WA320-5H 20-635
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Load meter specification (If equipped)


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

Description of • Parking brake dragging prevention does not function


Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Parking brake dragging prevention does not function
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Replace relay L112 with normal relay. 3) Turn starting
switch ON. 4) Operate parking brake switch.
Condition is Relay L112 is
Does condition become normal when parking abnormal. normal.
brake neutral safety relay L112 is replaced with
normal relay? Condition is Defective
normal. relay L112.

Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1
neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
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 Resistance 1zandbelow
between L112 (Male) (1) - (2)
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
Values Wiring harness between L112 Resistance between L112 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
1Mz and
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2) 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

20-636 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

b) Parking brake "non-applied" indicator does not light up (mechanical type)


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

Description of • Parking brake "non-applied" indicator does not light up


Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Parking brake "non-applied" indicator does not light up
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L53. 3) Connect T-adapter.
Place parking brake lever 1Mz and
Defective parking brake Between L53 Resistance
1 LOCK. above
lowest switch (Male) (3) and
(2) Place parking brake lever
Resistance 1zandbelow
FREE.
1) Turn starting switch OFF. 2) Disconnect connector L47. 3) Connect T-adapter.
Place parking brake lever 1Mz and
Defective parking brake Between L47 Resistance
2 middle switch LOCK to MIDDLE. above
(Male) (3) and
(1) Place parking brake lever MID- Resistance 1zandbelow
DLE to FREE.
Possible
Causes and 1) Turn starting switch OFF. 2) Replace relay L101 with normal relay. 3) Turn starting
switch ON. 4) Operate parking brake switch.
Standard
Values Relay L101 is
Does condition become normal Condition is abnormal. normal.
when parking brake relay L101
is replaced with normal relay? Condition is normal. Defective
relay L101.

Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
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 Resistance 1zandbelow
Between between L101 (Male) (1) - (2)
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L101 (Male) (1) - (2) above

WA320-5H 20-637
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L47, L53, L25 fuse FS1 termi-
nal.
3) Connect T-adapter.
Wiring harness between fuse FS1 (4) and L47
Resistance 1zandbelow
(Female) (1)
Wiring harness between L47 (Female) (2) and
Resistance 1zandbelow
J12 (6), (7) and L53 (Female) (1)
Wiring harness between L53 (Female) (2) and Resistance 1zandbelow
Wiring harness discontinu- J10 (19), (18) and L25 (Female) (17)
4 ity (Disconnection or defec- Wiring harness between L53 (Female) (2) and
tive contact) J10 (Female) (19), (20) and J05 (14), (16) and Resistance 1zandbelow
L101 (Female) (1)
Wiring harness between L53 (Female) (2) and
J10 (Female) (19), (20) and J05 (14), (17) and Resistance 1zandbelow
L101 (Female) (5)
Wiring harness between L101 (Female) (2) and
chassis ground Resistance 1zandbelow

Wiring harness between L47 (Female) (2) and Resistance 1zandbelow


Possible J12 (Female) (6), (4) and L101 (Female) (3)
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L101, L47, L53, both ends of
Values fuse FS1 terminal. 3) Connect T-adapter.
Resistance between L47
Wiring harness between fuse 1Mz and
FS1 (4) and L47 (Female) (1) (Female) (1) and chassis
above
ground
Wiring harness between L47 Resistance between L47
5 Wiring harness ground fault (Female) (2) and J12 (6), (5) (Female) (2), L53 (Female) (1) 1Mz and
above
and L53 (Female) (1) and chassis ground
Wiring harness between L47 Resistance between L47
(Female) (2) and J12 (6), (4) (Female) (2), L101 (Female) (3) 1Mz and
above
and L101 (Female) (3) and chassis ground
a In the above case, the fuse is blown.

Defective junction connec- • Carry out inspection, and if any abnormality is found, repair or replace.
6 tor (J05), (J10) and (J12)
1) Turn starting switch OFF. 2) Disconnect connector L25. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch

7 Defective machine monitor Between L25 Place parking brake lever


Voltage 1V and below
(17) and LOCK to MIDDLE.
chassis Place parking brake lever
ground Voltage 20 - 30V
FREE.

20-638 WA320-5H
white 20-639
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

Related circuit diagram

20-640 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]

WA320-5H 20-641
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]

Troubleshooting Code [E-5] (Defective boom kick-out function and


cancellation)
Controller
Action Code Failure Code
Code Trouble Defective boom kick-out function and cancellation
- - -

Description of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch system, lift
Trouble arm PPC detent system and lift arm detent relay system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Boom kick-out does not function or cannot be cancelled.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L113. 3) Replace lift arm detent
relay (L113) with normal relay. 4) Operate boom kick-out.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
1) Turn starting switch OFF. 2) Disconnect connector L113. 3) Connect T-adapter.
1 Defective lift arm detent Between L113 (Male) (1) and (2) Resistance 200 - 400z
relay (L113)
1) Turn starting switch OFF. 2) Disconnect connector L113. 3) Solid part check.
4) Applies impressed voltage between L113 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L113 (Male) (1) - (2)
L113 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L113 (Male) (1) - (2) above

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 1zandbelow
fuse FS1 (13)
Wiring harness between F04 (Female) (B) and
Resistance 1zandbelow
L113 (Female) (2)
Wiring harness between F04 (Female) (C) and
Resistance 1zandbelow
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L113 (Female) (1) and Resistance 1zandbelow
tive contact) fuse FS1 (13)
Wiring harness between L113 (Female) (3) and
Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between L113 (Female) (5) and Resistance 1zandbelow
L36 (Female) (1)
Wiring harness between L36 (Female) (2) and
Resistance 1zandbelow
chassis ground
a With all the above items, the boom kick-out does not function

20-642 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector F04, L113, L36 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F04 Resistance between F04
(Female) (B) and L113 1Mz and
(Female) (B), L113 (Female)
(Female) (2) (2) and chassis ground above

Wiring harness between L113 Resistance between L113


(Female) (5) and L36 (Female) (Female) (5), L36 (Female) (1) 1Mz and
above
(1) and chassis ground
a In this case, the boom kick-out detent does not function (lever returns to neutral)
5 Wiring harness ground fault Resistance between F04
Wiring harness between F04 (Female) (A), FS1 (13) and 1Mz and
(Female) (A) and fuse FS1 (13) above
Possible chassis ground
Causes and
Standard Wiring harness between L113 Resistance between L113 1Mz and
(Female) (1), fuse FS1 (13) and
Values (Female) (1) and fuse FS1 (13) above
chassis ground
Resistance between L113
Wiring harness between L113 1Mz and
(Female) (3), fuse FS1 (13) and
(Female) (3) and fuse FS1 (13) chassis ground
above

a In this case, the fuse is blown and no detents function (lever returns to neutral)

1) Turn starting switch OFF. 2) Disconnect connector L113, L36. 3) Connect T-


adapter. 4) Turn starting switch ON.
Wiring harness between L113 Voltage between L113
Hot short-circuiting (Female) (5) and L36 (Female) (Female) (5), L36 (Female) (1) 1V and below
6 between harnesses (1) and chassis ground
a In this case, the boom kick-out does not function (lever does not return to neu-
tral)

WA320-5H 20-643
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]

Related circuit diagram

20-644 WA320-5H
white 20-645
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]

Troubleshooting Code [E-6] (Defective bucket positioner function


and cancellation)
Controller
Action Code Failure Code
Code Trouble Defective bucket positioner function and cancellation
- - -

Description of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system,
Trouble bucket PPC detent system and bucket detent relay system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Bucket positioner does not function or cannot be cancelled.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L114. 3) Replace bucket detent
relay (L114) with normal relay. 4) Operate bucket positioner.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
1) Turn starting switch OFF. 2) Disconnect connector L114. 3) Connect T-adapter.
1 Defective bucket detent Between L114 (Male) (1) and (2) Resistance 200 - 400z
relay (L114)
1) Turn starting switch OFF. 2) Disconnect connector L114. 3) Solid part check.
4) Applies impressed voltage between L114 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L114 (Male) (1) - (2)
L114 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L114 (Male) (1) - (2) above

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 1zandbelow
fuse FS1 (13)
Wiring harness between F03 (Female) (B) and
Resistance 1zandbelow
L114 (Female) (2)
Wiring harness between F03 (Female) (C) and
Resistance 1zandbelow
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L114 (Female) (1) and Resistance 1zandbelow
tive contact) fuse FS1 (13)
Wiring harness between L114 (Female) (3) and
Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between L114 (Female) (5) and Resistance 1zandbelow
L37 (Female) (1)
Wiring harness between L37 (Female) (2) and
Resistance 1zandbelow
chassis ground
a With all the above items, the bucket positioner does not function

20-646 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector F03, L114, L37 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F03 Resistance between F03
(Female) (B) and L114 1Mz and
(Female) (B), L114 (Female)
(Female) (2) above
(2) and chassis ground
a In this case, the bucket positioner detent does not function (lever does not return
to neutral)

Wiring harness between L114 Resistance between L114 1Mz and


(Female) (5) and L37 (Female) (Female) (5), L37 (Female) (1)
above
(1) and chassis ground
5 Wiring harness ground fault a In this case, the bucket positioner does not function (lever returns to neutral)

Possible Resistance between F03


Wiring harness between F03 1Mz and
Causes and (Female) (A) and fuse FS1 (13) (Female) (A), FS1 (13) and above
chassis ground
Standard
Values Resistance between L114
Wiring harness between L114 1Mz and
(Female) (1) and fuse FS1 (13) (Female) (1), fuse FS1 (13) and above
chassis ground
Resistance between L114
Wiring harness between L114 1Mz and
(Female) (3), fuse FS1 (13) and
(Female) (3) and fuse FS1 (13) above
chassis ground
a In this case, the fuse is blown and no detents function (lever returns to neutral)

1) Turn starting switch OFF. 2) Disconnect connector L114, L37. 3) Connect T-


adapter. 4) Turn starting switch ON.
Wiring harness between L114 Voltage between L114
6 Hot short-circuiting (Female) (5) and L37 (Female) (Female) (5), L37 (Female) (1) 1V and below
between harnesses (1) and chassis ground
a In this case, the bucket positioner does not function (lever does not return to
neutral)

WA320-5H 20-647
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]

Related circuit diagram

20-648 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-7]

Troubleshooting Code [E-7] (Defective lift arm FLOATING holding


function and cancellation)
Controller
Action Code Failure Code
Code Trouble Defective lift arm FLOATING holding function and cancellation
- - -

Description of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING PPC detent
Trouble system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Lift arm FLOATING holding does not function or cannot be cancelled.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting

Defective lift arm FLOAT- 1) Turn starting switch OFF. 2) Disconnect connector L35. 3) Connect T-adapter.
1
ING PPC detent Between L35 (Male) (1) and (2) Resistance 30 - 50z
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector L35 and fuse FS1 terminal. 3)
Standard Connect T-adapter.
Values Wiring harness discontinu-
2 ity (Disconnection or defec- Wiring harness between fuse FS1 (13) and L35
Resistance 1zandbelow
(Female) (1)
tive contact)
Wiring harness between L35 (Female) (2) and Resistance 1zandbelow
chassis ground

Related circuit diagram

WA320-5H 20-649
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]

Troubleshooting Code [E-8] (The wiper does not function)


a) The rear wiper does not function
Controller
Action Code Failure Code The wiper does not function
Code Trouble a) The rear wiper does not function
- - -
Description of • The rear wiper does not function due defective rear wiper, switch, timer or wiring harness.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The rear wiper does not function.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L57. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
Between L57 (6) and chassis ground Voltage 20 - 30V
Between L57 (2) and chassis Turn wiper
ground switch Lo. Voltage 20 - 30V
1 Defective rear wiper motor
Between L57 (1) and chassis Turn wiper
Voltage 20 - 30V
ground switch Hi.
• 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.

1) Turn starting switch OFF. 2) Disconnect connector L48. 3) Insert T-adapter.


4) Connect connector. 5) Turn starting switch ON.
Between L48 (3) and chassis ground Voltage 20 - 30V
Between L48 (4) and chassis Turn wiper Voltage 20 - 30V
ground switch INT
2 Defective wiper timer Turn wiper
Possible Between L48 (2) and chassis
Causes and ground switch Voltage 20 - 30V
WASHER
20 - 30V o
Standard

0V OV o
Values
Between L48 (5) and chassis ground
(The voltage is output intermittently by wiper Voltage
20 - 30V
switch INT)
(Repeated)
1) Turn starting switch OFF. 2) Disconnect connector L05. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.

Between L05 Turn wiper switch Lo. Resistance 1zandbelow


(Male) (7) and 1Mz and
(5) Other than above. Resistance above

Between L05 Turn wiper switch Hi. Resistance 1zandbelow


(Male) (7) and 1Mz and
3 Defective rear wiper switch (4) Other than above. Resistance
above

Between L05 Turn wiper switch INT Resistance 1zandbelow


(Male) (7) and 1Mz and
(2) Other than above. Resistance
above

Between L05 Turn wiper switch INT Resistance 1zandbelow


(Male) (3) and 1Mz and
(5) Other than above. Resistance above

20-650 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L57 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between L05 (Female) (2) and Resistance 1V and below
L48 (Female) (4)
Wiring harness between L05 (Female) (3) and
Resistance 1V and below
L48 (Female) (5)
Wiring harness between L05 (Female) (5) and
Resistance 1V and below
L57 (Female) (2)
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L05 (Female) (4) and
L57 (Female) (1) Resistance 1V and below
tive contact)
Wiring harness between L48 (Female) (6) and Resistance 1V and below
L57 (Female) (5)
Wiring harness between fuse FS1 (14) and L05
Resistance 1V and below
(Female) (7)
Wiring harness between fuse FS1 (14) and L48
Resistance 1V and below
(Female) (3)
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
1Mz and
Values (Female) (2) and L48 (Female) (Female) (2), L48 (Female) (4)
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 1Mz and
(Female) (5) and L57 (Female) (Female) (5), L57 (Female) (2)
(2) and chassis ground above

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) 1Mz and
(Female) (6), L57 (Female) (5)
(5) above
and chassis ground
Resistance between L05
Wiring harness between fuse (Female) (7) and chassis 1Mz and
FS1 (14) and L05 (Female) (7) ground above

Resistance between L48


Wiring harness between fuse (Female) (3) and chassis 1Mz and
FS1 (14) and L48 (Female) (3) ground above

Wiring harness between fuse Resistance between L57 1Mz and


(Female) (6) and chassis
FS1 (14) and L57 (Female) (6) above
ground

WA320-5H 20-651
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]

Related circuit diagram

20-652 WA320-5H
white 20-653
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]

b) The rear wiper does not function


Controller
Action Code Failure Code The wiper does not function
Code Trouble
b) The rear wiper does not function
- - -
Description of • The rear wiper does not function due defective rear wiper, switch, timer or wiring harness.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The rear wiper does not function.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L52. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
Between L52 (4) and chassis ground Voltage 20 - 30V
Between L52 (2) and chassis Turn wiper
1 Defective rear wiper motor Voltage 20 - 30V
ground switch Lo.
• When the wiper switch is turned OFF during running of the wiper, the voltage is
applied between the L52 (Female) (1) and chassis ground until the wiper motor
stops.

1) Turn starting switch OFF. 2) Disconnect connector L05. 3) Insert T-adapter.


4) Connect connector. 5) Turn starting switch ON.

Between L05 Turn wiper switch Lo. Resistance 1zandbelow


(Male) (7) and 1Mz and
2 Defective rear wiper switch (9) Other than above. Resistance above

Between L05 Turn wiper switch OFF. Resistance 1zandbelow


(Male) (8) and 1Mz and
(9) Other than above. Resistance
above
1) Turn starting switch OFF. 2) Disconnect connector L05, L52 and fuse FS1 termi-
nal. 3) Connect T-adapter.
Possible
Causes and Wiring harness between L05 (Female) (8) and Resistance 1zandbelow
Standard L52 (Female) (1)
Values Wiring harness discontinu- Wiring harness between L05 (Female) (9) and
3 ity (Disconnection or defec- L52 (Female) (2) Resistance 1zandbelow
tive contact)
Wiring harness between fuse FS1 (14) and L05
(Female) (7) Resistance 1zandbelow

Wiring harness between fuse FS1 (14) and L57 Resistance 1zandbelow
(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) 1Mz and
(Female) (8), L52 (Female) (1)
(1) above
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 1Mz and
(Female) (7) and chassis
FS1 (14) and L05 (Female) (7) above
ground
Resistance between L52
Wiring harness between fuse 1Mz and
(Female) (6) and chassis
FS1 (14) and L52 (Female) (4) ground above

a In the all above cases, the fuse is blown.

20-654 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]

Related circuit diagram

WA320-5H 20-655
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]

Troubleshooting Code [E-9] (The window washer does not function)


Controller
Action Code Failure Code Code Trouble The window washer does not function
- - -

Description of • The window washer does not function due defective window washer motor, switch, timer (Front only) or wiring har-
Trouble ness.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The window washer does not function.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector B07, B06. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
• Front washer motor
Defective window washer
1
motor Between B07 (1) and chassis ground Voltage 20 - 30V
• Rear washer motor

Between B06 (1) and chassis ground Voltage 20 - 30V


1) Turn starting switch OFF. 2) Disconnect connector L05. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
• Common to front switch and rear switch.

Between L05 (Male) (7) and chassis ground Voltage 20 - 30V


1) Turn starting switch OFF. 2) Disconnect connector L05. 3) Connect T-adapter.
• Front switch

Possible Between L05 Turn washer switch ON. Resistance 1zandbelow


Causes and 2 Defective wiper switch (Male) (7) and
Standard Turn washer switch OFF. Resistance 1Mz and
(6) above
Values
• Rear switch

Between L05 Turn washer switch ON. Resistance 1zandbelow


(Male) (7) and 1Mz and
(10) Turn washer switch OFF. Resistance
above
Turn washer
Between L05 (Male) (7) and
and wiper low Resistance 1zandbelow
(9), (10)
switch ON.
1) Turn starting switch OFF. 2) Disconnect connector L48. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
Wiring harness between L48 (3) and chassis
ground Voltage 20 - 30V
Defective wiper timer Wiring harness between L48 Turn washer
3 Voltage 20 - 30V
(Relay) (2) and chassis ground switch ON.
Wiring harness between L48 (5) and chassis
ground
Voltage 20 - 30V
(0.2 to 0.8 sec. after the washer switch was
turned ON)

20-656 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L05, L48, B06, B07 and fuse
FS1 terminal. 3) Connect T-adapter.
• Front side

Wiring harness between L05 (Female) (6) and


Resistance 1zandbelow
B07 (Female) (1)
Wiring harness between L05 (Female) (6) and
Resistance 1zandbelow
L48 (Female) (2)
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L05 (Female) (3) and Resistance 1zandbelow
tive contact) L48 (Female) (5)
• Rear side

Wiring harness between L05 (Female) (10) and


B06 (Female) (1) Resistance 1zandbelow

• Common to front and rear side.

Wiring harness between fuse FS1 (14) and L05


(Female) (7) Resistance 1zandbelow

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
Values • Front side

Wiring harness between L05 Resistance between L05


(Female) (6) and B07 (Female) 1Mz and
(Female) (6), B07 (Female) (1)
above
(1) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (6) and L48 (Female) 1Mz and
(Female) (6), L48 (Female) (2) above
(2) and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (3) and L48 (Female) (Female) (7), L48 (Female) (5) 1Mz and
5 Wiring harness ground fault above
(5) and chassis ground
• Rear side

Wiring harness between L05 Resistance between L05


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

Resistance between L52


Wiring harness between fuse (Female) (7) and chassis 1Mz and
FS1 (14) and L05 (Female) (7) above
ground
a In the all above cases, the fuse is blown.

WA320-5H 20-657
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]

Related circuit diagram

20-658 WA320-5H
white 20-659
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Troubleshooting Code [E-10] (Lamps do not work properly)


a) Neither high beam nor low beam of headlamp light up
Controller
Action Code Failure Code Lamps do not work properly
Code Trouble a) Neither high beam nor low beam of headlamp light up
- - -

Description of • Head lamp (Hi beam and Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in
Trouble the head lamp system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Hi beam and Lo beam) does not light ON when the lamp switch is turned STEP 2.
Machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and relay,
Related between fuse and lamp)
Information
• When circuits for other lamp systems are normal

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector HEAD L, HEAD R. 3) Insert T-
adapter. 4) Connect connector. 5) Turn starting switch ON.
Between
HEAD L (3) Turn lamp switch STEP 2 and Voltage 20 - 30V
and chassis dimmer switch Lo.
ground
Between
HEAD L (3) Turn lamp switch STEP 2 and
Voltage 20 - 30V
and chassis dimmer switch Hi.
1 Defective head lamp ground
Between
HEAD R (3) Turn lamp switch STEP 2 and
and chassis Voltage 20 - 30V
dimmer switch Lo.
ground
Possible Between
Causes and HEAD R (3) Turn lamp switch STEP 2 and
Voltage 20 - 30V
Standard and chassis dimmer switch Hi.
Values ground
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
1Mz and
Turn lamp switch OFF. Resistance above
Between L04
(Male) (2) and Turn lamp switch 1 STEP. Resistance 1Mz and
(3) above

2 Defective lamp switch and Turn lamp switch STEP 2. Resistance 1zandbelow
dimmer switch
Between L04 Turn dimmer switch Lo. Resistance 1zandbelow
(Male) (4) and 1Mz and
(3) Turn dimmer switch Hi. Resistance
above

Between L04 1Mz and


Turn dimmer switch Lo. Resistance
(Male) (5) and above
(3) Turn dimmer switch Hi. Resistance 1zandbelow

20-660 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Replace relay L120 with normal relay. 3) Turn starting
switch ON.

Does condition become normal Relay L120 is


Condition is abnormal.
when the headlamp relay (left) normal.
L120 is replaced with normal Defective
relay? Condition is normal.
relay L120.

Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L120. 3) Solid part check.
3 4) Applies impressed voltage between L120 (Male) (1) - (2)
(Left side) (L120)
Between L120 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L120. 3) Solid part check.
Applies 24V impressed voltage Resistance 1zandbelow
Between between L120 (Male) (1) - (2)
L120 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L120 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace relay L119 with normal relay. 3) Turn starting
switch ON.

Does condition become normal Relay L119 is


Condition is abnormal. normal.
when headlamp relay (right)
L119 is replaced with normal Defective
relay? Condition is normal.
relay L119.

Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
4
(Right side) (L119) Between L119 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
Causes and 4) Applies impressed voltage between L119 (Male) (1) - (2)
Standard
Values Applies 24V impressed voltage
Between Resistance 1zandbelow
between L119 (Male) (1) - (2)
L119 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L119 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector L04, L120, L119, HEAD L,
HEAD R and fuse FS1 terminal (8), (9). 3) Connect T-adapter.
a When both sides are defective (in this case, clearance lamp also does not light
up)

Wiring harness between L04 (Female) (3) and


Resistance 1zandbelow
chassis ground
a When left side is defective

Wiring harness between L120 (Female) (5) and


Resistance 1zandbelow
HEAD L (Female) (3)
Wiring harness discontinu-
5 ity (Disconnection or defec- Wiring harness between fuse FS1 terminal (8)
Resistance 1zandbelow
tive contact) and L120 (Female) (1), (3)
Wiring harness between L120 (Female) (2) and
Resistance 1zandbelow
L04 (Female) (2)
a When right side is defective

Wiring harness between L119 (Female) (5) and Resistance 1zandbelow


HEAD R (Female) (3)
Wiring harness between fuse FS1 terminal (9)
Resistance 1zandbelow
and L119 (Female) (1), (3)
Wiring harness between L119 (Female) (2) and
Resistance 1zandbelow
L04 (Female) (2)

WA320-5H 20-661
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Related circuit diagram


Speed meter specification (STD)

9JF01508

20-662 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Related circuit diagram


Load meter specification (If equipped)

9JF01509

WA320-5H 20-663
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

b) Head lamp (Lo beam) does not light ON


Controller
Action Code Failure Code Each lamps does not function
Code Trouble
b) Head lamp (Lo beam) does not light ON
- - -

Description of • Head lamp (Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
Trouble lamp system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Lo beam) does not light ON when the lamp switch is turned STEP 2.
Machine

Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector HEAD L, HEAD R. 3) Insert T-
adapter. 4) Connect connector. 5) Turn starting switch ON.
Between
HEAD L (3) Turn lamp switch STEP 2 and
Voltage 20 - 30V
1 Defective head lamp and chassis dimmer switch Lo.
ground
Between
HEAD R (3) Turn lamp switch STEP 2 and
and chassis dimmer switch Lo. Voltage 20 - 30V
ground
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.

Turn lamp switch OFF. Resistance 1Mz and


Possible above
Between L04
Causes and (Male) (2) and 1Mz and
Standard (3) Turn lamp switch 1 STEP. Resistance above
Values
Defective lamp switch and Turn lamp switch STEP 2. Resistance 1zandbelow
2 dimmer switch
Between L04 Turn dimmer switch Lo. Resistance 1zandbelow
(Male) (4) and 1Mz and
(3) Turn dimmer switch Hi. Resistance
above

Between L04 1Mz and


Turn dimmer switch Lo. Resistance
(Male) (5) and above
(3) Turn dimmer switch Hi. Resistance 1zandbelow
1) Turn starting switch OFF. 2) Disconnect connector L04, HEAD L, HEAD R.
3) Connect T-adapter.
Wiring harness discontinu-
3 ity (Disconnection or defec- Wiring harness between L04 (Female) (4) and
Resistance 1zandbelow
HEAD L (Female) (1)
tive contact)
Wiring harness between L04 (Female) (4) and Resistance 1zandbelow
HEAD R (Female) (1)

a See "TROUBLESHOOTING CODE [E-10.(a)]".


Related circuit diagram

20-664 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

c) Head lamp (Hi beam) does not light ON


Controller
Action Code Failure Code Each lamps does not function
Code Trouble
c) Head lamp (Hi beam) does not light ON
- - -

Description of • Head lamp (Hi beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
Trouble lamp system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Hi beam) does not light ON when the lamp switch is turned STEP 2.
Machine

Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector HEAD L, HEAD R. 3) Insert T-
adapter. 4) Connect connector. 5) Turn starting switch ON.
Between
HEAD L (3) Turn lamp switch STEP 2 and
Voltage 20 - 30V
1 Defective head lamp and chassis dimmer switch Hi.
ground
Between
HEAD R (3) Turn lamp switch STEP 2 and
and chassis dimmer switch Hi. Voltage 20 - 30V
ground
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.

Turn lamp switch OFF. Resistance 1Mz and


above
Between L04
(Male) (2) and 1Mz and
Possible (3) Turn lamp switch 1 STEP. Resistance above
Causes and
Standard Defective lamp switch and Turn lamp switch STEP 2. Resistance 1zandbelow
2 dimmer switch
Values
Between L04 Turn dimmer switch Lo. Resistance 1zandbelow
(Male) (4) and 1Mz and
(3) Turn dimmer switch Hi. Resistance
above

Between L04 1Mz and


Turn dimmer switch Lo. Resistance
(Male) (5) and above
(3) Turn dimmer switch Hi. Resistance 1zandbelow
1) Turn starting switch OFF. 2) Disconnect connector L04, HEAD L, HEAD R.
3) Connect T-adapter.
a When left side is defective
Wiring harness discontinu-
3 ity (Disconnection or defec- Wiring harness between L04 (Female) (5) and Resistance 1zandbelow
J03 (4), (2) and HEAD L (Female) (2)
a When right side is defective
tive contact)

Wiring harness between L04 (Female) (5) and Resistance 1zandbelow


J03 (4), (2) and HEAD R (Female) (2)

a See "TROUBLESHOOTING CODE [E-10.(a)]".


Related circuit diagram

WA320-5H 20-665
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

d) Clearance lamp (Small lamp) does not light ON


Controller
Action Code Failure Code Each lamps does not function
Code Trouble
d) Clearance lamp (Small lamp) does not light ON
- - -

Description of • Clearance lamp (Small lamp) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the
Trouble clearance lamp system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Clearance lamp (Small lamp) does not light ON when the lamp switch is turned STEP 1.
Machine

Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector HEAD L, HEAD R. 3) Insert T-
adapter. 4) Connect connector. 5) Turn starting switch ON.
Between
HEAD L (5)
Turn lamp switch STEP 1. Voltage 20 - 30V
1 Defective clearance lamp and chassis
ground
Between
HEAD R (5)
and chassis Turn lamp switch STEP 1. Voltage 20 - 30V
ground
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
2 Defective lamp switch Between L04 1Mz and
Turn lamp switch OFF. Resistance
Possible (Male) (2) and above
Causes and (3) Turn lamp switch STEP 1. Resistance 1zandbelow
Standard
Values 1) Turn starting switch OFF. 2) Replace relay L117 with normal relay. 3) Turn starting
switch ON.

Does condition become normal Relay L117 is


Condition is abnormal.
when small lamp relay (left) normal.
L117 is replaced with normal Defective
relay? Condition is normal.
relay L117.
Defective small lamp relay
(Left side) (L117) 1) Turn starting switch OFF. 2) Disconnect connector L117. 3) Solid part check.
a When left side is defec-
3
Between L117 (Male) (1) and (2) Resistance 200 - 400z
tive
1) Turn starting switch OFF. 2) Disconnect connector L117. 3) Solid part check.
4) Applies impressed voltage between L117 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L117 (Male) (1) - (2)
L117 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L117 (Male) (1) - (2) above

20-666 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Replace relay L118 with normal relay. 3) Turn starting
switch ON.

Does condition become normal Relay L118 is


Condition is abnormal.
when small lamp relay (right) normal.
L118 is replaced with normal Defective
relay? Condition is normal. relay L118.
Defective small lamp relay
(Right side) (L118) 1) Turn starting switch OFF. 2) Disconnect connector L118. 3) Solid part check.
a When right side is
4
Between L118 (Male) (1) and (2) Resistance 200 - 400z
defective
1) Turn starting switch OFF. 2) Disconnect connector L118. 3) Solid part check.
4) Applies impressed voltage between L118 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L118 (Male) (1) - (2) Resistance 1zandbelow
L118 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L118 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector L04, L117, L118, HEAD L,
HEAD R and fuse FS2 terminal (10), (11). 3) Connect T-adapter.
a When both sides are defective (in this case, headlamp also does not light up)
Possible
Causes and Wiring harness between L04 (Female) (3) and
Standard chassis ground Resistance 1zandbelow

a When left side is defective


Values

Wiring harness between L117 (Female) (5) and


Resistance 1zandbelow
J10 (9), (10) and HEAD L (Female) (5)
Wiring harness between fuse FS2 (10) and L117
Resistance 1zandbelow
(Female) (1), (3)
Wiring harness discontinu- Wiring harness between L117 (Female) (2) and
5 ity (Disconnection or defec- Resistance 1zandbelow
L04 (Female) (1)
tive contact)
Wiring harness between HEAD L (Female) (4) Resistance 1zandbelow
and chassis ground
a When right side is defective

Wiring harness between L118 (Female) (5) and


Resistance 1zandbelow
HEAD R (Female) (5)
Wiring harness between fuse FS2 (11) and L118 Resistance 1zandbelow
(Female) (1), (3)
Wiring harness between L118 (Female) (2) and
Resistance 1zandbelow
L04 (Female) (1)
Wiring harness between HEAD R (Female) (4)
and chassis ground Resistance 1zandbelow

a See "TROUBLESHOOTING CODE [E-10.(a)]".


Related circuit diagram

WA320-5H 20-667
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

e) Turn signal lamp does not blink


Controller
Action Code Failure Code Each lamps does not function
Code Trouble
e) Turn signal lamp does not blink
- - -

Description of • Turn signal lamp does not blink due to defective switch, lamp or wiring harness (Ground fault) in the turn signal lamp
Trouble system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Turn signal lamp does not blink
Machine

Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.

Between L04 Turn turn-signal switch RIGHT. Resistance 1zandbelow


(Male) (6) and 1Mz and
1 Defective turn-signal switch (7) Turn turn-signal switch LEFT. Resistance
above

Between L04 Turn turn-signal switch RIGHT. Resistance 1zandbelow


(Male) (6) and 1Mz and
(8) Turn turn-signal switch LEFT. Resistance
above
1) Turn starting switch OFF. 2) Disconnect connector L06. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
Possible Turn hazard switch OFF. Resistance 1zandbelow
Causes and Between L06
(Male) (1) and 1Mz and
Standard Turn hazard switch ON. Resistance
Values (2) above

Between L06 Turn hazard switch OFF. Resistance 1zandbelow


(Male) (3) and 1Mz and
(2) Turn hazard switch ON. Resistance above
a When hazard switch does not function
2 Defective hazard switch

Wiring harness discontinuity


(Disconnection or defective Resistance 1Mz and
above
contact)
Between L06
(Male) (5) and 1) Turn starting switch OFF.
(6) 2) Disconnect connector L04,
L119, L120, HEAD L, HEAD R Resistance 1zandbelow
and fuse FS1 terminal (8), (9).
3) Connect T-adapter.

20-668 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L04, L119, L120, HEAD L,
HEAD R and fuse FS1 terminal (8), (9). 3) Connect T-adapter.
a When both sides are defective (in this case, headlamp also does not light up)

Wiring harness between L04 (Female) (3) and


chassis ground Resistance 1zandbelow

a When left side is defective

Wiring harness between L04 (Female) (8) and


J03 (10), (6) and HEAD L (Female) (6) Resistance 1zandbelow

Wiring harness between HEAD L (Female) (4) Resistance 1zandbelow


and chassis ground
Wiring harness between L04 (Female) (8) and
J03 (10), (9) and R22 (Female) (1) Resistance 1zandbelow

Wiring harness between R22 (Female) (6) and


chassis ground Resistance 1zandbelow

Wiring harness between J01 (Female) (17) and


Resistance 1zandbelow
D12 (2), (1) and J03 (7)
a When right side is defective

Wiring harness between L04 (Female) (7) and


J03 (20), (16) and HEAD R (Female) (6) Resistance 1zandbelow

Wiring harness between HEAD R (Female) (4)


and chassis ground Resistance 1zandbelow
Possible
Causes and Wiring harness discontinu-
Standard Wiring harness between L04 (Female) (7) and Resistance 1zandbelow
3 ity (Disconnection or defec- J03 (20), (19) and R23 (Female) (1)
Values tive contact)
Wiring harness between R23 (Female) (6) and
chassis ground Resistance 1zandbelow

Wiring harness between J01 (Female) (20) and


D11 (2), (1) and J03 (17) Resistance 1zandbelow

a When both sides are defective

Wiring harness between fuse FS1 (10) and J10


Resistance 1zandbelow
(4), (1) and L06 (Female) (1)
Wiring harness between fuse FS1 (2) and L06
Resistance 1zandbelow
(Female) (3)
Wiring harness between L06 (Female) (2) and Resistance 1zandbelow
L49 (Female) (B)
Wiring harness between L49 (Female) (E) and
Resistance 1zandbelow
chassis ground
Wiring harness between L49 (Female) (L) and
J01 (Female) (6) Resistance 1zandbelow

Wiring harness between L04 (Female) (6) and


J01 (Female) (4) Resistance 1zandbelow

a When hazard switch does not function

Wiring harness between L06 (Female) (5) and


Resistance 1zandbelow
J01 (Female) (4)
Wiring harness between L06 (Female) (6) and
J01 (Female) (18) Resistance 1zandbelow

a See "TROUBLESHOOTING CODE [E-10.(a)]".


Related circuit diagram

WA320-5H 20-669
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

f) Working lamp does not light ON


Controller
Action Code Failure Code Each lamps does not function
Code Trouble
f) Working lamp does not light ON
- - -

Description of • Working lamp does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the clearance lamp
Trouble system.

Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Working lamp does not light ON.
Machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Related • When circuits for other lamp systems are normal
Information
• When side lamps do not light up, carry out troubleshooting first for side lamp system.

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector C05, C06, B01 or B02.
3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON.
Turn front working lamp switch Voltage 20 - 30V
Between C05 ON.
(1) and chas-
sis ground Turn front working lamp switch Voltage 1V and below
OFF.
Turn front working lamp switch
Between C06 Voltage 20 - 30V
ON.
(1) and chas-
1 Defective working lamp sis ground Turn front working lamp switch Voltage 1V and below
OFF.
Turn rear working lamp switch Voltage 20 - 30V
Between B01 ON.
(1) and chas-
sis ground Turn rear working lamp switch
Voltage 1V and below
OFF.
Turn rear working lamp switch
Between B02 ON. Voltage 20 - 30V
(1) and chas-
sis ground Turn rear working lamp switch
Voltage 1V and below
OFF.
1) Turn starting switch OFF. 2) Disconnect connector C05, C06, B01 or B02.
Possible 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON.
Causes and
Standard Turn front working lamp switch
Between L07 ON. Resistance 1zandbelow
Values (Male) (2) and
2 Defective working lamp (3) Turn front working lamp switch 1Mz and
Resistance
switch OFF. above
Turn rear working lamp switch
Between L08 ON. Resistance 1zandbelow
(Male) (2) and
(3) Turn rear working lamp switch 1Mz and
Resistance
OFF. above
1) Turn starting switch OFF.2) Replace relay L122 with normal relay. 3) Turn starting
switch ON.
Relay L122 is
Does condition become normal Condition is abnormal.
normal.
when working lamp relay L122
is replaced with normal relay? Defective
Condition is normal.
relay L122.

Defective working lamp 1) Turn starting switch OFF. 2) Disconnect connector L122. 3) Solid part check.
3
relay (L122) Between L122 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L122. 3) Solid part check.
4) Applies impressed voltage between L122 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L122 (Male) (1) - (2)
L122 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L122 (Male) (1) - (2) above

20-670 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector L04, L119, L120, HEAD L,
HEAD R and fuse FS1 terminal (8), (9). 3) Connect T-adapter.
a When all lamps are defective

Wiring harness between L117 (Female) (5) and


L122 (Female) (1) Resistance 1zandbelow

Wiring harness between L122 (Female) (2) and


chassis ground Resistance 1zandbelow

a When front lamps are defective

Wiring harness between L122 (Female) (2) and


Resistance 1zandbelow
L07 (Female) (2)
Possible Wiring harness between fuse FS2 (12) and L122
Causes and Resistance 1zandbelow
Wiring harness discontinu- (Female) (1)
Standard 4 ity (Disconnection or defec-
Values tive contact) Wiring harness between L07 (Female) (3) and
Resistance 1zandbelow
C05 (Female) (1), C06 (Female) (1)
Wiring harness between C05 (Female) (2), C06
Resistance 1zandbelow
(Female) (2) and chassis ground
a When rear lamps are defective

Wiring harness between L122 (Female) (4) and


Resistance 1zandbelow
L08 (Female) (2)
Wiring harness between fuse FS2 (13) and L122
Resistance 1zandbelow
(Female) (3)
Wiring harness between L08 (Female) (3) and
Resistance 1zandbelow
B01 (Female) (1), B02 (Female) (1)
Wiring harness between B01 (Female) (2), B02
Resistance 1zandbelow
(Female) (2) and chassis ground

a See "TROUBLESHOOTING CODE [E-10.(a)]".


Related circuit diagram

WA320-5H 20-671
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]

Troubleshooting Code [E-11] (The horn does not sound)


Controller
Action Code Failure Code Code Trouble The horn does not sound
- - -
Description of • Horn does not sound due to defective switch, relay, horn or wiring harness in the horn system.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The horn does not sound.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


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

Between L116 (2) and chassis Voltage 1V and below


ground
Between L116 (5) and chassis Voltage 20 - 30V
ground
1) Turn starting switch OFF. 2) Replace relay L116 with normal relay. 3) Turn starting
switch ON.
Possible
Causes and 2 Defective horn relay (L116) Relay L116 is
Does condition become normal Condition is abnormal. normal.
Standard when horn and lamp relay L116
Values is replaced with normal relay? Defective
Condition is normal.
relay L116.
1) Turn starting switch OFF. 2) Disconnect connector L116. 3) Solid part check.
Between L116 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L116. 3) Solid part check.
4) Applies impressed voltage between L116 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L116 (Male) (1) - (2)
L116 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L116 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector F01, F02. 3) Insert T-adapter.
4) Connect T-adapter. 5) Turn starting switch ON.
Between F01 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
3 Defective horn Horn switch OFF Voltage 1V and below
(2)
Between F02 Push horn switch ON Voltage 20 - 30V
(Male) (1) and
(2) Horn switch OFF Voltage 1V and below

20-672 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]

Causes Standard Value in Normal State and Remarks on Troubleshooting


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

Wiring harness between L116 Resistance between L116


(Female) (5) and F01 (Female) (Female) (5), F01 (Female) (1), 1Mz and
F02 (Female) (1) and chassis above
(1), F02 (Female) (1)
ground
a In case of *1 above, fuse is blown
a In case of *2 above, horn does not stop sounding

Related circuit diagram

WA320-5H 20-673
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

Troubleshooting Code [E-12] (Defective the air conditioner)


a) The air conditioner does not work
Controller
Action Code Failure Code Defective the air conditioner
Code Trouble a) The air conditioner does not work
- - -
Description of • The air conditioner does not work.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The air conditioner does not work.
Machine
Related • If fuse FS2 (2) is blown, check wiring harness between fuse FS2 (2) - C03 (Female) (8) for short circuit with ground.
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector C03, fuse FS2 terminal.
3) Connect T-adapter.
Possible Wiring harness discontinu-
Causes and 1 ity (Disconnection or defec- Wiring harness between fuse FS2 (2) and C03 Resistance 1zandbelow
(Female) (8)
Standard tive contact)
Values Wiring harness between C03 (Female) (11) and Resistance 1zandbelow
chassis ground

2
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

20-674 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

Related circuit diagram

WA320-5H 20-675
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

b) Air does not flow out or amount of air cannot be adjusted.

Controller
Action Code Failure Code Defective air conditioner
Code Trouble
b) Air does not flow out or amount of air cannot be adjusted.
- - -
Description of • Air does not flow out or amount of air cannot be adjusted.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Air does not flow out or amount of air cannot be adjusted.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


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

20-676 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

Causes Standard Value in Normal State and Remarks on Troubleshooting


Wiring harness between fuse Resistance between fuse FS1 1Mz and
(2), A09 (Female) (3) and chas-
FS1 (2) and A09 (Female) (3) * above
sis ground
Wiring harness between C03 Resistance between C03
1Mz and
(Female) (7) and A09 (Female) (Female) (7), A09 (Female) (2) above
(2) and chassis ground
Wiring harness between C03 Resistance between C03
1Mz and
(Female) (4) and A10 (Female) (Female) (4), A10 (Female) (2)
(2) and chassis ground above
Wiring harness between C03 Resistance between C03 1Mz and
(Female) (5) and A11 (Female) (Female) (5), A11 (Female) (2) above
(2) and chassis ground
Wiring harness between C03 Resistance between C03
1Mz and
(Female) (6) and A13 (Female) (Female) (6), A13 (Female) (2)
above
(2) and chassis ground
Wiring harness between A09 Resistance between A09
3 Wiring harness ground fault 1Mz and
(Female) (4) and A01 (Female) (Female) (4), A01 (Female) (6)
(6) and chassis ground above
Wiring harness between A10 Resistance between A10
(Female) (4) and A01 (Female) 1Mz and
(Female) (4), A01 (Female) (5) above
(5) and chassis ground
Wiring harness between A11 Resistance between A11
(Female) (4) and A01 (Female) 1Mz and
(Female) (4), A01 (Female) (4)
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.
A11 relay.
when relay is replaced with nor-
mal relay? Relay is
Condition is abnormal.
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? Relay is
Condition is abnormal.
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

10
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

a See "TROUBLESHOOTING CODE [E-12.(a)]".


Related circuit diagram

WA320-5H 20-677
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

c) Does not cool or temperature cannot be adjusted.

Controller
Action Code Failure Code Defective air conditioner
Code Trouble
c) Does not cool or temperature cannot be adjusted.
- - -
Description of • Does not cool or temperature cannot be adjusted.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Does not cool or temperature cannot be adjusted.
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector A12, A15 and fuse FS2 termi-
nal. 3) Connect T-adapter.
Power supply wiring har-
ness discontinuity (Discon- Wiring harness between fuse FS2 (2) and A12
1 Resistance 1zandbelow
nection or defective (Female) (1), (4)
contact) Wiring harness between fuse FS2 (2) and A15 Resistance 1zandbelow
(Female) (1), (4)
1) Turn starting switch OFF. 2) Disconnect connector A02, A03, A05, A07, A08, A12,
A15, B04, C03, C04 and J06. 3) Connect T-adapter.
Wiring harness between A05 (Female) (1) and
Resistance 1zandbelow
chassis ground
Wiring harness between A05 (Female) (2) and
Resistance 1zandbelow
C03 (Female) (4)
Wiring harness between A05 (Female) (3) and Resistance 1zandbelow
B04 (Female) (2)
Wiring harness between A05 (Female) (4) and
A12 (Female) (2), A15 (Female) (2) Resistance 1zandbelow

Wiring harness between A12 (Female) (3) and


Resistance 1zandbelow
B04 (Female) (1)
Wiring harness between A15 (Female) (3) and
E16 (Female) (1) Resistance 1zandbelow

Wiring harness between B04 (Female) (3) and


Wiring harness discontinu- chassis ground Resistance 1zandbelow
2 ity (Disconnection or defec-
tive contact) Wiring harness between compressor magnet Resistance 1zandbelow
clutch (-) terminal and chassis ground
Possible
Causes and Wiring harness between C03 (Female) (16) and
A03 (Female) (2) Resistance 1zandbelow
Standard
Values Wiring harness between A03 (Female) (1) and
J06 (16), (15) and C03 (Female) (12) Resistance 1zandbelow

Wiring harness between A03 (Female) (1) and


Resistance 1zandbelow
J06 (16), (15) and A02 (Female) (4)
Wiring harness between A02 (Female) (1) and Resistance 1zandbelow
C03 (Female) (9)
Wiring harness between A02 (Female) (3) and
Resistance 1zandbelow
C04 (Female) (4)
Wiring harness between A02 (Female) (5) and
Resistance 1zandbelow
C03 (Female) (15)
Wiring harness between A02 (Female) (6) and Resistance 1zandbelow
C04 (Female) (3)
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

Wiring harness between fuse Resistance between fuse FS1


FS1 (2) and A15 (Female) (1), 1Mz and
(2), A15 (Female) (1), (4) and above
3 Wiring harness ground fault (4) * chassis ground
Wiring harness between A05 Resistance between A05 1Mz and
(Female) (3) and B04 (Female) (Female) (3), B04 (Female) (2)
above
(2) * and chassis ground
Resistance between A05
Wiring harness between A05
(Female) (4) and A12 (Female) (Female) (4), A12 (Female) (2), 1Mz and
A15 (Female) (2) and chassis above
(2), A15 (Female) (2)
ground

20-678 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

Causes Standard Value in Normal State and Remarks on Troubleshooting


Wiring harness between A12 Resistance between A12
(Female) (3) and B04 (Female) (Female) (3), B04 (Female) (1) 1Mz and
above
(1) and chassis ground
Wiring harness between A15 Resistance between A15
(Female) (3) and E16 (Female) 1Mz and
(Female) (3), E16 (Female) (1)
(1) and chassis ground above

Wiring harness between C03 Resistance between C03 1Mz and


(Female) (16) and A03 (Female) (16), A03 (Female)
(Female) (2) (2) and chassis ground above

Wiring harness between A03 Resistance between A03


(Female) (1) and J06 (16), (15) (Female) (1), C03 (Female) 1Mz and
above
and C03 (Female) (12) (12) and chassis ground
Wiring harness between A03 Resistance between A03
(Female) (1) and J06 (16), (15) (Female) (1), A02 (Female) (4) 1Mz and
and A02 (Female) (4) and chassis ground above
3 Wiring harness ground fault
Wiring harness between A02 Resistance between A02
1Mz and
(Female) (1) and C03 (Female) (Female) (1), C03 (Female) (9) above
(9) and chassis ground
Wiring harness between A02 Resistance between A02
1Mz and
(Female) (3) and C04 (Female) (Female) (3), C04 (Female) (4) above
(4) and chassis ground
Wiring harness between A02 Resistance between A02 1Mz and
(Female) (5) and C03 (Female) (Female) (5), C03 (Female)
above
(15) (15) and chassis ground
Wiring harness between A02 Resistance between A02 1Mz and
(Female) (6) and C04 (Female) (Female) (6), C04 (Female) (3)
above
(3) and chassis ground

a If marked * above, fuse is blown

1) Turn starting switch OFF. 2) Replace relay A15 with normal relay. 3) Turn starting
switch ON. 4) Start air conditioner
Defective compressor Condition is normal. Defective
4 Does condition become 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.

Turn air conditioner switch OFF. Resistance 1Mz and


5 Defective pressure switch Between A05 above
(Male) (1) and
(2) When air conditioner switch is
ON and cooling is in operation Resistance 1zandbelow

1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch
ON. 4) Start air conditioner.
6 Defective thermister Temperature: 25°C 37 - 50kz
Between A03 (Male) (1) and (2)
Temperature: 100°C 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? Motor is
Condition is abnormal.
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
8 Defective air conditioner Does condition become normal compressor.
compressor when air conditioner compres-
sor is replaced with normal Air condi-
compressor? tioner com-
Condition is abnormal.
pressor is
normal.
Turn starting switch OFF. 2) Replace diode D06 with normal diode.
Defective
Condition is normal. diode D06.
9 Defective diode (D06) Replace diode D06 with normal
diode Diode D06 is
Condition is abnormal. normal.

10
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

a See "TROUBLESHOOTING CODE [E-12.(a)]".


Related circuit diagram

WA320-5H 20-679
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

d) Impossible to switch between recirculated air and fresh air

Controller
Action Code Failure Code Defective air conditioner
Code Trouble
d) Impossible to switch between recirculated air and fresh air
- - -
Description of • Air conditioner system is defective, so it is impossible to switch between recirculated air and fresh air
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Impossible to switch between recirculated air and fresh air
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
adapter.
Wiring harness discontinu-
1 ity (Disconnection or defec- Wiring harness between C04 (Female) (1) and Resistance 1zandbelow
L51 (Female) (2)
tive contact)
Wiring harness between C04 (Female) (2) and Resistance 1zandbelow
L51 (Female) (1)
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector C04, L51. 3) Connect T-
Standard adapter.
Values
Wiring harness between C04 Resistance between C04
1Mz and
(Female) (1) and L51 (Female) (Female) (1), L51 (Female) (2)
2 Wiring harness ground fault above
(2) and chassis ground
Wiring harness between C04 Resistance between C04
(Female) (2) and L51 (Female) (Female) (2), L51 (Female) (1) 1Mz and
(1) and chassis ground above

3 Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

a See "TROUBLESHOOTING CODE [E-12.(a)]".


Related circuit diagram

20-680 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]

e) Impossible to switch vents


Controller
Action Code Failure Code Defective air conditioner
Code Trouble
e) Impossible to switch vents
- - -
Description of • Impossible to switch vents
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Impossible to switch vents
Machine
Related
Information

Causes Standard Value in Normal State and Remarks on Troubleshooting


1) Turn starting switch OFF. 2) Disconnect connector A03, A07, A08, C03, C04, J06.
3) Connect T-adapter.
Wiring harness between A07 (Female) (1) and C03 (Female) (1) Resistance 1zandbelow
Wiring harness between A07 (Female) (2) and C03 (Female) (2) Resistance 1zandbelow
Wiring harness between A07 (Female) (3) and C04 (Female) (11) Resistance 1zandbelow
Wiring harness between A07 (Female) (8) and C03 (Female) (13) Resistance 1zandbelow
Wiring harness discontinuity
1 (Disconnection or defective Wiring harness between A08 (Female) (1) and C04 (Female) (5) Resistance 1zandbelow
contact) Wiring harness between A08 (Female) (2) and C04 (Female) (6) Resistance 1zandbelow
Wiring harness between A08 (Female) (3) and C04 (Female) (12) Resistance 1zandbelow
Wiring harness between A08 (Female) (8) and C03 (Female) (14) Resistance 1zandbelow
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
A07 (Female) (6) Resistance 1zandbelow

Wiring harness between A03 (Female) (1) and J06 (16), (14) and
A08 (Female) (6) Resistance 1zandbelow

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) (1) and chassis ground above

Resistance between A07


Wiring harness between A07 (Female) (2), C03 (Female) 1Mz and
Possible (Female) (2) and C03 (Female) (2) above
(2) and chassis ground
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

Wiring harness between A07 Resistance 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 (Female) (1), C04 (Female) 1Mz and
(Female) (1) and C04 (Female) (5) above
(5) and chassis ground
2 Wiring harness ground fault
Wiring harness between A08 Resistance between A08
(Female) (2), C04 (Female) 1Mz and
(Female) (2) and C04 (Female) (6) above
(6) and chassis ground
Resistance between A08
Wiring harness between A08 (Female) (3), C04 (Female) 1Mz and
(Female) (3) and C04 (Female) (12) above
(12) and chassis ground
Resistance between A08
Wiring harness between A08 1Mz and
(Female) (8) and C03 (Female) (14) (Female) (8), C03 (Female)
(14) and chassis ground above

Wiring harness between A03 Resistance between A03


(Female) (1) and J06 (16), (14) and (Female) (1), J06 (16), (14), 1Mz and
A07 (Female) (6) and chassis above
A07 (Female) (6)
ground
Resistance between A03
Wiring harness between A03 (Female) (1), J06 (16), (14),
(Female) (1) and J06 (16), (14) and 1Mz and
A08 (Female) (6) A08 (Female) (6) and chassis above
ground

3
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel

a See "TROUBLESHOOTING CODE [E-12.(a)]".


Related circuit diagram

WA320-5H 20-681
white 20-682
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)

Method of using troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702


Failure code and cause table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
H-1 The machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-706
H-2 The travel speed is slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-707
H-3 The thrusting force is weak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
H-4 Engine stalls when traveling or engine speed drops excessively . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709
H-5 The gear is not shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710
H-6 The steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
H-7 The steering wheel is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
H-8 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
H-9 Machine deviates naturally to one side when traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
H-10 The brake does not work or does not work well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
H-11 The brake is not released or is dragged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
H-12 The lift arm does not rise or lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
H-13 The lift arm moves slowly or the lift arm rising force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
H-14 When rising, the lift arm comes to move slowly at specific height . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) . . . . . . . . . . . . . . . . 20-718
H-16 Hydraulic drifts of the lift arm occur often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
H-17 The lift arm wobbles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily . . . . . . . . 20-719
H-19 The bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
H-20 The bucket moves slowly or the tilting-back force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-721
H-21 The bucket comes to operate slowly in he midst of tilting-back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
H-22 The bucket cylinder cannot hold down the bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
H-23 Hydraulic drifts of the bucket occur often. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
H-24 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD") . . . . . . 20-723
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily. . . . . . . . . . 20-723
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy . . . . . . . . . . . . . . . . 20-723

WA320-5H 20-701
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART

METHOD OF USING TROUBLESHOOTING CHART


This troubleshooting chart, like the other troubleshooting charts (YES/NO type), determines the location from the
problem of occurring on the machine and categorizes the problem under one of the main components, such as the
steering system or work equipment hydraulic system. Use the following procedure to carry out accurate trouble-
shooting swiftly.

Step 1. Ask operator questions 2) Find the matching cause in the Causes col-

If a problem is found, the Q marks on the


The questions to ask the operator are given umn.
under the problem. If the answer to the question
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

When there is one Q mark


read the matrix and proceed with Step 2 and e.)
Step 3 to pinpoint the correct cause.

marked with Q in the same Causes column


Carry out troubleshooting for the other items
Example: Steering wheel will not turn
Ask the operator and check the following points. to check if the problem occurs, then make

When there are two Q marks


repairs.
o Broken part in steering equipment
• Did the problem suddenly start?

Go to Step 3) to narrow down the cause.

o Internal wear, defective seal in steering


• Was the steering wheel heavy before?
1. Steering wheel does not turn i Problem
related equipment (example)
Ask the operator the following questions.
Step 2. Checks before troubleshooting • Did the problem suddenly start?
Before measuring the oil pressure or starting the Yes = Equipment related to steering broken
troubleshooting, confirm the checks before start- • Was there previously any symptom, such as heaviness of
the steering wheel?
ing items, check for leakage of oil, or for loose Yes = Wear of equipment related to steering, defective seal
bolts.
This will prevent wasting time when trouble-
Checks before troubleshooting (example)
shooting.
• Is the oil level in the hydraulic tank correct? Is the type of oil
The items given under Checks before trouble-
correct?
shooting are checks that are particularly impor- • Is there any leakage of oil from the steering valve or Orbit-
tant to make about the condition of the machine roll?
before starting the actual troubleshooting. • Has the safety bar been removed from the frame?

Example: Checks before starting troubleshooting <Example 1>


• Is oil level and type of oil in hydraulic tank Remedy
correct? No.
Problems
• Is there any oil leakage from steering valve
Steering wheel does not turn in either direction (left and
or demand valve? 1
right)
• Is steering linkage adjusted properly? 2 In Item 1, movement of work equipment is abnormal
3 Steering wheel turns only in one direction (left or right)
Step 3. Method of reading matrix 4 Steering wheel is heavy and does not turn
1) Operate the machine when carrying out trou-
bleshooting of the items in the Troubleshoot-
<Example 2>
ing column. If any problems occur as the
Cause
result of the troubleshooting, put a check

a When carrying out the troubleshooting,


against the item. a b c d e
Remedy E
X C A X
check the easier items first. It is not nec- Problems X
Q Q Q Q
essary to follow the number order. 1
2 q q
3 Q Q
4 Q Q
5 Q Q

20-702 WA320-5H
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART

3) Operate the machine and carry out trouble-


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

5) Narrow down the causes. Causes to eliminate Common causes


Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the Cause
line for each troubleshooting item and in the a b c d e
same Cause column as each other) that Remedy E
have causes common with the problem X C A X
Problems X
Q Q Q Q
items found in the troubleshooting in Step 1)
1

a The items that are not common (items o 2 q q


and Step 3).

that do not have Q marks in the same 3 Q Q


cause common as each other) are prob- 4 Q Q
ably not the cause, so they can be elimi- o 5 q q
nated.
(The causes for Troubleshooting item 2 Nature of remedy
in the diagram on the right are c or e,
and the causes in Troubleshooting item Cause
5 are b or e, so Cause e is the common a b c d e
E
cause.)
Remedy
6) Repeat the operation in Steps 3), 4), and 5) X C A X
until the cause is narrowed down to 1 item (1 Problems X
Q Q Q Q
a If cause items are 2 or more, continue
common item). 1
o 2 q q
Q Q
until number of items becomes mini- 3
Q Q
mum.
4
o 5 Q q
7) Remedy
After narrowing down the common causes,

X: Replace E: Repair A: Adjust C: Clean


taken the action given in the remedy line.

WA320-5H 20-703
TESTING AND ADJUSTING FAILURE CODE AND CAUSE TABLE

FAILURE CODE AND CAUSE TABLE

Damper

Inching valve linkage


Inching valve
Part causing problem HST HST
HST pump
motor 2 motor 1

Low pressure relief valve (Charge relief valve)


Pump body (Piston pump end)

Pump body (Charge pump end)

Motor body

Motor body
High pressure cut-off valve

DA valve

forward and reverse solenoid valve

Mode selector solenoid valve (SOL a)

Angle stopper control solenoid valve


Angle stopper solenoid valve (SOL b)
High pressure relief valve
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
Q Q
HST related

The travel speed is slow at forward (Reverse is normal)


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

The steering wheel is heavy


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

The lift arm wobbles during operation


When the control lever is switched from "HOLD" to "RAISE", the
lift arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in he midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occur often
The bucket wobbles during travel with cargo
(The work equipment valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT", the
bucket falls temporarily
The control levers of the lift arm and bucket do not move
smoothly and heavy

20-704 WA320-5H
Q
Q
Q
Q
Clutch solenoid

Q
Q
Q
Q
Clutch

Q
Q
Transfer

WA320-5H
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
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
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

Work equipment system Brake Steering wheel HST related


FAILURE CODE AND CAUSE TABLE

20-705
TESTING AND ADJUSTING H-1

H-1 The machine does not start


Ask the operator about the following: Cause

o Breakage of HST pump and motor related equipment


• Has the machine come not start suddenly? HST HST
HST pump motor 2 motor 1
Others

o Internal wear of HST pump and motor related equip-


• Was there any problem of not traveling before? a b c d e f g h i j k l m n o

Low pressure relief valve (Charge relief valve)


Pump body (Piston pump end)
Pump body (Charge pump end)
Damper

High pressure cut-off valve

Inching valve linkage

Transfer
High pressure relief valve

DA valve
forward and reverse solenoid valve

Inching valve

Clutch solenoid
Clutch
Motor body

Motor body
ment, defective seal

Inspection before diagnosis


• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Is inching valve linkage properly adjusted?
• Is the any external oil leak found around the hydraulic piping,
pump and motor?

Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q

2 Does not travel forward (reverse is normal) Q Q

3 The machine does not start at reverse (Forward is normal) Q Q

Q Q Q
Does not travel forward or in reverse, motor makes sound
4
of rotation

20-706 WA320-5H
TESTING AND ADJUSTING H-2

H-2 The travel speed is slow


Ask the operator about the following: Cause

o Breakage of HST pump and motor related equipment


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

o Internal wear of HST pump and motor related equip-


before?

Low pressure relief valve (Charge relief valve)


Pump body (Piston pump end)

Mode selector solenoid valve (SOL a)


Pump body (Charge pump end)

Angle stopper solenoid valve (SOL b)

Inching valve linkage


High pressure relief valve

Angle stopper control solenoid valve


DA valve

forward and reverse solenoid valve

Inching valve

Clutch solenoid

Clutch
Motor body

Motor body
ment, defective seal
Inspection before diagnosis
• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Is the inching valve linkage adjusting appropriate?
• Is inching valve linkage properly adjusted?
• Is the any external oil leak found around the hydraulic piping,
pump and motor?

Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q

2 The travel speed is slow at forward (Reverse is normal) Q Q

3 The travel speed is slow at reverse (Forward is normal) Q Q

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

Q
5 Maximum travel speed in both forward and reverse is
approx. 18 km/h

Q Q
Abnormal sound comes from motor in both forward and
6 reverse when travel speed is 10 km/h or more

WA320-5H 20-707
TESTING AND ADJUSTING H

H -3 The thrusting force is weak


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

Inclination control solenoid valve


High pressure cut-off valve

Motor body

Motor body

Transfer
Inching valve linkage
High pressure relief valve

Inching valve

Clutch solenoid
Clutch
Remedy E E E E E E E E E E
No. Diagnosis X X X X X X X X X X
A
1 Rimpull is weak in both forward and reverse Q Q Q Q Q Q Q Q Q

2 The thrusting force is weak at forward (Reverse is normal) Q

3 The thrusting force is weak at reverse (Forward is normal) Q

Q Q Q
Rimpull is weak in both forward and reverse, but maximum
4
travel speed is reached the linee.

20-708 WA320-5H
TESTING AND ADJUSTING H-4

H-4 Engine stalls when traveling or engine speed drops excessively


Ask the operator about the following: Cause

o Dirt in HST pump, motor related equipment


• Was there any problem before? HST HST
Others
pump motor 2
a b c
Inspection before diagnosis
• Is the any external oil leak found around the hydraulic piping,

Inclination stopper solenoid valve (SOLb)

Inclination control solenoid valve


DA valve
pump and motor?

Remedy E E E
No. Diagnosis X X X

1 Engine stalls when traveling or engine speed drops exces- Q Q Q


sively

Q
Machine moves when the direction the lever is at F or R
2
and engine is at Li

WA320-5H 20-709
TESTING AND ADJUSTING H-5

H-5 The gear is not shifted


a If the speed range switch and the monitor display do not Cause

a When the travel speed is slow, carry out troubleshooting for


match, check the electrical wiring. HST HST
Others
motor 2 motor 1
H-2 first. a b c d

Inclination stopper solenoid valve (SOLb)

Inclination control solenoid valve

Clutch solenoid

Clutch
Remedy E E E E
No. Diagnosis X X X X

1 The gear is not shifted Q Q Q Q

20-710 WA320-5H
TESTING AND ADJUSTING H-6

H-6 The steering wheel does not turn


Ask the operator about the following: Cause

o Breakage of steering related equipment


• Did the problem suddenly start? Hydraulic
pump Others

o Internal wear of steering related equipment, defective


• Was there previously any symptom, such as heavy steering? a b c d e

Obit-roll
Steering Defective hydraulic pump or PTO

Priority valve

Internal defective steering cylinder (Defective piston seal)


Emergency steering valve (*1)
Steering pump and switch pump
seal
Inspection before diagnosis
• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Has the safety bar been removed from frame?

Relief valve
Spool
Remedy E E E
No. Diagnosis X X X X X X

Q Q Q Q Q
1 Steering wheel does not turn in both directions (left and
right)

Q
In condition in Item 1, movement of work equipment is
2 abnormal

Q
In condition in Item 1, movement of work equipment is nor-
3
mal
4 Steering wheel turns only in one direction (left or right) Q Q

5 Steering wheel is heavy and does not turn Q Q Q Q

6 Oil pressure of steering circuit is low or there is no pressure Q

Q
Emergency steering does not function in both directions
7
(left and right)

a There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is

a If the steering pump is abnormal (broken), check the priority valve at the same time.
felt in the steering, check the operation of the work equipment also.

*1. This warning is given only when the emergency steering is installed.

WA320-5H 20-711
TESTING AND ADJUSTING H-7

H-7 The steering wheel is heavy


Ask the operator about the following: Cause

o Breakage of steering related equipment


• Did the problem suddenly start? Hydraulic
pump Valve Others

o Internal wear of steering related equipment, defective


• Was there previously any symptom, such as heavy steering? a b c d e f

Obit-roll internal defect


Internal defective steering cylinder (Defective piston seal)

Priority valve

Clogging of hydraulic oil return filter, defective bypass valve


Clogging of oil cooler
The steering pump is defective The hydraulic pump is defective
seal
Inspection before diagnosis
• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Is there any abnormality in steering gear box,column, link-
age?
• Is steering valve control lever stopper adjusted properly?
• Is the any external oil leak found around the hydraulic piping,
valve and cylinder?
• Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
• Is the tire inflation pressure correct?

Relief valve
Spool
Check for abnormalities
• Measure operating effort of steering wheel and time taken to
turn steering, and check standard judgment value table to
see if there is any abnormality.

Remedy E E E E E E E
No. Diagnosis X X X X X X X
A C C

Q Q Q Q Q
Steering wheel is heavy when turned in both directions (left
1 and right)

Q Q
2 Steering wheel is heavy when turned in one direction (left
and right)

3 Steering wheel is heavy particularly when engine is running


at low speed Q Q Q Q

Q Q
Lift arm lifting speed is slow when engine is running at full
4 speed
5 Steering wheel is heavy and there is jerking Q Q

6 Hydraulic oil overheats Q Q Q

7 Oil pressure of steering circuit is low or there is no pressure Q Q

8 Pressure rises in return piping of steering cylinder Q

20-712 WA320-5H
TESTING AND ADJUSTING H-8, H-9
H-8

H-8 Steering wheel shakes or jerks


Checks before troubleshooting Cause
• Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves
• Is there any play in the center hinge pin bearing or steering
a b c
cylinder pin or bushing?

Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)

Defective cushion valve


Defect inside drbitrol
• Is there any variation in the tire inflation pressure?
• Is the steering wheel play correct?

Check for abnormalities


• Operate at a safe place and check how the steering wheel

a In cases where the steering wheel is heavy but does not


shakes and under what conditions.

shake, go to "H-7 The steering wheel is heavy".

Remedy E E E
No. Diagnosis X X X

1 Chassis shakes when traveling on rough road surface Q Q Q

2 Shakes when steering is suddenly turned during operation


or travel Q Q Q

3 Chassis shakes when accelerating during travel operations Q Q Q

4 Chassis shakes when engine is started Q

5 Excessive shock when steering wheel is turned back Q

H-9 Machine deviates naturally to one side when traveling


Causes: Defective steering
• Defective operation of safety valve
: Oil leakage inside steering cylinder
: Variation in tire inflation pressure

WA320-5H 20-713
TESTING AND ADJUSTING H-10

H-10 The brake does not work or does not work well
Ask the operator about the following: Cause

o Breakage of brake equipment


• Has the brake come not to work suddenly? a b c d e f g h i j k

Mixing of air in brake circuit


Metal contact due to complete wear of brake lining in axle
Defective slack adjuster

Defective brake pump (For charge)


Wear or abnormality of brake lining in axle

Defective operation of accumulator charge valve

Brake linkage
Defective operation of brake piston in axle
Defective brake piston seal in axle

Defect inside brake valve


Defective seal of accumulator piston, insufficient gas pressure
o Wear of lining and disc, defective seal
• Has the brake come not to work gradually?

Inspection before diagnosis


• Is the oil level in the hydraulic tank appropriate?
• Is the play of brake pedal appropriate?
• Oil leak from brake tube and connector, deformation of tube.
• Tire air pressure and state of tire tread.

Check abnormality
• Measure the braking force and check referring to the stan-
dard value table if the brake does not work practically.

Remedy E E E E E E E
No. Diagnosis X X X X X X X X X

1 When the brake pedal is stepped on, only a little resistance Q Q Q Q Q


is felt

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


felt

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


axle brake

Q Q Q Q
When the four wheels are jacked up, the axle is placed on a
4 table and the brake is applied at the first forward speed,
only a specific wheel rotates

5 An airflow is observed in bleeding air from brake circuit, and Q


the brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q

7 Much metal powders are mixed in the axle oil Q

8 The brake pedal leg-power and stroke are normal, but the Q Q Q Q Q Q Q Q Q
brake does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q

10 The accumulator is not charged, and a buzzer sounds Q Q Q

11 The brake works after some time lag Q Q Q

20-714 WA320-5H
TESTING AND ADJUSTING H-11

H-11 The brake is not released or is dragged


Ask the operator about the following: Cause
• Has the brake pedal returned completely? a b c d
• Is the parking brake released completely?

Defective slack adjuster


Wear or abnormality of brake lining in axle
Defective operation of brake piston in axle
Defective brake piston seal in axle
Check abnormality
• Abnormal heat of brake.
• Does the machine travel smoothly inertia on a level ground?

Remedy E E E E
No. Diagnosis X X X X

1 The brake pedal is released, but the brake is still applied Q Q Q Q

Q Q
When the brake pedal is released, oil is drained from the air
2 bleeder, the circuit oil pressure drops and the brake is
released

Q Q Q
When the four wheels are jacked up, the axle is placed on a
3 table, the engine is stopped, the parking brake is released
and the tires are rotated by hand but a specific tire hardly
rotates

WA320-5H 20-715
TESTING AND ADJUSTING H-12

H-12 The lift arm does not rise or lower


Ask the operator about the following: Cause

o Seizure or breakage of each equipment


• Has the lift arm come not to work suddenly? Priority Cut-off HST PPC Work equip-
Tank to Pump valve valve pump valve ment valve
Cylinder
Did any abnormal noise occur at the time (And where)? a b c d e f g h i j k l m

o Wear of parts or deformation of spring


• Was there the phenomenon that the lift arm worked slowly?

Breakage inside valve body (Lift arm spool)


Defective HST charge pump

Defective cut-off relief valve


Clogging of pump suction port or mixing of much air in oil

Defective low-pressure relief valve

Damage of lift arm cylinder piston seal


Defective steering pump

Defective operation of spool

Defective unload valve


Defective check valve

Defective operation of spool


Defective work equipment pump

Defective operation of main relief valve


Inspection before diagnosis
• Is the oil level in the hydraulic tank appropriate?
• Is the stroke of the lift arm control lever appropriate?
• Is the engine speed appropriate?

Remedy C E E E E E E E E E
No. Diagnosis E X X X X X X X X X X X X

1 The bucket cannot operate and the lift arm cannot rise Q Q Q Q Q Q Q Q Q Q Q

2 The bucket operates but the lift arm cannot rise Q Q

Q Q Q Q
3 The lift arm can rise without load but cannot rise when
loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q

5 Large hydraulic drift of lift arm cylinder Q Q

Q Q
When the engine is at full throttle, the steering operation is
6 heavy and slow

20-716 WA320-5H
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

Defective low-pressure relief valve

Wear or breakage inside valve body (Lift arm spool)

Damage of lift arm cylinder piston seal


Clogging of pump suction port or mixing of much air in oil

Defective operation or improper adjustment of main relief valve


Defective operation of spool

Defective cut-off relief valve

Defective check valve

Defective operation of spool


Defective unload valve
Defective work equipment pump and steering pump
the lift arm rising speed when the lift arm is loaded and make
sure referring to the criterion table that the speed is abnor-
mal.

Remedy C E E E E E E E E
E X
A
No. Diagnosis X X X X X X X X X

Q Q Q Q Q Q Q Q
1 The bucket tilting force and speed are abnormal, and the lift
arm rising speed is slow

Q Q Q
The bucket tilting force and speed are normal, and the lift
2 arm rising speed is slow

Q Q
When the oil temperature rises in No. 1, the lift arm speed
3
becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q

5 Large hydraulic drift of lift arm cylinder Q Q

6 The relief oil pressure from the relief valve of the work Q
equipment valves is low

Q
The relief oil pressure from the relief valve of the work
7
equipment valves is too high

WA320-5H 20-717
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."

Inspection before diagnosis


• Is the stroke of the lift arm control lever appropriate?

Cause
• Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
• Oil leak from lift arm cylinder piston seal

H-16 Hydraulic drifts of the lift arm occur often

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

Have hydraulic drifts come to occur often gradually? o Wear of parts



Inspection before diagnosis


• Is the lift arm spool at the neutral position? o The spool detent is defective

Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective
Diagnosis and Cause

H-17 The lift arm wobbles during operation


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

Diagnosis and Cause


Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-15. Hydraulic drifts of the lift arm occur often."
2. When the lift arm cylinder cannot lift the machine, see "H-15. The lift arm cylinder cannot hold down the bucket."

after the lift arm cylinder operates to full stroke o The cause is vacuum generated inside the cylinder
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with the normal hydraulic drift and

a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective

20-718 WA320-5H
TESTING AND ADJUSTING H-18

H-18 When the control lever is switched from "HOLD" to


"RAISE," the lift arm falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the lift arm falls temporarily due to its own
weight. When the control lever is completely set to "RAISE," the lift arm returns to normal.

Cause
• Improper adhesion of lift arm spool check valve of the work equipment valve

WA320-5H 20-719
TESTING AND ADJUSTING H-19

H-19 The bucket does not tilt back


Ask the operator about the following: Cause
• Has the bucket come not to work suddenly o Seizure or Priority Cut-off HST PPC
Tank to Pump Valve Work Equip- Cylinder
breakage of each equipment valve pump Valve ment Valve
• Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j k l m

o Wear of parts or deformation of spring


• Was there the phenomenon that the bucket worked slowly?

The low-pressure relief valve is defective


Clogging of pump suction port or mixing of much air in oil

Breakage inside valve body (Bucket spool)


The hydraulic pump and the switch pump are defective
The HST charge pump (which is used as PPC pump, too) is defective

Defective operation of spool

Defective cut-off relief valve

The spool is defective

Damage of bucket cylinder piston seal


Defective operation of main relief valve
The steering pump is defective

Defective unload valve


Defective check valve
Inspection before diagnosis
• Is the stroke of the bucket control lever appropriate?

E E E E E E E
E
Remedy C A
No. Diagnosis X X X X X X X X X X X

1 The lift arm cannot operate and the bucket cannot tilt back Q Q Q Q Q Q Q Q Q Q

2 The bucket can lift the machine but cannot tilt back, or the Q Q Q
lift arm operates but the lift arm cannot tilt back

3 The bucket can tilt back without load but cannot in digging
Q Q Q
or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q

5 Large hydraulic drift of bucket cylinder Q Q

6 When the engine is at full throttle, the steering operation is Q Q


heavy and slow

20-720 WA320-5H
TESTING AND ADJUSTING H-20

H-20 The bucket moves slowly or the tilting-back force is


insufficient
Inspection before diagnosis Cause
• Is the stroke of the bucket control lever appropriate? Tank to Priority Cut-off HST PPC Work equipment
Cylinder
• Seizure of work equipment linkage bushing (Does any Pump valve valve pump valve valve
abnormal noise occur?) a b c d e f g h i j k l

Wear or breakage inside valve body (Bucket spool)


Clogging of pump suction port or mixing of much air in oil
The hydraulic pump and the switch pump are defective

Defective operation of low-pressure relief valve

Defective operation or improper adjustment of main relief valve


Defective operation of spool

Defective cut-off relief valve

Damage of bucket cylinder piston seal


Defective check valve

Defective operation of spool

Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Defective unload valve
Check of Abnormality
• 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 E
E X
A
No. Diagnosis X X X X X X X X X X

Q Q Q Q Q Q Q Q
The lift arm rising force and speed are abnormal, and the
1 bucket tilting force and speed are abnormal

Q Q Q Q
2 The lift arm rising force and speed are normal, and the
bucket tilting force and speed are abnormal

3 When the oil temperature rises in No. 1, the bucket speed Q Q


becomes worse
4 The hydraulic pump is causing an abnormal noise Q Q

5 Large hydraulic drift of bucket cylinder Q Q Q

Q Q Q
The relief oil pressure from the relief valve of the work
6
equipment valves is low

7 The relief oil pressure from the relief valve of the work Q
equipment valves is too high

WA320-5H 20-721
TESTING AND ADJUSTING H-21

H-21 The bucket comes to operate slowly in he midst of tilting-


back
Inspection before diagnosis
• Deformation of bucket cylinder in appearance

Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-20. The bucket moves slowly or the tilting-back force is insufficient."

H-22 The bucket cylinder cannot hold down the bucket


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

Inspection before diagnosis


• Is the stroke of the bucket control lever appropriate?

Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal

H-23 Hydraulic drifts of the bucket occur often

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

Have hydraulic drifts come to occur often gradually? o Wear of parts



Inspection before diagnosis


• Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is defective

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

20-722 WA320-5H
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.

H-25 When the control lever is switched from "HOLD" to "TILT,"


the bucket falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due to its own
weight. When the control lever is completely set to "TILT," the bucket returns to normal.

Cause
• Improper adhesion of bucket spool check valve of the work equipment valve

H-26 The control levers of the lift arm and bucket do not move
smoothly and heavy
Check of Abnormality Cause
• Refer to the criterion value table and check if the lever oper- PPC
ating efforts are large practically. valve
a
Defective operation of relief valve

E
Remedy C
No. Diagnosis

Q
Becomes heavy in some places during operation regard-
1
less of oil pressure and oil temperature

Q
Becomes heavy overall during operation regardless of oil
2
pressure and oil temperature

WA320-5H 20-723
white 20-724
TROUBLESHOOTING OF ENGINE
(S MODE)

Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-802


S-1 Starting performance is poor (Starting always takes time) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
S-2 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
(1) Engine does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) . . . . . . . . . . . . . . . . 20-809
(3) Exhaust smoke comes out but engine does not start(Fuel is being injected) . . . . . . . . . . . . . . . 20-810
S-3 Engine does not pick up smoothly (Follow-up is poor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811
S-4 Engine stops during operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
S-5 Engine does not rotate smoothly (Hunting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
S-6 Engine lacks output (or lacks power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
S-7 Exhaust smoke is black (Incomplete combustion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
S-8 Oil consumption is excessive (or exhaust smoke is blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-816
S-9 Oil becomes contaminated quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817
S-10 Fuel consumption is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
S-11 Oil is in cooling water, or water spurts back, or water level goes down . . . . . . . . . . . . . . . . . . . . . . 20-819
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
S-13 Oil level rises (Water, fuel in oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
S-14 Water temperature becomes too high (Overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-822
S-15 Abnormal noise is made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
S-16 Vibration is excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824

WA320-5H 20-801
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS


This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.

[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in B are items that can be
obtained from the user, depending on the user’s
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
w
Questions

(A) (b)
(c) w
(d) Q
(e) Q
(B)
Check items

(C)

i q
q
shooting
Trouble-

ii
iii q

20-802 WA320-5H
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

The basic method of using the troubleshooting chart is as follows.


Items listed for [Questions] and [Check items] that have a relationship
with the Cause items are marked with !, and these, causes that have a
high probability are marked with T.
Check each of [Questions] and [Check items] in turn, and marked the ! Causes
or T in the chart for items where the problem appeared. The vertical col-
umn (Causes) that has the highest number of points is the most probable

n)
jectio
cause, so start troubleshooting for that item to make final confirmation of
the causes.

ive in
*1. For [Confirm recent repair history] in the [Questions] Section, ask

ce ss
the user, and mark the Cause column with # to use as reference

zzle
renc
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
er, in

timin
pum
*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

e iz
ing the causes, but it can be included if necessary to determine

s
pisto
a
ed tu

ctive
ged,
oper
the order for troubleshooting.

ged
Worn

Defe
Clog

Clog
Im p r
Seiz
EEE
*1 Confirm recent repair history

w
*2 Degree of use of machine Operated for long period

WA320-5H 20-803
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS

• Example of troubleshooting when exhaust gas is black


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

S-7 Exhaust gas is black (incomplete combustion)


General causes why exhaust gas is black
• Insufficient intake of air Causes
• Improper condition of fuel injection

head

ized)
• Excessive injection fuel

tion)

er se
r and
injec
ray

seat
e sp

lung
arge
valve
e
leara (excessiv
fectiv
ce

ck, p
boch
eren

and
le, de
ent

p (ra
n tur
air cle er, interf

valve
nder

e
r
elem

ing
p

uffle
c
pum

pum
n
nozz

e
n tim

e
li

ed m
g, cy

ct of
betw
aner
harg

ction

tion
Impro injection

lve c
jectio

conta
n rin

logg

injec
of air
Q

rboc

je
Legend

a
in
w

per in

c
pisto

per v
: Possible causes (judging from Questions and check items)

ed tu

ctive

ctive
ctive
hed,
t

age
ged

ged
: Most probable causes (judging from Questions and Check items)

Impro
: Possible causes due to length of use (used for a long period)

Worn

Leak
Crus
Defe

Defe
Defe
Clog

Clog
Seiz
: Items to confirm the causes.

EEE E
Confirm recent repair history

w Q Q
Degree of use Operated for long period

w Q Q
Suddenly became black
Color of exhaust gas
w
Gradually became black
Questions

w
Black under light load

w Q Q Q
Engine oil must be added more frequently

Q Q Q Q
Suddenly
Power was lost

Q Q
Gradually

w
Non-specified fuel is being used

w
Noise of interference is heard from around turbocharger

w
Dust indicator lamp is red

Q w Q Q Q Q
Blow-by gas excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after start- w Q
Check items

w
ing engine, temperature of some cylinders is low

w
Match marks on fuel injection pump are out of alignment

w
Seal on injection pump has come off

Q Q w
Clanging sound is heard from around cylinder head

w
Exhaust noise is abnormal

w
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

q
q
When turbocharger is rotated by hand, it is found to be heavy

q q
When air cleaner element is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
q
Speed does not change when operation of certain cylin-
Troubleshooting

ders is stopped

q
When check is made using delivery method, injection tim-
ing is found to be incorrect
Injection pump test shows that injection amount is incorrect q
q
When valve clearance is checked directly, it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal q
q
When control rack is pushed, it is found to be heavy, or
does not return
Replace

Replace
Replace

Replace

Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean

Remedy

20-804 WA320-5H
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

wQw
vertical columns for the causes intersect:
(1) Clogged air cleaner element:

QQ
(2) Air leakage between turbocharger

Q
and head

(4) Defective contact of valve, valve seat: Q


(3) Clogged, seized injection nozzle:

(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 item marked q. The Remedy is


troubleshooting area and carry out the

given as [Clean], so carry out cleaning, and the


exhaust gas color should return to normal.

WA320-5H 20-805
TESTING AND ADJUSTING S-1

S-1 Starting performance is poor


(Starting always takes time)
General causes why exhaust smoke comes out but engine takes time
to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air Causes
• Improper selection of fuel
(At ambient temperature of -10°C or below, ASTM D975 No. 2 die-

a Battery charging rate


sel fuel is used)

eat
Charging rate

lve s
Ambient 100% 90% 80% 75% 70%

filter
temperature

e , va
t
m en
20°C 1.28 1.26 1.24 1.23 1.22

uze
r

a te r
raine
r
linde
f valv
er ele
0°C 1.29 1.27 1.25 1.24 1.23

p ga
ir he
t
g , cy

s
a ct o
-10°C 1.30 1.28 1.26 1.25 1.24

pum
ilter,

ke a
clean
n rin
cont
• The specific gravity should exceed the valve for the charging rate

fuel f
fe e d
l inta
ir
pisto
of 70% in the above table.

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.

EEE
Confirm recent repair history

w w Q Q Q
Degree of use of machine Operated for long period

w
Gradually became worse
Ease of starting

w
Starts when warm
Questions

w
Indicator lamp does not light up

w w w
Engine oil must be added more frequently

Q Q
Replacement of filters has not been carried out according to operation Manual

w
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Q Q
w
Engine does not pick up smoothly, and combustion is irregular
Blow-by gas is excessive
Check items

Timing lock on fuel injection pump does not match


Mud is stuck to fuel tank cap
w w
When Engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened

Q Q
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
q q
q
When compression pressure is measured, it is found to be low

q
When air cleaner element is inspected directly, it is found to be clogged

q
When fuel filter, strainer are inspected directly, they are found to be clogged

q
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting

Heater mount does not become warm


Is voltage 26 - 30V between alternator terminal B and termi- Yes
nal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace

Replace
Correct
Clean
Clean
Clean

Remedy

* Use a test stand

20-806 WA320-5H
q
Replace Defe
ctive

q
w w
Replace Defe regu
lator
ctive
a

q
w
w
Replace

E
Defe ltern
ctive a to r

q
w
w
Q
Q
Replace Defe or de
t

WA320-5H
ctive erior
a te d

w
*Adjust Defe injec
t io batte
ctive n no
zzle ry

q
w
w
Q
Q
Replace Defe injec
tion t
ctive
in im ing

q
Q w
Correct Defe jectio
ctive n pu

q
w Q
Q
Clean Clog Leak
a
mp (
r a ck
ged ge, c

w
Replace Defe air b
re a
loggin , plunge
g, air r stu
ctive ther
hole ck)

w
Replace Defe fe e d
p in f
in fue
l pipin
Causes
ctive
boos
ump uel ta
nk g
TESTING AND ADJUSTING

t com
pens
ator
ca n c
el

20-807
S-1
TESTING AND ADJUSTING S-2

S-2 Engine does not start


(1) Engine does not turn

General causes why engine does not turn


Causes

a If internal parts of the engine are seized, carry


• Internal parts of engine seized

out troubleshooting for "Engine stops during


operations".

witch
• Defective electrical system

ion
nect
• Failure in power train

ircuit

y rela r safety s
ry
batte

l co n
ng c

oid
a
rated

witch
starti

in
otor

solen
y
term
ctive fety relay
ing m
terio

ing s
g of

l cu t
ttery
ar

a tte r
or de
wirin

g ge
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
E E
Confirm recent repair history
Questions

w Q Q
Degree of use of machine Operated for long period

w
Condition of horn when start- Horn sounds
ing switch is turned ON
w
Horn volume is low

w w
Speed of rotation is low
When starting switch is
w
Makes grating noise
turned to START, pinion

Q Q Q
moves out, but Soon disengages pinion again
Makes rattling noise and does not turn

w Q Q
When starting switch is turned to START, pinion does not move
out
Q w
Check items

When starting switch is turned to ON, there is no clicking sound


w
w
Battery terminal is loose

w
When starting switch is turned ON, linkage is not actuated
Troubleshooting of defective wiring in starting circuit

When battery is checked, battery electrolyte is found to be low

Specific gravity of electrolyte, voltage of battery is low q


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

q
2) When terminal B and terminal C of starting motor are con-
Troubleshooting

nected, engine starts

q
3) When terminal B and terminal C of starting safety relay are
connected, engine starts

q
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts

q
5) There is no 24V between battery relay terminal b and termi-
nal E

q
When ring gear is inspected directly, tooth surface is found to be
chipped

q
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Remedy -

20-808 WA320-5H
TESTING AND ADJUSTING S-2

(2) Engine turns but no exhaust smoke comes out


(Fuel is not being injected)

General causes why engine turns but no exhaust smoke


Causes
comes out
• Supply of fuel impossible

d)
• Supply of fuel is extremely small

seize
a Standards for use of fuel
• Improper selection of fuel (particularly in winter)

nger
t, key

ank
, plu
shaf

fuel t
strain iston
AMBIENT TEMPERATURE

n fee mp (rack
KIND OF

rive
-4 14 32 50 68°C

le in
iner
FLUID

oid
r

pipin
p
-20 -10 0 10 20°F

e
mp d

er ho
olen
tr
u

leakin tank
s
u
p

fuel
p
n pu

ump
d

cu t s
ASTM D975 No. 2

se d
reath
n

ilter,

in
jectio

g
Diesel fuel

jectio

fuel u
fuel
uel f

fuel
feed

air b
roke
ASTM D975 No. 1

in

t
en, in

n
f
ctive

ctive
oper
fficie
ed b
ged
ged

ged
ged
D e fe

Defe
Br ok

Clog
Clog

Clog
Clog

Im p r
Seiz

I n su
EE E
Confirm recent repair history
Questions

Exhaust smoke suddenly stops coming out (when starting again) w w w


Degree of use of machine Operated for long period

Replacement of filters has not been carried out according to Oper- w w


ation Manual
w
w
Fuel tank is found to be empty

w
There is leakage from fuel piping

w
Mud is stuck to fuel tank cap

w
When starting switch is turned ON, linkage is not actuated
When fuel filter is drained, fuel does not come out

w Q Q Q
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is
Check items

loosened
2) No fuel spurts out even when injection pump piping sleeve w w w
nut is loosened
Rust and water are found when fuel tank is drained Q Q Q
Inspect injection pump directly q
q
When control rack is pushed, it is found to be heavy, or does not
return
q
Troubleshooting

Inspect feed pump directly


q q
When fuel filter, strainer are inspected directly, they are found to
be clogged

q
When feed pump strainer is inspected directly, it is found to be
clogged
When fuel cap is inspected directly, it is found to be clogged q
q
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

Remedy

WA320-5H 20-809
TESTING AND ADJUSTING S-2

(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)

General causes why exhaust smoke comes out but


Causes
engine not start

.)
• lack of rotating force due to defective electrical sys-

er etc
tem

)
st u ck
er lev
• Insufficient supply of fuel

k ca p
y
sp r a
, rock
nger
• Insufficient intake of air

stem

l tan
er

ctive
, plu
valve

heat
• Improper selection of fuel and oil

y
el sy

in fue
atter
r
rack

defe
e
tem (

ke air
n

t
leane rainer
m en
li

in fu
ed b
r
mp (

r hole
r

zzle,
e sys

linde
strain

r ele
l inta
iorat
ir
st
n pu

a
n no
n valv

g , cy

a th e
ump

ing,

se d
ctrica
lter,

r
Worn e injectio

Leak e or dete

jectio
e
ed p

clogg
n rin

fuel u
broke

fi

r
air b
air c
le
fuel

e
e
pisto

in
f

ctive

age,
ctive,

oper
ged
ged
ged

ged
ged
ctiv

ctiv
D e fe

D e fe
D e fe
Clog
Clog
Clog

Clog
Clog
Im p r
Defe

EEE E
Confirm recent repair history

w w
Degree of use of machine Operated for long period
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around w

w
cylinder head
Questions

Q Q
Engine oil must be added more frequently
Non-specified fuel is being used
Replacement of filters has not been carried out according to Oper- w w w

w w
ation Manual

w
Rust and water are found when fuel tank is drained

w
Dust indicator lamp is red

w
Indicator lamp does not light up

Q
Starting motor cranks engine slowly

Q
Mud is stuck to fuel tank cap
When fuel lever is placed at FULL position, it does not contact stopper

w
When engine is cranked with starting motor,
Check items

1) Little fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel comes out even when fuel filter air bleed plug is w w Q

w
loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting w

w
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly q
When control rack is pushed, it is found to be heavy, or does not q

q
return
When compression pressure is measured, it is found to be low
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

q
clogged

q
When air cleaner element is inspected directly, it is found to be clogged

q
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or operation q

q
is too heavy

q
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace

Replace
Correct

Correct
Clean
Clean
Clean

Clean
Clean

Remedy

20-810 WA320-5H
TESTING AND ADJUSTING S-3

S-3 Engine does not pick up smoothly


(Follow-up is poor)

General causes why engine does not pick up smoothly


Causes
• Insufficient intake of air
• Insufficient supply of fuel
• Improper condition of fuel injection

ca p

eat
pray
• Improper fuel used

lve s
l pipin uel tank
tive s

d va
efec

er
a ce
nger

e an
n
ent

leakin er hole in
r

g
li
aine
zle, d

valve er, interf


er

p plu
r

reath nce
elem

f valv
train

d
p str

ed tu ring, cylin

a
ed in ction noz
pum

g fue
clear
er, s
aner

a ct o
pum

rg
o ch a
ction
t
air cle

il

cont
f
feed

air b
fuel

inje

n
b
je
pisto
r

ctive
oper

ged,
ged
ged
ged
ged

ged
Worn

Defe
Clog
Clog
Clog
Clog

Clog
Clog
Im p r
Seiz

Seiz
EEE E E
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to Oper- w w w
Questions

ation Manual
w w w w
w
Non-specified fuel is being used

Q w Q Q
Engine oil must be added more frequently

w w
Engine pick-up suddenly became poor

w
Rust and water are found when oil is drained

w
Dust indicator lamp is red

Q w
Noise of interference is heard from around turbocharger

w w w Q
Blue under light load
Color of exhaust gas

w
Black

w
Clanging sound is heard from around cylinder head
Check items

w
Mud is stuck to fuel tank cap
There is leakage from fuel piping
w w Q
High idling speed under no load is normal, but speed suddenly
drops when load is applied
There is hunting from engine (rotation is irregular) Q w Q Q
w Q
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Blow-by gas excessive w
When air cleaner element is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
When feed pump strainer is inspected directly, it is found to be q
Troubleshooting

clogged
Speed does not change when operation of certain cylinders is q

q
stopped

q q
When control rack is pushed, it is found to be heavy, or does not return

q
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be outside q

q
standard value

q
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace

Replace
Correct

Correct
Adjust
Clean
Clean
Clean

Clean

Remedy

WA320-5H 20-811
TESTING AND ADJUSTING S-4

S-4 Engine stops during operations

General causes why engine stop during operations


Causes
• Seized parts inside engine

tc.)
• Insufficient supply of fuel

ver, e

t u ck)
a If there is overheating and the engine stops,
• Overheating

ker le

ger s
od
carry out troubleshooting for overheating.

k
e, roc

el tan
plun
ting r
ring

ke y
t
a If the engine stops because of a failure in the
• Failure in power train

men

l pipin ton
(valv

rack,
t bea

in fu
nnec

pis
haft,
quip

ainer

g
stem

iner

leakin d pump

mp (
hole
power train, carry out troubleshooting for the

shaf
n , co

train

s
e
e

p str
a
y

tank
p driv
chassis.

n pu
r
r
rank

r train
t

g fue
ther
ia
pisto

gear

s
valve

fe e
auxil

pum
filter,
el in

Failu e injectio
a
c

pum

powe
eized
eized

ized

eized
amic

r
um p

eed

air b
fu
fu e l
e l
t
e
n dyn

f
en fu
en, s
en, s

en, s

en, s

re in
en p

ged,
fficie
ged
ged

ged
ctiv
Broke

Defe
Brok
Brok

Brok
Brok
Brok

Brok
Clog
Clog

Clog
Clog
Insu
EE
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and w w w w w w Q Q w

w Q Q
engine stopped suddenly
Condition when engine
Questions

w Q Q
Engine overheated and stopped
stopped

w Q Q Q
Engine stopped slowly
There was hunting and engine stopped
w w
Replacement of filters has not been carried out according to Oper-
ation Manual
Q Q Q Q
w
Non-specified fuel is being used

w
Fuel level lamp lights up

Q Q w
Fuel tank is found to be empty

w
When feed pump is operated, operation is too light or too heavy

w
Mud is stuck to fuel tank cap
Check items

w w
Engine rotates, but stops when power train is operated

w
Does not turn at all

w w
When it is attempted to turn Turns in opposite direction
by hand using barring tool
w
Moves amount of backlash

w w
Shaft does not turn

w w Q Q
Rust and water are found when tank is drained
Troubleshooting of chassis

Metal particles are found when oil is drained

q q
q
Remove oil pan and inspect directly

q
Remove head cover and inspect directly

q
When gear train is inspected, it does not turn
Troubleshooting

Rotates when pump auxiliary equipment is removed


q
When fuel filter, strainer are inspected directly, they are found to
be clogged

q
When feed pump strainer is inspected directly, it is found to be
clogged
Inspect feed pump directly q
q
When control rack is pushed, it is found to be heavy, or does not
return
Replace
Replace
Replace
Replace
Replace

Replace
Replace

Replace
Correct
Clean
Clean

Clean

Remedy -
Add

20-812 WA320-5H
TESTING AND ADJUSTING S-5

S-5 Engine does not rotate smoothly


(Hunting)

General causes why engine does not rotate smoothly


Causes
• Air in fuel system

um p
ozzle
• Defective governor mechanism

eed p nd feed p
and n
• Defective electric governor mechanism

a If hunting stops when electric governor rod is dis-


(engine with electric governor)

ump
a

ank
l tank
k
connected, carry out troubleshooting for the

fuel t
c
r
erno
rol ra
rnor

n fue
chassis.

een f
le in
strain r
v
adjus n of gove

e
low
cont
o

twee
er
strain
t of g

betw
er ho
o
k
n of

uit be
ficien eed is to
n
tm e n

l in ta
ump

ircuit
reath
ilter,
Defe e operatio

io

c
a t

ir
ed p

ir in c
c
t fu e
oper

fuel f

air b
sp

in
e

ir
idling

ged a
f

g ed a
ctive
ctive

ged
ged

ged
ctiv

Insuf
D e fe

Defe

Clog
Clog

Clog
Clog
Clog
Low
EE
Confirm recent repair history

w w w Q
Degree of use of machine Operated for long period

Q w Q Q Q Q
Occurs at a certain speed range

Occurs even when speed is raised Q Q Q Q


Occurs at low idling
Questions

Condition of hunting

Occurs on slopes w
w w
Replacement of filters has not been carried out according to Oper-
ation Manual
w
Q Q
Fuel tank is found to be empty

w w
Rust and water are found when tank is drained
Leakage from fuel piping
w
When feed pump is operated,
Check items

w
1) No response, light, return is quick

w w
2) No response, light, return is normal

w w
Engine speed sometimes rises too far

w w
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor level is moved it is found to be stiff q q
When injection pump is tested, governor is found to be improperly q
adjusted
Troubleshooting

When control rack is pushed, it is found to be heavy, or does not q

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

Clean
Clean

Clean

Remedy
Add

WA320-5H 20-813
TESTING AND ADJUSTING S-6

S-6 Engine lacks output


(or lacks power)

General causes why engine lacks output


Causes
• Insufficient intake of air
• Insufficient supply of fuel
• Improper condition of fuel injection

ent
justm
tive a eat
y
• Improper fuel used

ragm
plung tive spra

es
(if non-specified fuel is used, output drops)

ank
d

iaph
d valv
e

t
a If there is overheating and lack of output, carry
• Lack of output due to overtaking

g, cy terferenc

e l
efec

tor d
m
in fu
er

aking ge, defec


e an

hrag
t

er

ing
m en

jectio nozzle, d

e n sa
er
strain

le
r
out troubleshooting for overheating.

a n ce
linde

ip
f valv
strain

diap
o
er, in
er ele

p
h
ump

om p
l
th e r
e
clear
ump

linka
fu
a ct o

gate
harg

filter,

p
lean

o st c
n

brea
io
n
ed p
n rin

valve

west
lever
t

cont
rboc

injec
air c

fuel

o
ir
le

b
e
pisto

a
f
ed tu

ctive

ctive
ctive
ed in
oper

ged,
fuel
ged

ged
ged
ged

ged
Worn

D e fe

D e fe
D e fe
Bent
Clog

Clog
Clog
Clog

Clog
Clog
Im p r
Seiz

Seiz
E EEE E
Confirm recent repair history

w w w
Degree of use of machine Operated for long period

Q Q Q Q Q Q
Suddenly
Questions

Power was lost

w
Gradually
Engine oil must be added more frequently
Replacement of filters has not been carried out according to Oper- w w w

w w w w
ation Manual

w
Non-specified fuel is being used

w w
Dust indicator lamp is red

w
Black
Color of exhaust gas

w
Black under light load

w Q
Noise of interference is heard from around turbocharger

w Q Q Q
Blow-by gas excessive
Check items

Engine pickup is poor and combustion is irregular


High idling speed under no load is normal, but speed suddenly w w Q
drops when load is applied
When exhaust manifold is touched immediately after starting w Q

Q Q Q Q
engine, temperature of some cylinders is low

w
There is hunting from engines (rotation is irregular)

Q w
Clanging sound is heard from around cylinder head

w
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be q

q
clogged

q q
When turbocharger is rotated by hand, it is found to be heavy
When compression pressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are found to q
be clogged
q
Troubleshooting

When feed pump strainer is inspected directly, it is found to be


clogged
Speed does not change when operation of certain cylinders is q
stopped
When control rack is pushed, it is found to be heavy, or does not q
return
When valve clearance is checked directly, it is found to be outside q

q
standard value

q
When level is placed at FULL position, it does not contact stopper

q
When feed pump is operated, operation is too light or too heavy
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace

Replace

Replace

Replace
Replace
Correct

Correct
Adjust

Adjust
Clean

Clean
Clean

Clean

Remedy

20-814 WA320-5H
TESTING AND ADJUSTING S-7

S-7 Exhaust smoke is black


(Incomplete combustion)

General causes why exhaust smoke is black


Causes
• Insufficient intake of air
• Improper condition of fuel injection

head

)
eized
n)
• Excessive injection of fuel

jectio

r and

, plun at
y

ger s
sp r a

se
ive in

arge
valve
ctive
e

s
renc

b o ch
( e xce

(rack
defe

and
ent
terfe

n tur
valve
der

n ce
r
zzle,
elem

iming
um p

um p
uffle
er, in

twee
leara
li
n no

ion p

tion p
ed m
g , cy

ct o f
aner

tion t
harg

e
lve c

b
jectio

conta
t

clogg
n rin
ir cle

injec

injec
of air
injec
rboc

v a
pisto
in
a
ed tu

ctive

ctive
ctive
hed,
oper

oper

age
ged

ged
Worn

Leak
D e fe

D e fe
Defe
Crus
Clog

Clog
Impr

Impr
Seiz
EEE E
Confirm recent repair history

w Q Q
Degree of use of machine Operated for long period

w Q Q
Suddenly became black
Color of exhaust gas
w
Gradually became black
Questions

w
Black under light load

w Q Q Q
Engine oil must be added more frequently

Q Q Q Q
Suddenly
Power was lost

Q Q
Gradually

w
Non-specified fuel is being used

w
Noise of interference is heard from around turbocharger

w
Dust indicator lamp is red

Q w Q Q Q Q
Blow-by gas excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting w Q
Check items

w
engine, temperature of some cylinders is low

w
Timing lock on fuel injection pump does not match

w
Seal on injection pump has come off

Q Q w
Clanging sound is heard from around cylinder head

w
Exhaust noise is abnormal

w
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy q
When air cleaner element is inspected directly, it is found to be q

q q
clogged
When compression pressure is measured, it is found to be low
q
Troubleshooting

Speed does not change when operation of certain cylinders is


stopped
When check is made using delivery method, injection timing is q

q
found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly, it is found to be outside q

q
standard value
When muffler is removed, exhaust color returns to normal
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
Clean

Remedy

WA320-5H 20-815
TESTING AND ADJUSTING S-8

S-8 Oil consumption is excessive


(or exhaust smoke is blue)

a Do not run the engine at idling for more than 20 min-


Causes
utes continuously. (Both low and high idling)
General causes why oil consumption is excessive

rger
• Abnormal combustion of oil

o ch a
)
gine
• External leakage of oil

Turb
ss en

l
d

n se a
• Wear of lubrication system

r hea

ce
h o se

st e m
surfa
r
er le

coole

r o ke
linde

y
ther
r (lin

se a l
s
e), b
g
r oil

il coo pan or cy

a ke
lu
a
linde

d
end
ain p
e

seal,
o
ing

, guid
m int
or br

e
te r
il pip

e
w er
g , cy

oil dr

in
oil fil

rear
ring

in fro
( st e m
ther

Worn al at turb
r
oil

at blo
le
om o
n rin
iston

rom

from
m
brea

ke n
d
o

valve
e
pisto

se a l

su ck
f
f

, bro
en p

en o
age
age
age
age
ged

se
Worn

Worn

Worn

Worn
Leak
Leak
Leak
Leak
Br ok

Br ok

D u st
Clog
E EE E
Confirm recent repair history

w Q
Degree of use of machine Operated for long period

w Q
Oil consumption suddenly increased

Q w Q
Engine oil must be added more frequently
Questions

w w
Engine oil becomes contaminated quickly

w w Q Q
Exhaust smoke is blue under light load

w
Excessive
Amount of blow-by gas

w w w w
None

w
Area around engine is dirty with oil

w Q
There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
w
Check items

When turbocharger air supply pipe is removed, inside is found to


be dirty with oil
Oil level in clutch or TOROFLOW transmission damper chamber w

w
rises
Clamps for intake system are loose
When compression pressure is measured, it is found to be low q q
When breather element is inspected, it is found to be clogged with q

q q q q
dirty oil
Troubleshooting

q
There is external leakage of oil from engine

q q
Pressure-tightness test of oil cooler shows there is leakage

q
Excessive play of turbocharger shaft

q
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with q
oil
Replace
Replace

Replace
Replace
Replace
Correct
Correct
Correct
Correct

Correct
Correct
Correct
Clean

Remedy

20-816 WA320-5H
TESTING AND ADJUSTING S-9

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly


Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel

en d
• Improper oil used

rbine
• Operation under excessive load

tu b e
se

e r tu
drain
r
er ho
r line

harg
e a th
linde

er oil
e

rboc
lack
id
e gu
r
er, b
g, cy

harg

e is b
at tu
turbo r
le
, valv
er

il coo
eath

c
n rin

se a l
mok
oil filt
valve
r
pisto
b

ust s
ctive
ged
ged

ged
ged
Worn

Worn

E xh a
Defe
Clog
Clog

Clog
Clog
E E E
Confirm recent repair history

w
Degree of use of machine Operated for long period
Questions

Q
Engine oil must be added more frequently

w
Non-specified fuel is being used

w
Black under light load
Color of exhaust gas

w Q Q Q
Black

w
Carry out troubleshooting for "Exhaust smoke is black".
Excessive
Check items

Amount of blow-by gas

Q w Q
None

w
When oil filter is inspected, metal particles are found

w
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly

When compression pressure is measured, it is found to be low q q


When breather element is inspected directly, hose is broken or is q
Troubleshooting

q
found to be clogged with dirty oil

q
When oil filter is inspected directly, it is found to be clogged

q
When oil cooler is inspected directly, it is found to be clogged

q
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
Replace

Replace
Replace

Replace
Clean

Clean
Clean

Remedy -

WA320-5H 20-817
TESTING AND ADJUSTING S-10

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive


Causes
• Leakage of fuel
• Improper condition of fuel injection

n)
• Excessive injection of fuel

jectio

kage
n)
al ins ead cove el filter

pisto
ive in

rol lin
mp (
u
ing, f
r
ce ss

co n t
nger

d pu
el pip
y

g
spra
p (ex

p plu
timin

fu e l
e fe e
m fu
eh

nt of
lder
pum

m
n

id
u
jectio

insid
tion p

e fro
le ho

stme
tion

fuel in
a ka g
l
oil se
e
n o zz
injec

injec

adju
of fu
le
ctive
ctive
ctive
ctive

ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe

Defe
Defe
Exte
EE E
Confirm recent repair history
Degree of use of machine Operated for long period
More than for other machines of w Q
Questions

Q Q
Condition of fuel same model
consumption
Q Q
Gradually increased

w Q Q Q
Suddenly increased

Q
Black
Exhaust smoke color

w
White

w
Seal on injection pump has come off
There is irregular combustion
w Q
Check items

When exhaust manifold is touched immediately after starting

w
engine, temperature of some cylinders is low

w
Match mark on injection pump is misaligned

Q w w
There is external leakage of fuel from engine

Q w
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is q
excessive
Speed does not change when operation of certain cylinders is q
stopped
Troubleshooting

When control rack is pushed, it is found to be heavy, or does not q


return
When check is made using delivery method, injection timing is q

q
found to be incorrect

q
Remove head cover and inspect directly
Remove feed cover and inspect directly
When engine speed is measured, low and high idling speeds are q
found to be high
Replace
Replace

Correct
Correct
Correct
Adjust

Adjust

Adjust

Remedy

20-818 WA320-5H
TESTING AND ADJUSTING S-11

S-11 Oil is in cooling water, or water spurts back,


or water level goes down

General causes why oil is in cooling water


Causes
• Internal leakage in lubrication system
• Internal leakage in cooling system

oil co gasket

ck
-ring

r blo
ler
ad
o
d, he
re, O

linde
ng
y pitti
r hea

in cy
ler co

train
se d b
linde

r a cks
il coo

ower
y

s ca u
nal c
en o

en p
en c
Brok
Brok
Brok
Hole
Inter
E E
Confirm recent repair history
Questions

Q Q Q
Degree of use of machine Operated for long period

Q Q
Suddenly increased
Oil level

Q Q
Gradually increased

w Q Q
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
w
Check items

Excessive air bubbles inside radiator spurts back


Hydraulic oil, transmission oil is cloudy white w
When hydraulic oil transmission oil is drained, water is found w

Pressure-tightness test of oil cooler shows there is leakage q q


q
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage


Remove oil pan and inspect directly q q
Replace
Replace
Replace
Replace
Replace

Remedy

WA320-5H 20-819
TESTING AND ADJUSTING S-12

S-12 Oil pressure caution lamp lights up


(Drop in oil pressure)

General causes why oil pressure lamp lights up


• Leakage, clogging, wear of lubricating system Causes
• Defective oil pressure control
• Improper oil used (improper viscosity)

a Standards for engine oil selection


• Deterioration of oil due to overheating

Selection of SAE No. according to

sens ing
Type of oil ambient temperature

ip
n
pan
oil pa

or
ulic p
g
-30 -20 -10 0 10 20 30 40°C

razin
e oil

nsor
e
r valv

ydra
side
SAE30CD

ipe b

sure
strain rnal

en su ipe insid

e
an

f valv

vel s
ed h
er in

mp

Defe e regulato
jou

Defe e oil pres


SAE10WCD

tion p
er

il
il
oil pu

l in o
r u sh

oil le
Engine oil

relie
oil filt
ing,

oil p

in
SAE10W-30CD

c
bear

r , fu e
c
of oil
ctive

ctive

ctive
ing,
ged

ged
ged

ctiv

ctiv
SAE15W-40CD
Worn

Wate
Leak
L a ck
Defe

Defe

Defe
Brok
Clog

Clog
Clog
EE E
Confirm recent repair history
Degree of use of machine Operated for long period
w
Questions

Replacement of filters has not been carried out according to Oper-

Q Q
ation Manual

w Q
Non-specified fuel is being used

w Q
Caution lamp lights up

w w w w Q Q Q
Lights up at low idling

w
Condition when oil pressure Lights up at low, high idling
lamp lights up
w w Q Q
Lights up on slopes

w
Sometimes lights up
Check items

w w
There is crushing, leakage from hydraulic piping (external)

w
Oil level sensor lamp lights up

w
When oil level in oil pan is inspected, it is found to be low

w Q
Metal particles are found when oil is drained

w
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil

q q
q q q
When oil filter is inspected, it is found to be clogged
Carry out troubleshooting for

q
Troubleshooting

Remove oil pan and inspect directly


Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or valve q q
"Oil level rises".

q
guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within standard q
valve
Replace

Replace
Replace
Correct

Correct
Adjust
Adjust
Clean
Clean
Clean
Clean

Remedy -
Add

20-820 WA320-5H
TESTING AND ADJUSTING S-13

S-13 Oil level rises (Water, fuel in oil)

a If there is oil in the cooling water, carry out trouble-


Causes
shooting for "Oil is in cooling water".
General causes why oil level rises

r
• Water in oil (milky white)

co ve
• 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
g a sk
surfa
e
sleev
le ho O-ring

ction
y equ

lock
head

pipin
se a l

je

der b
lder

xiliar
ore,

, dam er head,

g
rear

st a t
from

n
y pitti
p au

cylin
ler c

Defe e part ins


o
aged

m
fu e l
n o zz

pum
il coo

de b
r
ylind

side
h e
f

t
o

s ma
ctive

ctive

ctive

ks in
en o

en c

age
ctiv
Worn

Leak
Defe

Defe

Defe

Crac
Brok

Brok

Hole
E EE E
Confirm recent repair history
Questions

w Q Q Q Q
Degree of use of machine Operated for long period

w w w
There is oil in radiator cooling water

w Q Q
Fuel must be added more frequently

w
Exhaust smoke is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an abnor- w Q
Check items

mal number of bubbles appear, or water spurts back


Oil level goes down in clutch, TORQFLOW transmission, or w

w
damper chamber

w w w
Oil level goes down in hydraulic tank

w
Engine oil smells of diesel fuel
Water temperature is low
q
q
Pressure-tightness test of oil cooler shows there is leakage

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

q
When compression pressure is measured, it is found to be low
Troubleshooting

Inspect rear seal directly


When pump auxiliary equipment is removed, seal is found to be q

q
damaged

q
Remove head cover and inspect directly

q
Remove injection pump and inspect directly

q q
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace

Replace

Replace

Replace
Replace
Correct

Correct

Correct

Remedy

WA320-5H 20-821
TESTING AND ADJUSTING S-14

S-14 Water temperature becomes too high


(Overheating)

General causes why water temperature becomes too


Causes
high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system

e
ratur
a Carry out troubleshooting for chassis.

n)
• Rise in oil temperature in power train

uge
t ope

t
aske

m pe
il coo pulley
e ga
r fins

s no

ad g

oil te
ratur

n fa n
ler
(doe
diato

d, he
valve

erter
e
e

ing
, wor
r
emp
o st a t

e
r
ed ra

r hea
o
crush p

conv
t

sure

y pitt
a

en o
to r c
pum

ling w
Lack e water t

ping
therm

e
pres
brok
radia

de b
rque
ylind
ater

p
o
li
o f co
s

s ma
ctive

ctive

in to
en w
ged,

ged,

en c
ged

ctiv

belt
D e fe
D e fe

D e fe
Br ok

Br ok
Clog
Clog

Clog

Hole
Rise
F an
EE EE
Confirm recent repair history

w Q Q
Degree of use of machine Operated for long period

w w Q Q
Suddenly overheated
Questions

Condition of overheating

w Q
Always tends to overheat

w
Rise quickly
Water temperature gauge

w
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

Q w
Excessive air bubbles inside radiator, water spurts back

w
Engine oil level has risen, oil is cloudy white
Check items

w w
There is play when fan pulley is rotated

w
Radiator shroud, inside of underguard are clogged with dirt or mud

w
When light bulb is held behind radiator, no light passes through

w
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than engine w
water temperature

Temperature difference between top and bottom radiator tanks is q


Carry out troubleshooting for chassis.

excessive
Temperature difference between top and bottom radiator tanks is q

q
slight
Troubleshooting

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

q
When function test is carried out on thermostat, it does not open

q
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set pressure q

q
is found to be low

q
When compression pressure is measured, it is found to be low
Remove oil pan and inspect directly
Replace

Replace
Replace

Replace
Replace
Replace
Replace
Correct
Correct

Correct

Remedy -
Add

20-822 WA320-5H
TESTING AND ADJUSTING S-15

S-15 Abnormal noise is made

a Judge if the noise is an internal noise or an external


Causes
noise.

.)

head
ine)

ition)
er, etc
General causes why abnormal noise is made

s eng

)
eized

f pos
tion)

nder
• Abnormality due to defective parts

er lev
er les

d cyli
• Abnormal combustion

injec

out o
ger s

m (va rance
, rock
er (lin
• Air sucked in from intake system

er an
sive
, plun

oard
e
a
e
renc
e n ce

e cle
lv
ylind

ozzle

fan b p (exces

harg
ing b
(rack

terfe

h
erfer

f valv
ing, c

c
cklas
n

ide m een turbo


(divid
syste
n

in
ump
r, int
g
io
ton r

um

ent o
in

lt

a
c t

b
h

valve
d inje
tion p
p

uffler
s
arge
of pis

train
d bu

tion

tw
justm

air be
amic
boch

seize
injec
injec
fa n ,

gear
seize
wear

a d
n dyn

f
r

rmed

ct ins
age o
ed tu

ctive
ctive

ctive
ssive

oper
ged,
ing,

Broke
Defe
Defe
Defo
Defe

Defe
Miss
Clog

Impr
Leak
Exce
Seiz
E
Confirm recent repair history

Q Q
Degree of use of machine Operated for long period
Questions

Q Q Q
Gradually occurred
Condition of abnormal noise

Q Q
Suddenly occurred

w
Non-specified fuel is being used

w
Engine oil must be added more frequently

w Q Q
Black under light load
Color of exhaust gas

w w
Black

w
Metal particles found in oil filter

w
Blow-by gas excessive

w
Noise of interference is heard from around turbocharger
Check items

Engine pickup is poor and combustion is abnormal


When exhaust manifold is touched immediately after starting w Q

w
engine, temperature of some cylinders is low

Q Q Q Q Q Q
Seal on injection pump has come off

w w
Abnormal noise is loud when accelerating engine
Clanging sound is heard from around cylinder head
Leakage of air between turbocharger and cylinder head, loose w

w
clamp
Vibrating noise is heard from around muffler
q
q
When compression pressure is measured, it is found to be low

q q
When turbocharger is rotated by hand, it is found to be heavy
Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is q
Troubleshooting

stopped
When control rack is pushed, it is found to be heavy, or does not q

q
return

q
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside q

q
standard value

q
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace

Replace

Replace

Replace
Replace
Replace
Correct

Correct

Correct

Remedy

WA320-5H 20-823
TESTING AND ADJUSTING S-16

S-16 Vibration is excessive

a If there are abnormal noise together with the vibra-


Causes
tion, carry out troubleshooting also for "Abnormal

ck)
)
noise is made".

ction
tc. stu
General causes why vibration is excessive

ion

l inje
ver, e
ligne
cu sh
• Defective parts (abnormal wear, breakage)

r)

e fue
ker le
mpe
misa
• Improper combustion

ke n
aring

e, roc
essiv
a
, bro
• Abnormal combustion

aft (d
a in

(valv
in be

(exc
t
bolts

sh
ngine utput sh
e r
ackla
w

m
, ma

ump
syste
o
nting

d p
ain b
g rod

tion p
o
n

alve
ing
m ou

a
side

mic v
r
b u sh
ectin

injec
r
art in
gine

e a
dyna
e
conn

g
ca m

ctive
er of
e en
en p

oper
ctive
Worn
Worn
Loos

Cent

Defe
Brok

Impr
Defe
EEE
Confirm recent repair history

Q Q
Degree of use of machine Operated for long period
Questions

Q Q Q
Suddenly increased
Condition of vibration

Q Q
Gradually increased

w w
Non-specified fuel is being used

w w
Metal particles are found in oil filter

Q Q
Metal particles are found when oil is drained

Q Q
Oil pressure is low at low idling
Check items

Q Q Q Q
Vibration occurs at mid-range speed

w Q
Vibration follows engine speed

w
Exhaust smoke is black
Seal on injection pump has come off
q
q
Remove oil pan and inspect directly

q
Remove side cover and inspect directly
Troubleshooting

q
Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are found q

q
to be incorrect

q
Remove front cover and inspect directly

q
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
Replace
Replace
Replace
Replace

Replace
Correct
Correct

Adjust

Remedy

20-824 WA320-5H
30 DISASSEMBLY AND ASSEMBLY

How to read this manual . . . . . . . . . . . . . . . . . 30 - 2 Removal, installation of operator's cab


Precautions when carrying out operation. . . . . 30 - 4 assembly . . . . . . . . . . . . . . . . . . . . 30 - 185
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . 30 - 6 Removal, installation of operator's cab glass
Sketch of special tools . . . . . . . . . . . . . . . . . . . 30 - 9 (Stuck glass) . . . . . . . . . . . . . . . . . 30 - 191
Removal, installation of fuel injection pump Removal, installation of center hinge pin . . . 30 - 199
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 14 Removal, installation of counterweight . . . . . 30 - 210
Removal, installation of nozzle holder Removal, installation of air conditioner unit
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 18 assembly . . . . . . . . . . . . . . . . . . . . 30 - 212
Removal, installation of cylinder head Removal, installation of air conditioner
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 20 compressor assembly . . . . . . . . . . 30 - 215
Removal, installation of engine assembly . . . 30 - 28 Removal, installation of monitor panel . . . . . 30 - 216
Removal, installation of radiator assembly . . 30 - 35
Removal, installation of air aftercooler . . . . . . 30 - 36
Removal, installation of hydraulic oil cooler
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 38
Removal, installation of cooling fan and
fan motor assembly . . . . . . . . . . . . 30 - 40
Removal, installation of fuel tank assembly . . 30 - 42
Removal, installation of transfer. . . . . . . . . . . 30 - 44
Disassembly, assembly of transfer assembly 30 - 46
Removal, installation of parking brake
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 66
Disassembly, assembly of parking brake
assembly . . . . . . . . . . . . . . . . . . . . 30 - 68
Removal, installation of front axle assembly . 30 - 73
Removal, installation of rear axle assembly. . 30 - 75
Disassembly, assembly of axle housing
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 78
Disassembly, assembly of differential
assembly. . . . . . . . . . . . . . . . . . . . . 30 - 91
Removal, installation of HST pump and
4-gear pump assembly . . . . . . . . . 30 - 115
Removal, installation of HST motor 1
assembly. . . . . . . . . . . . . . . . . . . . 30 - 118
Removal, installation of HST motor 2
assembly. . . . . . . . . . . . . . . . . . . . 30 - 120
Removal, installation of work equipment
control valve assembly . . . . . . . . . 30 - 122
Removal, installation of travel damper valve
assembly. . . . . . . . . . . . . . . . . . . . 30 - 124
Removal, installation of hydraulic tank
assembly. . . . . . . . . . . . . . . . . . . . 30 - 126
Removal, installation of work equipment
assembly. . . . . . . . . . . . . . . . . . . . 30 - 128
Disassembly and assembly of HST pump
assembly. . . . . . . . . . . . . . . . . . . . 30 - 135
Disassembly and assembly of HST motor
assembly. . . . . . . . . . . . . . . . . . . . 30 - 162
Disassembly, assembly of hydraulic cylinder
assembly. . . . . . . . . . . . . . . . . . . . 30 - 178

WA320-5H 30-1.
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

HOW TO READ THIS MANUAL


REMOVAL AND INSTALLATION OF
ASSEMBLIES
Special tools Installation
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
Section, identifying which step the instructions
t: Special tools which cannot be substi-
1) Necessity
are intended for.

q: Special tools which are very useful if


tuted, should always be used. • Marks shown in the INSTALLATION Section
stand for the following.

k : cautions which must be followed when


available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
2) Distinction of new and existing special tools doing the work.

a:
N: Tools with new part numbers, newly
developed for this model. This mark gives guidance or precau-
R: Tools with upgraded part numbers, tions when doing the procedure.

2:
remodeled from already available tools This mark stands for a specific coating
for other models. agent to be used.
Blanks: Tools already available for other models,
3:
used without any modification. This mark indicates the specified
3) Circle mark (Q) in sketch column: torque.

5:
A circle mark means that a sketch of the spe-
This mark indicates an amount of oil or
cial tool is presented in the section of
water to be added.

a Part No. of special tools starting with 79*T


Sketches for Special Tools.

Sketches of special tools


means that they are locally made parts and as
• Various special tools are illustrated for the con-
such not interchangeable with those made by
venience of local manufacture.
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.

k : cautions which must be followed when


This mark indicates safety-related pre-

doing the work.

a:
This mark gives guidance or precau-
tions when doing the procedure.
This mark shows that there are instruc-
[*1] :
tions or precautions for installing parts.

6:
This mark shows oil or water to be
drained.

4 : Mass of a part or component.

30-2 WA320-5H
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

DISASSEMBLY AND ASSEMBLY OF


ASSEMBLIES
Special tools Assembly
• Special tools which are deemed ncessary for dis- • Section titled ASSEMBLY contain procedures,
assembly and assembly are listed in this section. precautions and the know-how for the work, as
• List of the special tools contains the following well as the amount of oil or water to be added.
kind of information. • Various symbols used in the ASSEMBLY Sec-
tion are explained and listed below.
t: Special tools which cannot be substi-
1) Neccessity

k : cautions which must be followed when


This mark indicates safety-related pre-

q: Special tools which are very useful if


tuted, should always be used.
doing the work.

a:
available, can be substituted with com-
mercially available tools. This mark gives guidance or precau-
2) Distinction of new and existing special tools tions when doing the procedure.

2:
N: Tools with new part numbers, newly This mark stands for a specific coating
developed for this model. agent to be used.
R: Tools with upgraded part numbers,
3:
remodeled from already available tools This mark indicates the specified
for other models. torque.
Blanks: Tools already available for other models,
5:
used without any modification. This mark indicates an amount of oil or
water to be added.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketches of special tools

a Part No. of special tools starting with 79*T


Sketches for Special Tools. • Various special tools are illustrated for the con-
venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.

k : cautions which must be followed when


This mark indicates safety-related pre-

doing the work.

a:
This mark gives guidance or precau-
tions when doing the procedure.

6:
This mark shows oil or water to be
drained.

WA320-5H 30-3d
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN
CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precau-
tions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-

a Precautions when handling piping during disassembly


ing after removal.

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628

2) Split flange type hoses and tubes


Nominal
number Flange (hose end) Sleeve head (tube end) Split flange

04 07379-00400 07378-10400 07371-30400


05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

Nominal Dimensions (mm)


number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

30-4 WA320-5H
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

2. Precautions when carrying out installation work


• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydrau-
lic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylin-
der 100 mm from the end of its stroke.

a When using the machine for the first time after repair or long storage, follow the same procedure.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.

WA320-5H 30-5d
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST


a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
a Necessity: t:
q:
Cannot be substituted, should always be installed (used).

a New/remodel:
Extremely useful if available, can be substituted with commercially available part.
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available
for other models.

a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL
Blank: Tools already available for other models, used without any modification.

TOOLS).

New/remodel
Necessity
Symbol

Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks

1 795-799-1131 Gear t 1
Fuel injection pump Removal, installation of fuel injection
t
assembly pump
2 795-799-1390 Remover 1

q
A
Nozzle holder assembly 3 795-799-1171 Puller 1 Removal of nozzle holder assembly

Cylinder head assembly 4 790-331-1110 Wrench t 1 Tightening of cylinder head bolt

1 790-201-2840 Spacer t 1

t Q
Press fitting of output shaft bearing
2 793T-417-1110 Push tool 1 N

790-101-5201 Push tool kit t 1 Press fitting of parking brake case


oil seal

• 790-101-5311 • Plate 1
3
• 790-101-5221 • Grip 1

• 01010-51225 • Bolt 1

Transfer assembly and 793T-417-1120 Push tool t 1 N Q


D
t
parking brake assembly
4 790-101-5221 Grip 1
Press fitting of parking brake case
t
dust seal
01010-81225 Bolt 1

5 799-301-1500 Oil leak tester t 1

6 799-401-3200 Adapter q 1

7 02789-00315 Cap q 1
Removal, installation of parking
q
brake cylinder rod pin
8 799-101-5160 Nipple 1

9 790-190-1500 Pump q 1

793T-623-1170 Push tool t 1 Q


Press fitting of axle shaft bearing
t Q
1
inner race
793T-422-1440 Push tool 1 N

793T-422-1410 Seal support t 2 N Q

01010-80860 Bolt t 6

t Q
2 Axle shaft oil seal support
793T-422-1420 Seal support 2 N
Axle housing assembly H
01010-80860 Bolt t 6

793T-659-1110 Push tool t 1 Q


Press fitting of axle shaft bearing
t
3
inner race
790-201-2750 Spacer 1

t Q
Adjustment of axle shaft bearing
4 793T-422-1430 Holder 1 N
shim

30-6 WA320-5H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/remodel
Necessity
Symbol

Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks

5 799-301-1500 Oil leak tester t 1 Check of operation of clutch piston

t
Removal, installation of pinion shaft
6 797-101-1211 Wrench 1
nut

t
No-load operating torque of anti-slip
7 793-615-1100 Wrench 1
differential

8 790-201-2840 Push tool t 1

t Q
Press fitting of pinion shaft bearing
9 797T-423-1320 Push tool 1

t Q
Differential assembly H Press fitting of pinion shaft cage oil
10 797T-423-1130 Push tool 1
seal

11 793-520-2202 Installer q 3 Installation of brake piston and


check for brake oil leakage

13 790-190-1500 Pump assembly t 1 Check for brake oil leakage

14 799-401-3100 Adapter t 1 Check for brake oil leakage

15 0289-0-00210 Cap nut t 1 Check for brake oil leakage

16 799-101-5160 Nipple t 1 Check for brake oil leakage

790-502-1003 Repair stand t 1 Disassembly, assembly of hydraulic


cylinder
1
790-101-1102 Hydraulic pump t 1

t
790-102-2303
2 or Wrench assembly Removal, installation of cylinder
1
790-102-3802 (for steering) head

3 790-302-1340 Socket (for boom) t 1 Removal, installation of piston nut

t
Press fitting of cylinder head bush-
790-201-1702 Push tool kit 1 ing

790-101-5021 • Grip 1

01010-50816 • Bolt 1
4
790-201-1821 • Push tool (boom) 1
Hydraulic cylinder
U
assembly 790-201-1831 • Push tool (bucket) 1

• Push tool
790-201-1741 1
(steering)

790-201-1500 Push tool kit t 1 Installation of dust seal

790-101-5021 • Grip 1

01010-50816 • Bolt 1
5 790-201-1630 • Plate (boom) 1

790-201-1640 • Plate (bucket) 1

• Push tool
790-201-1550 1
(steering)

6 790-720-1000 Expander q 1 Installation of piston ring

WA320-5H 30-7d
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

New/remodel
Necessity
Symbol

Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks

q
Ring
796-720-1680 (boom and bucket) 1

q
Ring
07281-01589 (boom and bucket) 1
7

796-720-1740 Ring (steering) q 1


Hydraulic cylinder
q
assembly U
07281-00809 Ring (steering) 1

t
Wrench assembly
790-102-4300 (for boom and 1
8 bucket)

790-102-4310 Pin t 2

t
Collection and supply of air condi-
799-703-1200 Service tool kit 2
tioner refrigerant

t
Vacuum pump
799-703-1100 1
(100 V)

t
1 Vacuum pump
799-703-1110 1
(220 V)

t
Vacuum pump
799-703-1120 (240 V) 1

t
Installation of operator's X
cab glass
799-703-1400 Gas leak tester 1

t
Adjustment of clearance of window
2-1 793-498-1120 Clear plate 2
glass

2-2 793-498-1130 Plate t 2

2-3 793-498-1110 Magnet t 2

3 793-498-1210 Lifter (Suction cup) t 2 Removal, installation of window


glass

30-8 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS

SKETCH OF SPECIAL TOOLS


Note) We will not be liable for any result of use of special tools manufactured according to the following drawings.

D2 Push tool

9JF00891

D4 Push tool

9JF00892

WA320-5H 30-9d
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS

H1-1 Push tool aWhen using this tool, connect H1-2 to it.
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.

9JF00902

H1-2 Push tool aWhen using this tool, connect H1-1 to it.

9JF01421

30-10 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H2 Seal support

9JF01422

H2 Seal support

9JF01423

WA320-5H 30-11d
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H3 Push tool

9JF00899

H4 Holder

9JF01424

30-12 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H9 Push tool

DXW06324

H10 Push tool

CWH10643

WA320-5H 30-13d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

REMOVAL, INSTALLATION OF
FUEL INJECTION PUMP
ASSEMBLY
SPECIAL TOOLS
AJS00169

New/Remodel
Necessity

Sketch
Q'ty
Symbol Part No. Part Name

1 795-799-1131 Gear t 1

t
A
2 795-799-1390 Remover 1

7. Remove cotter pin (10) and nut (11), and then


remove engine stop solenoid rod (12) from the
REMOVAL fuel injection pump.

k
Lower the work equipment to the ground
and stop the engine.

k
Disconnect the cable from the negative (-)
terminal of the battery.
AJF00957

1. Open the engine right side cover.


2. Remove fuel control cable mounting nut (1) and
disconnect the fuel control cable from the fuel
injection pump. [*1]

8. Disconnect engine stop solenoid terminals PULL


(7), HOLD (8), and GND (9). [*3]

AJF00168 9. Remove engine stop solenoid (13) and bracket


(14) together. [*4]

3. Disconnect fuel supply hoses (2) and (3). AJS00170

4. Disconnect fuel filter (4).

5. Disconnect fuel return hose (5).

6. Remove 6 fuel injection tubes (6). [*2]

30-14 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

a Use a filter wrench, etc. to remove the cap.


10. Remove fuel tubes (15) and (16). [*5] 14. Remove cap (21).

11. Remove lubrication tubes (17) and (18). 15. Remove fuel injection pump nut (22) and washer

a Take care not to drop the nut and washer


(23).

into the case.

AJF00958

AJF00961

12. Remove boost compensator tube (19).

16. Using tool A2, disconnect the fuel injection pump


shaft and pump drive gear.

AJS00171

AJF00962

13. Using timing pin (20), match the timing gear to


the fuel injection timing.

a For details, see TESTING AND ADJUST-


Gear: Use tool A1.

ING, Testing and adjusting fuel injection tim- 17. Remove fuel injection pump bracket (24).
ing.

AJF00963
AJF00960

WA320-5H 30-15d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

18. Remove 4 fuel injection pump mounting nuts (25) INSTALLATION


a Install the fuel injection pump assembly accord-
and fuel injection pump assembly (26).

ing to the following procedure.


1. Check that the timing pin is matched to the injec-

a For details, see TESTING AND ADJUST-


tion timing.

ING, Testing and adjusting fuel injection tim-

a See step 13 of the removal procedure.


AJS00172 ing.

2. Remove plug (27) and turn over timing pin (28) of


the fuel injection pump, and then install them to

a Check that the cut of the pin is meshed with


the fuel injection pump again.

projection (a) in the pump.

9JF01042

3. Install fuel injection pump assembly (26) and


tighten 4 nuts (25).

3 Fuel injection pump mounting nut:


9.8 ± 2 Nm {1.0 ± 0.2 kgm}

AJS00172

30-16 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

a Adjust the fuel control cable. For details, see


4. Install fuel injection pump bracket (24). [*1]

3 Fuel injection pump bracket TESTING AND ADJUSTING, Measuring, testing


mounting bolt (on injection pump operating force of accelerator pedal.
side): 22 ± 2 Nm {2.2 ± 0.2 kgm} [*2]

3 Fuel injection tube nut (on injection pump


side): 24 ± 4 Nm {2.45 ± 0.41 kgm}
Fuel injection tube nut (on nozzle holder
side): 30 ± 5 Nm {3.06 ± 0.51 kgm}

[*3]

3
AJF00963
Engine stop solenoid terminal:
0.98 - 1.27 Nm {0.1 - 0.13 kgm}

a Set the cap sideways so that water will not col-


lect.
[*4]

3
5. Install washer (23) and tighten fuel injection
Engine stop solenoid bracket mounting

a Take care not to drop the nut and washer


pump nut (22) temporarily.
nut: 14 - 21 Nm {1.4 - 2.1 kgm}

into the case. a Adjust the engine stop solenoid. For details, see

k
TESTING AND ADJUSTING, Adjusting engine
Tighten the nut to the following stop solenoid.
torque temporarily so that it will
[*5]

3
not damage the timing pin.

3
Fuel tube joint bolt (on fuel filter side):
Temporary tightening torque of
19.6 - 29.4 Nm {2.0 - 3.0 kgm}
fuel injection pump nut:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
• Bleeding air
Bleed air from the fuel system.

9JF01043

6. Disengage the timing pin of the fuel injection


pump on the timing gear side from projection (a)
and return it to the original position.
7. Tighten fuel injection pump nut (22) permanently.

3 Permanent tightening torque of


fuel injection pump nut:
95 ± 10 Nm {9.7 ± 1.01 kgm}

a After the above step, carry out installation in the


reverse order to REMOVAL, 1 - 14.

WA320-5H 30-17d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY

REMOVAL, INSTALLATION OF
4. Remove spill tube (2). [*2]
NOZZLE HOLDER ASSEMBLY
SPECIAL TOOLS

New/Remodel
Necessity

Sketch
Q'ty
Symbol Part No. Part Name
AJS00174
A 3 795-799-1171 Puller t 1

REMOVAL

k
Lower the work equipment to the ground
and stop the engine. 5. Loosen and remove nozzle holder assembly (3).

a Take care that dirt and foreign matter will not


[*3]

1. Open the engine right and left side covers. enter the mounting part of the nozzle holder
assembly
2. Remove air cleaner (10).

AJS00175
AJS00173

a If the nozzle holder is difficult to remove, use


3. Remove fuel injection tubes (1). [*1] tool A3.

AJF00965 9JF01048

30-18 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY

INSTALLATION
• Carry out installation in the reverse order to
removal.

[*1]

3 Fuel injection tube nut (on injection pump


side): 24 ± 4 Nm {2.45 ± 0.41 kgm}
Fuel injection tube nut (on nozzle holder
side): 30 ± 5 Nm {3.06 ± 0.51 kgm}

[*2]

3 Spill tube joint bolt: 9 Nm {0.9 kgm}

[*3]

3 Nozzle holder:
60 Nm ± 9 Nm {6.1 ± 0.9 kgm}

• Bleeding air
Bleed air from the fuel system.

WA320-5H 30-19d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

REMOVAL, INSTALLATION OF
CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS

New/Remodel
AJS00150

Necessity

Sketch
Q'ty
Symbol Part No. Part Name

3 795-799-1171 Puller t 1

t
A
4 790-331-1110 Wrench 1

REMOVAL 4. Remove cotter pin (10) and nut (11), and then
remove engine stop solenoid rod (12) from the

k
fuel injection pump.
Stop the vehicle on a level place and set the
safety bar to the frame.

k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.

k
Disconnect the cable from the negative (-) AJF00957
terminal of the battery.

1. Remove the engine hood assembly. For details,


see Removal, Installation of engine assembly.
2. Drain the coolant.

6 Coolant: 17 l
5. Disconnect the following engine stop solenoid

a Disconnect the wiring harness clamps, too.


3. Remove the air conditioner compressor accord- terminals and wiring connectors. [*3]
ing to the following procedure.
1) Disconnect wiring connector E16 (1) and • (71): PULL [*21]
ground terminal E22 (2). [*1] • (72): HOLD [*21]
2) Remove clamps (3) (4 pieces). • (73): GND [*21]
3) Loosen 2 mounting bolts (4) and 2 mounting • (14): E14
bolts (5).
4) Loosen 2 locknuts (6) and 2 adjustment bolts
(7). 6. Remove air compressor bracket (42).
5) Remove air conditioner compressor belt (8).
[*2]
6) Remove 2 mounting bolts (4), 2 mounting
bolts (5), and air conditioner compressor and

a Place the air conditioner piping by the


bracket assembly (13).

side of the engine without disconnecting


it.

30-20 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

7. Remove engine stop solenoid bracket (43). [*4] 12. Remove hose (19) on the upper side of the after-
cooler. [*7]

13. Remove air hose (17) between the air cleaner


and turbocharger. [*6]

AJS00151

AJS00141

8. Disconnect intake air heater terminal.


• (15): E09
[*5]

9. Remove the mounting bolts of heater relay (16). 14. Remove the muffler according to the following
procedure.
1) Remove 4 mounting bolts (21).
2) Remove 4 mounting bolts (22).
3) Remove drain tube mounting bolt (29) and
drain tube (24).

AJS00152

AJS00154

10. Disconnect air hose (17) between the air cleaner


and turbocharger. [*6]

11. Remove air cleaner and bracket assembly (20).

AJS00153

WA320-5H 30-21d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

15. Lift off muffler and bracket assembly (23). 1) Lift off turbocharger and exhaust manifold

4
assembly (32).

4
Muffler and bracket assembly: 35 kg
Turbocharger and exhaust mani-
fold assembly: 40 kg

AJS00155
AJS00158

16. Remove the turbocharger and exhaust manifold


assembly according to the following procedure. 18. Remove alternator belt cover (34) and alternator
1) Disconnect turbocharger lubrication tubes belt.
(25) and (26). [*8]
2) Remove exhaust manifold heat insulation 19. Disconnect radiator inlet hose (18). [*10]
cover (30). [At this time, bracket (29) comes
off, too.]

AJS00159
AJS00156

20. Disconnect wiring connector E02 (35) and alter-


nator terminal E11 (36). [*11]
17. Remove mounting bolts (31) of the turbocharger
and exhaust manifold assembly (12 pieces). [*9]
21. Remove mounting bolts (37) and (38) and alter-
nator (39).

AJS00157
AJS00160

30-22 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

22. Remove alternator bracket (40) and thermostat 28. Disconnect 6 fuel injection tubes (33). [*14]
and housing assembly (41) together. [*12]

AJS00163
AJS00161

29. Remove spill tube clamp (51).


23. Remove air hose (44). [*13]
30. Disconnect heater hose (52).
24. Remove air intake connector (45) and heater
(46).

AJS00164

AJS00162

31. Remove 6 fuel injection tubes (33). [*14]

25. Remove boost compensator tube (47).


32. Remove spill tube (53). [*15]
26. Remove fuel tubes (48) and (49).

27. Remove fuel filter (50).

AJS00165

WA320-5H 30-23d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

a Loosen the locknut, and then loosen adjust-


33. Remove 6 nozzle holders (54). [*16] 35. Remove rocker arm (56). [*18]

ment screw by 2 - 3 turns.

AJS00166

9JF01044

a If the nozzle holder is difficult to remove, use


tool A3.

36. Remove push rods (57). [*19]

9JF01048
9JF01045

34. Remove 6 cylinder head covers (55). [*17]

37. Lift off cylinder head assembly (58). [*20]

4 Cylinder head assembly: 55 kg

AJS00167 38. Remove cylinder head gasket (59). [*21]

9JF01046

30-24 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY

a Tighten the exhaust manifold mounting bolts in 3


INSTALLATION [*9]

• Carry out installation in the reverse order to times according to the following procedure.

3
removal.
[*1] Exhaust manifold mounting bolt:

3
1st time: Tighten the bolts to 24 ± 4 Nm
Ground terminal: {2.45 ± 0.41 kg} in the order
59 - 74 Nm {6 - 7.5 kgm} of 1 - 12.
2nd time: Tighten the bolts to 43 ± 6 Nm

a Adjust the tension of the air conditioner compres-


[*2] {4.38 ± 0.61 kg} in the order
of 1 - 12.
sor belt. For details, see TESTING AND 3rd time: Tighten the bolts to 43 ± 6 Nm
ADJUSTING, Testing and adjusting air condi- {4.38 ± 0.61 kg} again in the
tioner compressor belt tension. order of 1 - 4.

[*3]

3 Engine stop solenoid terminal:


0.98 - 1.27 Nm {0.1 - 0.13 kgm}

a Set the cap sideways so that water will not col-


lect. missing CJP10526
[*4]

3 Engine stop solenoid bracket mounting


nut: 14 - 21 Nm {1.4 - 2.1 kgm}

[*5]

3 Intake air heater terminal:


2.45 - 2.94 Nm {0.25 - 0.3 kgm