WA150-5 SEBM033805 Troubleshooting

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
CHECK BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . 20-213
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No. . . . . . . . . . . . . . . . . 20-214
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-239
CONNECTOR TYPES AND MOUNTING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243
CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-250
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE) . . . . . . . . . . . . . . . . . . . . . . . . . 20-401
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) . . . . . . . . . . . . . . . . . . . . . 20-701
TROUBLESHOOTING OF ENGINE (S MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
WA150-5 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely
fitted.
k
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
k
When removing the plug or cap from a location which is under pressure from oil, water or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. If components externally, so check any item that is consid-
are disassembled immediately after a failure ered to be necessary.
occurs: 4. Confirming the failure.
• Parts that have no connection with the fail- Confirm the extent of the failure yourself, and
ure or other unnecessary parts will be disas- judge whether to handle it as a real failure or as
sembled. a problem with the method of operation, etc.
• It will become impossible to find the cause of a When operating the machine to re-enact the
the failure. troubleshooting symptoms, do not carry out
It will also cause a waste of man hours, parts, or any investigation or measurement that may
oil and grease. At the same time, it will also lose make the problem worse.
the confidence of the user or operator. For this 5. Troubleshooting
reason, when carrying out troubleshooting, it is Use the results of the investigation and inspec-
necessary to carry out thorough prior investigation in Steps 2 - 4 to narrow down the causes of
tion and to carry out troubleshooting in accor- the failure, then use the troubleshooting flow-
dance with the fixed procedure. chart to locate the position of the failure exactly.
2. Points to ask the user or operator. a The basic procedure for troubleshooting is
1) Have any other problems occurred apart as follows.
from the problem that has been reported? 1) Start from the simple points.
2) Was there anything strange about the 2) Start from the most likely points.
machine before the failure occurred? 3) Investigate other related parts or infor-
3) Did the failure occur suddenly, or were there mation.
problems with the machine condition before 6. Measures to remove root cause of failure.
this? Even if the failure is repaired, if the root cause of
4) Under what conditions did the failure occur? the failure is not repaired, the same failure will
5) Had any repairs been carried out before the occur again.
failure? When were these repairs carried To prevent this, always investigate why the prob-
out? lem occurred. Then, remove the root cause.
6) Has the same kind of failure occurred
before?
3. Check before troubleshooting.

1) Check the oil level.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 WA150-5
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA150-5 20-203
(1)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on 'Handling electric equipment' and 'Handling hydraulic
equipment' (particularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELECTRIC

EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protector or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations they are fre-
quently removed and installed again, so they are
likely to suffer deformation or damage. For this
reason, it is necessary to be extremely careful
when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Faulty contact of connectors
(faulty contact between male and female).
Problems with faulty contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or oxi-
dation of the contact surfaces.
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion, but there is excessive
force on the wiring, and the plating peels to
cause improper connection or breakage.
20-204 WA150-5
(1)
12 (3) Disconnections in wiring

If the wiring is held and tugged and the con-
nectors are pulled apart, or components are
lifted with a crane with the wiring still con-
nected, or a heavy object hits the wiring, the
crimping compression of the connectors to
the wire may be loosened, or the soldering
may be damaged, or the wiring may be bro-
ken.
(4) High pressure water entering a connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the connec-
tor depending on the direction of the water
jet. The connector is designed to prevent
water from entering, but if water does enter,
it is difficult for it to be drained. Therefore, if
water should get into the connector, the pins
will be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before pass-
ing electricity through it.
(5) Oil, grease or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, and this will
cause a defective contact. If there is oil or
grease or dirt stuck to the connector, wipe it
off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is water or oil present, it will
increase the contamination of the points,
so clean with air until all water and oil
has been removed.
WA150-5 20-205
(1)
2) Removing, installing, and drying connectors and

wiring harnesses
• Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For connec-
tors which have a lock stopper, press down
the stopper with your thumb and pull the con-
nectors apart.
a Never try to pull apart with one hand.
(2) When removing the connectors from the
clips, pull the connector in a parallel direction
to the clip.
a If the connector is twisted to the left and
right or up and down, the housing may
break.
(3) Action to take after removing connectors.

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left for a long time, it is
particularly easy for improper contact to
occur, so always cover the connector.
20-206 WA150-5
(1)
• Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
faulty contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has gotten inside the con-
nector, warm the inside of the wiring with
a dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
(2) Assemble the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks
into position.
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
a When blowing with dry air, there is dan-
ger that the oil in the air may cause
improper contact, so clean with properly
filtered air.
12 (4) When the wiring harness clamp of the con-

nector has been removed, always return it to
its original condition and check that there is
no looseness of the clamp.
• Connecting connectors (DT type connector)
Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal) : a, b, d
• Incomplete locking state (Diagonal) : c
WA150-5 20-207
(1)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows:
(1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with air,
there is the risk that oil in the air may
cause a faulty contact, so avoid blowing
with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
be careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
spray it with contact restorer and reas-
semble.
20-208 WA150-5
(1)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits.
This controls all of the electronic circuits on
the machine, so be extremely careful when
handling the control box.
(2) Do not open the cover of the control box
unless necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
(5) Do not leave the control box in a place
where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in the circuit.
WA150-5 20-209
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dust proof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from enter-
ing. Never leave any openings opened or
blocked with a rag, this could cause particles or
dirt to get into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper environ-
mental regulation for any disposal of oil.
4) Do not let any dirt, or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-210 WA150-5
(1)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic tank;
but drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultra fine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so it
is an extremely effective device.
WA150-5 20-211
(1)
TROUBLESHOOTING CHECK BEFORE TROUBLESHOOTING
CHECK BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel - Drain

3. Check oil level in hydraulic oil tank - Add oil
4. Check oil filter (Hydraulic, HST) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check play of steering wheel Max. 60 mm Adjust
Air, Hydraulic, Mechanical equipment
10. Check emergency steering - Repair
11. Check tire inflation pressure and damage - Air charge or

replace
Before Starting Checking Item
Tightening torque (See DIS-

12. Check loosen of hub nut ASSENBLY AND ASSEM- Tighten
BLY)
13. Check effect of foot brake - Adjust
14. Check effect of parking brake - Adjust or repair
15. Check operation of steering - Adjust or repair
16. Check direction of rear view mirror and under mirror - Adjust
17. Check effect of exhaust gas color and sound - Adjust or repair
18. Check effect body mounting rubber - Replace
19. Check sound of horn - Repair
20. Check flashing of lamps - Repair or replace
21. Check operation of gauge when during operation - Adjust or repair
Electrical equipment
22. Check operation of monitor panel - Adjust or repair

23. Check operation of machine monitor system - Adjust or repair
24. Check for missing central warning lamps - Repair or replace
25. Check for looseness, corrosion of battery terminal, wir- - Tighten or clean
ing
26. Check for looseness, corrosion of alternator terminal,
wiring - Tighten or clean
27. Check for looseness, corrosion of starting motor termi- - Tighten or clean
nal, wiring
28. Check for abnormal noise, smell - Repair
29. Check for oil leakage - Repair
30. Carry out air bleeding - Bleed air
31. Check battery voltage (Engine stopped) 24 V Charge or replace
Others Checking Item
32. Check battery electrolyte level - Add

33. Check for discolored, burnt, exposed wiring - Replace
34. Check for missing wiring clamps, hanging wire - Repair
35. Check for water leakage on wiring (Pay particular atten-
tion to water leaking on connectors or terminals) - Dry
36. Check for blown, corroded fuses - Replace

37. Check alternator voltage (Engine running at 1/2 throttle After running for several min- Replace
of above) utes: 28 - 29V
38. Check sound of actuation of battery relay (When starting
switch is turned ON, OFF) - Replace
20-212 WA150-5
(1)
CATEGORIES, PROCEDURE, AND METHOD OF USING
TROUBLESHOOTING TROUBLESHOOTING CHARTS
CATEGORIES, PROCEDURE, AND METHOD OF USING

TROUBLESHOOTING CHARTS
1. Categories of troubleshooting codes
a If the machine monitor displays a failure code, the name of the controller is also displayed at the same
time, so the troubleshooting codes are categorized according to the name of each controller. (This may
also includes some failure codes for the electrical system that are not displayed)
a Failures of the hydraulic and mechanical system that the machine monitor cannot display are catego-
rized as H mode.
Error code System for troubleshooting
HST Troubleshooting of HST controller system
MON Troubleshooting of machine monitor system
ECSS Troubleshooting of travel damper system (ECSS controller system)
E Troubleshooting of electrical system
H Troubleshooting of hydraulic, mechanical system
S Troubleshooting of engine
2. Procedure for troubleshooting

a If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows.
1) When error code is displayed on machine monitor
If a error code is displayed on the machine monitor at the same time as the problem occurs, check the
content of the display, then go to the applicable troubleshooting for the error code.
2) If no error code is displayed on the machine monitor but the failure is recorded in memory
If it is impossible to check the error code display on the machine monitor when a problem occurs, use
the troubleshooting history display function in the service mode of the machine monitor to check if there
is a failure code.
If a error code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for
the error code.
3) If no error code is displayed and no failure history is recorded
If it is impossible to check the failure display on the machine monitor when a problem occurs, and there
is also no error code recorded in the troubleshooting history display function in the service mode of the
machine monitor, it is probable that are problem has occurred in the hydraulic or mechanical system or
in the electrical system that the controller cannot detect.
In such a case, check the condition of the failure carefully, then go to the applicable troubleshooting for
the failure.
WA150-5 20-213
(1)
PHENOMENA CONSIDERED TO BE FAILURES
TROUBLESHOOTING AND TROUBLESHOOTING No.
PHENOMENA CONSIDERED TO BE FAILURES AND

TROUBLESHOOTING No.
aWith mark q go to troubleshooting No. on error code display.
Troubleshooting
No. Phenomena considered to be failures Erroe HST ECSS MON E H S mode
code mode mode mode mode mode (Engine)
Failures related to error code
1 Error code is displayed on error code display unit q

(LED display unit)
Failures related to engine (S mode)
2 Starting performance is poor (starting always takes S-1

time)
3 Engine does not rotate S-2a)
4 Engine Engine rotates but no exhaust smoke S-2b)

does not comes out
start
5 Exhaust smoke comes out but engine S-2c)
does not start
6 Engine does not pick up smoothly (follow-up is S-3

poor)
7 Engine stops during operations S-4
8 Engine does not rotate smoothly (hunting) S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive (or exhaust smoke is S-8

blue)
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil in cooling water (or water spurts back, or water

level goes down) S-11
15 Oil pressure caution lamp light ON (drop in oil pres- S-12

sure)
16 Oil level rises (water, fuel in oil) S-13
17 Water temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
Failures related to HST (HST mode)
20 Defective HST controller power source (HST con- HST-1

troller does not function)
21 Travel speed does not shifted HST-2
22 HST output cannot be controlled (traction control) HST-3
23 Travel speed limit cannot be changed when gear HST-4

speed selector switch is in "1st" position
24 Travel speed is not increased HST-5
Failures related to travel damper
25 Travel damper does not operate or is not reset ECSS-1
Failures related to monitor (MON mode)
26 The parking brake indicator lamp does not light ON MON-1
27 The brake oil pressure caution lamp does not light MON-2
ON
The engine water temperature caution lamp does
28 not light ON or the engine water temperature gauge MON-3
does not rises when engine is started
20-214 WA150-5
(1)
Troubleshooting
The HST oil temperature caution lamp does not light
29 ON or the HST oil temperature gauge does not rises MON-4
when engine is started
30 The fuel level gauge does not rises or goes down MON-5
31 The radiator coolant level caution lamp does not

light ON MON-6
32 The steering oil pressure caution lamp does not MON-7

light ON
33 The emergency steering oil pressure indicator lamp MON-8

does not light ON
34 Input fault in monitor panel mode switch 1 [t] (panel

switch 1) MON-9
35 Input fault in monitor panel mode switch 1 [U] MON-10

(panel switch 2)
36 Input fault in monitor panel mode switch 2 [<] (panel

switch 3) MON-11
37 Input fault in monitor panel mode switch 2 [>] (panel MON-12

switch 4)
38 The alarm buzzer does not sound or stop MON-13
39 The wiper does not function MON-14
40 The each lamps do not light ON MON-15
Failures related to electrical system (E mode)
41 The engine does not start E-1
42 The engine does not stop E-2
43 Preheating is impossible or constant E-3
44 Defective parking brake system E-4
45 Defective lift arm kick-out function and cancellation E-5
46 Defective bucket leveler function and cancellation E-6
47 Defective lift arm FLOATING holding and cancella- E-7

tion
48 Direction shift does not function normally E-8
49 The wiper does not function E-9
50 The window washer does not function E-10
51 The each lamps do not light ON E-11
52 The horn does not sound E-12
53 The air conditioner does not work E-13
Failures related to hydraulic and mechanical system (H mode)
54 The machine does not start H-1
55 The travel speed is slow H-2
56 The thrusting force is weak H-3
57 Engine stalls when traveling or engine speed drops H-4

excessively
58 Travel speed (gear) does not shifted H-5
59 The steering wheel dose not turn H-6
60 Steering is heavy H-7
61 The steering wheel shakes or jerks H-8
WA150-5 20-215
(4)
Troubleshooting
Failures related to hydraulic and mechanical system (H mode)
62 Machine
ing
deviates naturally to one side when travel- H-9
63 The brake does not work or does not work well H-10
64 The brake is not released or is dragged H-11
65 The lift arm does not rise or goes down H-12
66 The lift arm moves slowly or the lift arm rising force
is insufficient H-13
67 When rising, the lift arm comes to move slowly at H-14

specific height
68 The lift arm cylinder cannot hold down the bucket

(The bucket rises in the air) H-15
69 Hydraulic drifts of the lift arm occur often H-16

70 The lift arm wobbles during operation H-17
71 When the control lever is switched from "HOLD" to H-18

"RAISE", the lift arm falls temporarily
72 The bucket does not tilt back H-19
73 The bucket moves slowly or the tilting-back force is H-20

insufficient
74 The bucket comes to operate slowly in the midst of H-21

tilting-back
75 The bucket cylinder cannot hold down the bucket H-22
76 Hydraulic drifts of the bucket occur often H-23
77 The bucket wobbles during travel with cargo (The H-24

work equipment valve is set to "HOLD")
78 When the control lever is switched from "HOLD" to

"TILT", the bucket falls temporarily H-25
79 The control levers of lift arm and bucket do not H-26

move smoothly and heavy
80 The travel damper does not operate and machine H-27

pitches and bounces
20-216 WA150-5
(4)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
Num- X Type Connector

ber of T-adapter Part
Pins Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
• Grommet: red • Grommet: red
20-218 WA150-5
(1)
Num- SWP Type Connector

BWP04708
BWP04707
6 799-601-7050
BWP04710
BWP04709
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
WA150-5 20-219
(1)
Num- SWP Type Connector

Pins Male (Female housing) Female (Male housing)
Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red
20-220 WA150-5
(1)
Num- M Type Connector

Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
BWP04718
BWP04717
2 799-601-7090
BWP04719 BWP04720
3 799-601-7110
BWP04721 BWP04722
4 799-601-7120
BWP04723 BWP04724
6 799-601-7130
BWP04725 BWP04726
8 799-601-7340
WA150-5 20-221
(1)
Num- S Type Connector

ber of T-adapter
Part Number
BWP04728
8 BWP04727 799-601-7140
10 BWP04729 BWP04730
799-601-7150
(white)
12 BWP04731 BWP04732
(white) 799-601-7350
16 BWP04733 BWP04734
(white) 799-601-7330
20-222 WA150-5
(1)
Num- S Type Connector

Number
BWP04736
10 BWP04735
(blue) —
— —
12 BWP04737 BWP04738
799-601-7160
(blue)
16 BWP04739 BWP04740
(blue) 799-601-7170
WA150-5 20-223
(1)
Num- MIC Type Connector

Number
7 Body part number: 79A-222-2640 Body part number: 79A-222-2630 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
11 Body part number: 79A-222-2680 Body part number: 79A-222-2670 —

BWP04742
BWP04741
5 799-601-2710
Body part number: 79A-222-2620 Body part number: 79A-222-2610

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-224 WA150-5
(1)
Num- MIC Type Connector

Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

— Body part number: 79A-222-2770 Body part number: 79A-222-2760 —

WA150-5 20-225
(1)
Num- AMP040 Type Connector

Number
BWP04752
BWP04751
8 799-601-7180
Housing part number: 79A-222-3430

— (Quantity: 5 pieces)
BWP04753 BWP047544
12 799-601-7190
Housing part number: 79A-222-3440

— (Quantity: 5 pieces)
BWP04755 BWP04756
16 799-601-7210
— Housing part number: 79A-222-3450

(Quantity: 5 pieces)
BWP04757 BWP04758
20 799-601-7220
— Housing part number: 79A-222-3460

(Quantity: 5 pieces)
a Terminal part number: 79A-222-3470 (for all numbers of pins).
20-226 WA150-5
(1)
Num- AMP070 Type Connector

Number
10 799-601-7510
— Part number: 7821-92-7330
BWP04761 BWP04762
12 799-601-7520
— Part number: 7821-92-7340
BWP04763 BWP04764
14 799-601-7530
— Part number: 7821-92-7350
BWP04765 BWP04766
18 799-601-7540
— Part number: 7821-92-7360
BWP04767 BWP04768
20 799-601-7550
— Part number: 7821-92-7370
WA150-5 20-227
(4)
Num- L Type Connector

ber of T-adapter
Part Number
BWP04770
2 BWP04769 —
— —
Num- PA Type Connector

ber of T-adapter
Pins Male (Female housing) Female (Male housing) Part Number
BWP04772
9 BWP04771 —
— —
Num- BENDIX (MS) Type Connector

BWP04774
BWP04773
10 799-601-3460
— —
20-228 WA150-5
(1)
Num- KES1 Automobile Type Connector

ber of T-adapter
Part Number
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
WA150-5 20-229
(1)
Num- KES1 Automobile Type Connector

ber of T-adapter
Part Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
Num- Connector for relay (Socket)

BWP04786
BWP04785
5 799-601-7360
— —
BWP04788
BWP04787
6 799-601-7370
— —
Type F Type Connector

(shell
size Pin (Male terminal) Body (Female terminal) T-adapter
code) Part Number
4 —
— —
20-230 WA150-5
(1)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle) Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

08191-11205, 08191-11206 08191-14105, 08191-14106
18-8
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
WA150-5 20-231
(1)

799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
20-232 WA150-5
(1)

799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
WA150-5 20-233
(1)

799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-23 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
20-234 WA150-5
(1)

799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
WA150-5 20-235
(1)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-236 WA150-5
(1)
DT Series connector
Number
Number
8GR:
799-601-9060
8B:
8 799-601-9070
8G:
799-601-9080
8BR:
799-601-9080
Part number:08192-1820 T (normal type) Part number:08192-1810 T (normal type)

08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR:
799-601-9110
12B:
12 799-601-9120
12G:
799-601-9130
12BR:
799-601-9140
Part number: 08192-1920 T (normal type) Part number:08192-1910 T (normal type)

08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
WA150-5 20-237
(1)
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle) Number
1 —
Part number:08192-31200 (Contact size #12) Part number:08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-238 WA150-5
(1)
DRC26 Series connector
No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.
24 799-601-9360
— Part No. : 7821-93-3110
40
799-601-9350
(A)
— Part No. : 7821-93-3120
40
799-601-9350
(B)
— Part No. : 7821-93-3130
WA150-5 20-238-1
(4)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
a The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P Q Q Q Q Q Q

799-601-3100 For measuring box MS-37P Q
799-601-3200 For measuring box MS-37P Q
799-601-3300 For measuring box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 CASE Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 CASE Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
WA150-5 20-239
(1)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Cace Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Blown Q Q
799-601-9110 DT 12P-Gray Q Q
20-240 WA150-5
(1)
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Blown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD30 24-9 Q Q
799-601-9260 HD30 2-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 For measuring box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DRC26 40P Q
799-601-9360 DRC26 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For boost pres- 3P Q

sure, fuel
799-601-9430 PVC socket 2P Q
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P Q
for HST controller
AMP 1-963215-1
799-601-9720 AMP 1-963217-1 16P Q
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P Q
for HST controller
WA150-5 20-241
(4)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

a The address column of the table indicates each address of a connector placement diagram (diagram in
three dimensions) and an electrical circuit system diagram.
a Symbols of the circuit diagram address column of the table:
HST: HST System, MON: Monitoring system, E: Electrical system.
a The item enclosed by parentheses in the connector type column indicates the color of the connector body.
(B: Black, Br: Brown, G: Green, Gr: Gray, W: White)
Address
Connec- Connector Number Installation Name System Drawing
tor No. Type of pins Layout
Drawing HST MON E
A01 M 6 Blower motor, resister V-7 F-8
A02 SWP 6 Air mixing servomotor V-6 F-8
A03 M 2 Thermistor V-7 F-8
A05 Sumitomo 4 Air conditioner pressure switch V-8 E-8
A07 SWP 8 L.H. side blower servomotor R-1 D-8
A08 SWP 8 R.H. side blower servomotor N-4 D-8
A09 Sumitomo 5 Blower relay (Main) U-8 B-1
A10 Sumitomo 5 Blower relay (HI) U-8 B-1
A11 Sumitomo 5 Blower relay (M2) T-9 B-1
A12 Sumitomo 5 COND relay T-9 A-1
A13 Sumitomo 5 Blower relay (M1) S-9 A-1
A15 Sumitomo 5 Magnet clutch relay T-9 A-1
Intermediate connector
AL1 S 16 (Air conditioner relay harness) T-9 C-3
B01 M 2 Rear working lamp (Right side) I-9 Q-1

B02 M 2 Rear working lamp (Left side) J-8 Q-1
B04 DT-T 3 Condenser motor H-9 N-3
B05 X 2 Coolant level sensor G-9 N-2
Intermediate connector (Bulkhead har-
BL1 DT-T 6 ness) H-2, W-1
BR1 DT-T 4 Intermediate connector (Grill harness) J-8 Q-3 P-1

C03 AMP040 16 Air conditioner controller E-9 B-9
C04 AMP040 12 Air conditioner controller E-9 C-9
C05 M 2 Front working lamp (Right side) D-8 C-9
C06 M 2 Front working lamp (Left side) E-9 C-9
C07 KES1 2 Room lamp F-9
C08 M 1 Door switch (Left side) (Room lamp) F-9
C09 M 1 Door switch (Right side) (Room lamp) D-8
C10 Terminal 1 Ground D-9
C11 PA 9 AM/FM radio D-9
C12 M 2 Speaker (Left side) G-9
C13 M 2 Speaker (Right side) F-9
C14 VHC 8 Warning lamp (beacon) switch E-9
C15 M 1 Warning lamp connector E-9
C16 Plug 1 Warning lamp (beacon) C-8
C17 Terminal 1 Ground D-8
C18 Terminal 1 Ground D-9 C-8
C19 VCH 8 Defroster switch E-9
WA150-5 20-243
(1)
Address
Connec- Connector Number
tor No. Type of pins Installation Name Layout System Drawing
Drawing HST MON E
C20 Sumitomo 5 Defroster relay F-9
C21 Yazaki 1 Rear glass (Defroster) F-9
C22 Yazaki 1 Rear glass (Defroster) H-9
C23 Terminal 1 Ground C-8
CAN1 DT-T 3 CAN connector O-7 F-1 K-2
CAN2 DT-T 3 CAN connector N-3 F-1 K-2
CL1 S 16 Intermediate connector (Cab harness) A-6, N-3 B-8
CL2 S 12 Intermediate connector (Cab harness) A-6, N-3 C-8
D01 Yazaki 3 Diode (Forward and reverse solenoid) X-9 A-4 H-1
D03 Yazaki 2 Diode (Fuel-cut solenoid) X-9 M-9
D04 Yazaki 2 Diode (Fuel-cut solenoid) X-9
D05 Yazaki 3 Diode (ECSS solenoid, heater relay) X-7 J-1 M-9
D06 Yazaki 2 Diode (Magnet clutch) W-9 N-9
D07 Yazaki 3 Diode (Engine started) W-9 A-3 H-1 N-9
D08 Yazaki 2 Diode (Engine started) W-7 N-9
D09 Yazaki 4 Diode (Parking brake, HST motor 2 sole- X-8 A-3
noid)
D10 Yazaki 2 Diode (Washer motor [F]) W-8 O-9
D11 Yazaki 2 Diode (Hazard) O-1 O-9
D12 Yazaki 3 Diode (HST controller power source) W-9 A-3 I-1
D13 Yazaki 2 Diode (Washer motor [R]) W-8 O-9
D14 Yazaki 2 Diode (Hazard) P-1 P-9
D15 Yazaki 2 Diode (Engine started) W-8 P-9
E01 DT-T 2 Safety relay AC-1 W-4 Q-6
E02 Sumitomo 3 Alternator L-6 Q-2 Q-6
E03 Terminal 1 Fuel-cut solenoid Z-5 R-5
E06 Terminal 1 Heater relay AA-3 T-1 R-5
E09 Terminal 1 Ribbon heater AA-4 T-2 R-4
E10 Terminal 1 Starting motor B terminal AD-3 X-4 R-6
E11 Terminal 1 Alternator B terminal L-6
E12 DT-T 2 Engine speed sensor AA-1 K-1
E13 DT-T 3 Engine water temperature sensor (Pre- L-5 Q-1

heating)
E14 X 2 Engine water temperature sensor (Monitor) AB-6 W-3
E15 Terminal 1 Engine oil pressure switch AA-5 W-2
E16 DT-T 2 FREON compressor magnet clutch Y-8
E19 Terminal 1 Safety relay Z-2 W-4 R-6
E20 Terminal 1 Safety relay Z-2 W-4 R-6
E21 Terminal 1 Starting motor C terminal AD-3 X-4 R-6
E22 Terminal 1 Ground Y-7
E23 Terminal 1 Fuel-cut solenoid (HOLD) Z-5 R-5
20-244 WA150-5
(1)
Address
Drawing HST MON E
E24 Terminal 1 Fuel-cut solenoid (GND) Z-4 R-5
E25 Terminal 1 Ground AC-3
ER1 DT 6 Intermediate connector (Engine harness) AD-1 Q-4 Q-5
ER2 DT-T 12 Intermediate connector (Engine harness) AD-2 I-1 Q-4 P-5
ER3 L 2 Intermediate connector (Engine harness) K-3, U-2 Q-5

AD-2
F01 Yazaki 2 Horn (HI) A-5 N-2
F02 Yazaki 2 Horn (LOW) E-1 N-2
F03 DT-T 3 Bucket positioner proximity switch A-4 N-3
F04 DT-T 3 Lift arm kick-out proximity switch A-5 N-2
F07 DT-T 2 ECSS solenoid D-1 Q-4
F10 Terminal 1 Ground D-1 P-7 O-1
F11 DT-T 3 Steering pump pressure switch (Low pres- - O-8

sure)
F12 DT-T 3 Emergency steering pressure switch -
F13 DT-T 2 Oil temperature sensor A-2 Q-8
FL1 S 10 Intermediate connector (Front harness) B-8, P-1 M-6 M-5
FL2 DT-T 6 Intermediate connector (Front harness) C-8, P-1 M-6 M-4
FL3 DT-T 4 Intermediate connector (Emergency steer- Q-1 M-7

ing harness)
FS1 - - Fuse box S-9 A-2 K-9 L-3
FS2 - - Fuse box S-9 L-9 L-2
HEAD L SWP 6 Front combination lamp (Left side) F-1 P-8 N-1
HEAD R SWP 6 Front combination lamp (Right side) A-5 P-8 N-1
J01 J 20 Junction connector (Orange) Q-1 A-1 D-1
J02 J 20 Junction connector (Blue) N-4 B-1 B-1 E-1
J03 J 20 Junction connector (Blue) N-4 B-1 B-1 E-1
J04 J 20 Junction connector (Gray) S-9 B-1 C-1 F-1
J05 J 20 Junction connector (Brown) X-7 D-1 G-1
J06 J 20 Junction connector (Brown) W-6 C-1 D-1 G-1
J07 J 20 Junction connector (Green) P-8 D-1 H-1
J08 J 20 Junction connector (Orange) X-7 D-1 E-1 H-1
J09 J 20 Junction connector (Pink) X-6 E-1 E-1 I-1
J10 J 20 Junction connector (Blue) W-7 F-1 I-1
J11 J 20 Junction connector (Brown) P-8 E-1 G-1 J-1
J12 J 20 Junction connector (Orange) W-7 F-1 G-1 J-1
L02 DT 4 Starting switch P-8 A-8 K-2 A-6
L03 DT-T 4 Speed selector switch O-7 E-8
L04 SWP 8 Light combination switch N-2 E-8 A-8
L05 S 10 Wiper switch (Front, rear) O-2 A-5
L06 VCH 8 Hazard switch O-1 I-8 L-1
L07 VCH 8 Front working lamp switch Q-1 K-1
L08 VCH 8 Rear working lamp switch Q-1 K-1
L09 VCH 8 ECSS switch Q-8 L-9
L10 VCH 8 Monitor mode switch 1 N-5 A-8
WA150-5 20-245
(1)
Address
Drawing HST MON E
L11 VCH 8 Monitor mode switch 2 N-5 A-8
L12 Yazaki 2 Cigar lighter N-4
L13 DT-T 2 Steering horn switch O-1 A-5
L14 DT-T 4 Intermediate connector (ECSS controller) N-2 M-3
L15 DT-T 4 FNR switch O-1 F-8 D-8 A-8
L17 DT-T 2 Parking brake selection connector (Electri- V-5 G-8

cal type)
L18 DT-T 2 Parking brake selection connector V-6 G-8

(Mechanical type)
L19 VCH 8 Parking brake switch N-5
L20 DT-T 2 Parking brake selection connector (Selec- V-5 G-8

tion)
L21 AMP040 16 Monitor panel controller N-3 B-8 C-1
L22 AMP040 12 Monitor panel controller N-2 G-7 C-8 C-1
L23 AMP040 20 Monitor panel controller N-5 G-7 C-8 D-1
L34 DT-T 2 Stop lamp switch V-3 L-1
L35 DT-T 2 PPC valve, electrical detent (Liftarm float) Q-8 C-1
L36 DT-T 2 PPC valve, electrical detent (Liftarm raise) N-7 C-1
L37 DT-T 2 PPC valve, electrical detent (Bucket tilt) N-6 C-1
L38 M 2 Power supply (Battery) V-5
L39 M 2 Power supply (Key-ON) J-4, V-5
L40 Terminal 1 Ground (HST controller) O-7 H-1
L41 AMP 1- 16 HST controller N-7 B-8 J-1

963217-1
L42 AMP 2- 16 HST controller O-7 C-8 J-1

963217-1
L43 DT-T 4 Checker N-6 D-8
L44 M 4 For steering controller R-1
L45 SWP 6 Auto-grease N-5
L46 M 2 Caution buzzer N-7 F-8
L47 DT-T 2 Parking brake switch (Intermediate) V-4 H-8
L48 M 6 Interval wiper timer P-8 G-8
L49 KES1 4 Flasher unit R-1 F-8 L-8
L50 M 4 Power supply V-4
L51 X 2 Air servomotor S-9 D-8
L52 M 4 Rear wiper motor G-9, U-8 H-8
L53 DT-T 2 Parking brake switch (Bottom) V-4 H-8
L54 M 3 Travel speed control dial P-8 E-8
L55 DT-T 2 Air suspension seat V-8
L56 VCH 8 Traction control switch Q-8 F-8
L57 M 6 Front wiper motor A-7, N-2 G-8
L58 M 2 DC converter V-4
L100 Terminal 1 Ground V-7 G-1 L-1 C-3
L101 R 5 Mechanical parking brake relay N-9 A-7
L102 R 5 HST controller power hold relay M-8 A-6 A-7
L103 R 5 Shift control relay N-8 A-6
20-246 WA150-5
(1)
Address
Drawing HST MON E
L104 R 5 Parking brake indicator relay (Electrical N-9 A-6

type)
L105 R 5 Parking brake safety relay N-8
L106 R 5 Neutral safety relay M-8 A-4 I-9
L107 R 6 Reverse relay M-8 A-5 A-4 K-9
L108 R 5 Forward relay N-7 A-5 A-4
L109 R 5 Back buzzer relay M-9 I-9
L110 R 5 ECSS relay N-9 L-9
L111 R 5 HST solenoid safety relay M-9 A-4
L112 R 5 Parking brake neutral safety relay M-9 A-3
L113 R 5 Boom kick-out relay N-9 H-9
L114 R 5 Bucket positioner relay N-8 H-9
L115 R 5 Auto preheating relay M-9 A-3 I-9
L116 R 5 Horn relay N-9 I-9
L117 R 5 Small lamp relay (Left side) U-9 A-6 J-9
L118 R 5 Small lamp relay (Right side) X-5 A-6 J-9
L119 R 5 Head lamp relay (Right side) W-4 A-5 K-9
L120 R 5 Head lamp relay (Left side) T-9 A-5 K-9
L121 R 5 Stop lamp relay U-8 K-9
L122 R 6 Working lamp relay U-8 J-9
LR1 DT 2 Intermediate connector (Rear harness) I-3, X-2 H-4 M-5 M-6
LR2 L 2 Intermediate connector (Rear harness) I-3, X-3 H-4 M-5 M-6
LR3 L 2 Intermediate connector (Rear harness) I-3, X-2 H-4 M-5 M-6
LR4 DT-T 12 Intermediate connector (Rear harness) I-3, W-3 H-3 M-4 M-6
LR5 DT-T 6 Intermediate connector (Rear harness) H-3, W-2 H-3 M-4 M-5
LR6 DT-T 6 Intermediate connector (Rear harness) I-3, W-2 M-4 M-5
LR7 DT-T 2 Intermediate connector (Rear harness) H-3, W-2 M-3 M-4
LT1 DT-T 12 Intermediate connector (HST harness) I-2, X-2 G-6 M-6 M-3
LT2 DT-T 4 Intermediate connector (HST harness) I-2, X-1 H-5 M-6 M-3
LT3 DT-T 4 Intermediate connector (HST harness) I-2, X-1 M-5
MF1 DT 12 Multi-function N-6 D-8
MF2 8 Multi-function Q-8 E-8
MF3 DT-T 12 Multi-function X-4 H-6 I-5 B-4
MF4 DT-T 2 Multi-function X-4
R00 Terminal 1 Ground (Battery) J-9 X-5
R01 Terminal 1 Battery relay J-3, L-2 X-6 R-7

AD-2
R02 Terminal 1 Slow blow fuse (30A) L-2 L-4 X-7 R-8
R04 Terminal 1 Battery relay J-3 L-2 X-6 R-7
R07 Terminal 1 Slow blow fuse (120A) L-3 X-7 R-7
R08 DT-T 4 Fuel solenoid cut timer K-2 P-8
R09 Terminal 1 Fuel solenoid pull relay K-1 Q-9
WA150-5 20-247
(1)
Address
Drawing HST MON E
R10 Terminal 1 Fuel solenoid pull relay K-1 Q-9
R11 Terminal 1 Slow blow fuse (30A) L-3 R-8
R12 Terminal 1 Slow blow fuse (30A) L-2 R-8
R15 Terminal 1 Battery relay (+) J-1 L-3 X-6 R-7
R16 Terminal 1 Battery relay (-) J-1 L-3 X-6 R-7
R19 DT-T 2 Fuel solenoid pull relay K-2 Q-8
R20 Terminal 1 Ground I-2 H-1 O-1 P-1
R21 X 2 Fuel level sensor K-4 U-8
R22 M 6 Rear combination lamp (Left side) L-6 P-2 Q-1
R23 M 6 Rear combination lamp (Right side) I-9 P-2 Q-2
R24 DT-T 2 License lamp I-9 O-1 Q-2
R25 KES1 2 Front window seal washer K-8 Q-3
R26 KES1 2 Rear window seal washer K-8 Q-3
R27 Terminal 1 Ground (License lamp) K-8 O-1 R-2
R28 Terminal 1 Ground E-1 P-1
RR1 L 2 Intermediate connector (power supply har- K-3 J-4 Q-5 O-6
ness)
RR2 DT-T 6 Intermediate connector (power supply har- J-1 J-4 Q-5 O-6
ness)
T01 DT-T 4 F-R solenoid AB-1 K-2 W-1
T05 DT-T 2 Clutch control EPC solenoid I-2 K-7
T06 DT-T 2 HST motor 1 EPC solenoid H-1 K-8
T07 DT-T 4 HST motor 2 EPC solenoid and motor 2 G-2 K-8 R-8 Q-3
overrun solenoid
T09 DT-T 4 Speedometer sensor H-3 K-9 Q-4
T10 X 2 HST oil temperature sensor L-5 R-8
T11 DT-T 3 HST oil pressure sensor G-1 K-5
T12 X 2 Brake oil pressure sensor G-1, S-8

AA-1
T13 Terminal 1 HST filter clogging sensor G-2 T-6
T14 Terminal 1 Ground I-2 J-5 U-6 Q-3
TRI DT-T 2 Intermediate connector H-3 O-5
20-248 WA150-5
(1)
Type of connector Detailed information

AMP040 040-type connector manufactured by NIHON AMP
AMP070 070-type connector manufactured by NIHON AMP
AMP 1-963217-1 1-963217-1-type connector manufactured by NIHON AMP
AMP 2-963217-1 2-963217-1-type connector manufactured by NIHON AMP
DRC DRC-type connector manufactured by NIHON DEUTSCH
DT DT-type connector manufactured by NIHON DEUTSCH (08192-1XXXX)
DT-T DT-T-type connector manufactured by NIHON DEUTSCH (08192-2XXXX)
DTM DT-MT-type connector manufactured by NIHON DEUTSCH (08192-0XXXX)
D-sub 17JE-23250 manufactured by DAIICHI DENSHI KOGYO
J 090-type splice manufactured by SUMITOMO DENSO
KES0 KES0-type connector (08027-0XXXX)
KES1 KES1-type connector (08027-1XXXX)
L L-type connector manufactured by YAZAKI (08056-2XXXX)
M M-type connector manufactured by YAZAKI (08056-0XXXX)
PA PA-type connector manufactured by YAZAKI
R PH156-05020-type connector (5-pole), PH168-06050-type connector (6-pole) manufac-

tured by SHINAGAWA JIDOSHA DENSEN
S S-type connector manufactured by YAZAKI (08056-1XXXX)
SWP SWP-type connector manufactured by YAZAKI (08055-1XXXX)
VCH V-Series connector manufactured by CARLING SWITCH
X X-type connector manufactured by YAZAKI (08055-0XXXX)
One-pin connector Round pin-type 1-pole connector
Relay manufactured by JIDOUSHA DENKI KOGYO
SUMITOMO Connector manufactured by SUMITOMO
Terminal Round terminal or ordinary terminal
HOSHIDEN TCP8927-63-1100 or TCP8927-53-1110 manufactured by HOSHIDEN
YAZAKI Connector manufactured by YAZAKI
WA150-5 20-249
(1)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
CONNECTOR LAYOUT DRAWING
20-250 WA150-5
(1)
WA150-5 20-251
(1)
20-252 WA150-5
(1)
WA150-5 20-253
(1)
20-254 WA150-5
(1)
TROUBLESHOOTING OF HST
CONTROLLER SYSTEM (HST MODE)
.HST controller system diagram ................................................................................................................. 20-302

Before troubleshooting code display ........................................................................................................... 20-304
Before troubleshooting electrical system .................................................................................................... 20-305
Information contained in troubuleshooting table ......................................................................................... 20-306
Error Code [989F00] (HST motor protection caution (00)).......................................................................... 20-308
Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX) ...................................... 20-309
Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch (LC))......................... 20-311
Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ)) ............................. 20-312
Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ)) .............................. 20-314
Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ)) ................................ 20-316
Troubleshooting Code [HST-1]
(Defective HST controller power source (HST controller does not function)) .......................................... 20-318
Troubleshooting Code [HST-2] (Travel speed does not shifted)................................................................. 20-320
Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be controlled ..................... 20-323
HST-4 Travel speed limit cannot be changed when gear speed selector switch is in "1st" position........... 20-325
HST-5 Travel speed is not increased (Abnormality in speed sensor system)............................................. 20-328
WA150-5 20-301
(1)
TROUBLESHOOTING HST CONTROLLER SYSTEM DIAGRAM
HST CONTROLLER SYSTEM DIAGRAM
20-302 WA150-5
(1)
TROUBLESHOOTING HST CONTROLLER SYSTEM DIAGRAM
WA150-5 20-303
(1)
(1)
monitor
Error
Code
989F00
989F00
AB00L6
989FN1
15B0NX
D5ZHL6
DAJ0KR
DD18LD
DD17LD
DD16LD
DD15LD
DX20KZ
DX19KZ
DLE2LC
DHE4L6
DDS5L6
2G42ZG
DGE3L6
DAF0KT
AB00MA
DDK3KB
DW26KZ
DGR4KA
DGR1KX
DGH1KX
DGE2KX
DHH1KX
B@C7NS
B@BCZK
B@BAZG
B@BCNS
B@CRNS
20-304
HST controller
Failures related to
Failures related to
E03
E02
E01
E01
E01
E01
E01
E01
E01
E03
E01
E01
E01
E01
E03
E03
E03
E03
E02
E03
E03
E03
E03
E01
E01
E02
E02
E00
E01
E03
E03
E00
Code
Action
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
Defective machine monitor
q q
q
q q
q
q
q
q
q
Defective HST controller
TROUBLESHOOTING
q
Defective starting switch
q
Defective monitor panel mode switch 1 [t]
q
Defective monitor panel mode switch 1 [U]
q
Defective monitor panel mode switch 2 [<]
q
Defective monitor panel mode switch 2 [>]
q
q
q
Defective derectional lever
Battery is deteriorated
q q
Defective battery relay
Defective fuse, fusible link
q
Defective alternator
q
Defective engine revolution sensor
ERROR CODE AND POSSIBLE CAUSES TABLE
q
Defective HST motor 2 solenoid
q
q q
q
Defective clutch solenoid
Engine oil pressure drops
q
q q
Defective engine oil pressure sensor
Engine water temperature overheating
q
q q
Defective engine water temperature sensor (high temperature)
q
Defective engine water temperature sensor (low temperature)
Possible Causes
Engine cooling water level lacks
q q
q Defective coolant level sensor
Defective HST oil pressure sensor
HST oil filter clogging
BEFORE TROUBLESHOOTING CODE DISPLAY
q q
Defective HST oil filter sensor
HST oil temperature overheating
q
q q
Defective HST oil temperature sensor
Brake oil pressure drops
q q
Defective brake oil pressure sensor
Axle oil temperature overheating
q
q
q q
Defective axle oil temperature sensor
Steering oil pressure drops
q q
Defective steering oil pressure sensor
Defective relay
q
q
q
q
q q
q q
q q
q
q
Wiring harness discontinuity
q
q
q
q
q
q
q
q q
q q q
q q
q
q
q
q
q
q
Wiring harness ground fault
q q q
q q q q
q
q
q
q
q q
WA150-5
Wiring harness hot short-circuiting
TROUBLESHOOTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM

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

1 20A Starting switch
2 10A Hazard lamp
3 10A HST control A
Permanent power source 4 10A Parking brake A
(Fuse box 1)
5 10A Meter, panel
6 10A Car radio A, Room lamp
7 10A Spare power supply (battery +24 V)
8 10A Head lamp
9 — (Spare 1)
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 Spare power supply (+24 V when key is ON)
7 10A DC converter
Switch power source 8 10A Parking brake 2
(Fuse box 2)
9 10A Horn
10 10A Side marker lamp
11 — (Spare 2)
12 20A Front working lamp
13 20A Rear working lamp
14 — (Spare 3)
15 — (Spare 4)
WA150-5 20-305
(1)
TROUBLESHOOTING 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
contents fully before proceeding to actual troubleshooting work.
Action Code Error Code Controller
Code
Trouble Trouble displayed in trouble data
Panel Panel Panel
display display display
Description • Condition when machine monitor or controller detected trouble.
of Trouble
Machine
monitor or • Action to take to protect system or equipment when machine monitor or controller detected trouble.
controller
Reaction
Effect on • Condition that appeared as problem on machine when action (given above) was taken by machine
Machine monitor or controller.
Related • Information related to troubleshooting or error that occurred.

Information
Causes Standard Value in Normal State and Remarks on Troubleshooting

<Data to fill in>
• Normal standard values used to judge probable cause
• Remarks regarding decision-making
1
<Condition when wiring harness is defective>
• Disconnection
There is defective connection of connector or disconnection in wiring
harness
• Short circuit with ground
2 Wiring harness not wired to ground (GND) circuit is in contact with
ground (GND) circuit
• Short circuit with power source
Probable cause Wiring harness not wired to power supply (24 V) circuit is in contact
Possible when trouble
Causes and with power supply (24 V) circuit
occurred
Standard (the numbers are
Values <Points to remember when troubleshooting>
index numbers and 1) Method of displaying connector No. and handling T-adapter
do not indicate the Unless there is special instruction, insert or connect the T-adapter as
order of priority) follows
•If there is no indication for the male or female terminal of the connec-
tor No., disconnect the connector and insert the T-adapter in both
the male and female terminals
3 •If there is indication for the male or female terminal of the connector
No., disconnect the connector and connect the T-adapter to only
the terminal indicated (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 follows to carry out troubleshooting
•Connect the (+) lead to the wiring harness for the pin No. given first
•Connect the (-) lead to the wiring harness for the pin No. given last
20-306 WA150-5
(1)
Related circuit diagram
This is part of electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow: Roughly indicates the location in the machine where it is installed.
Phenomena code table

a For problem codes marked "See list", see the list below.
Phenomena Disconnec-
code Details tion Details
KA Disconnection L0 Double engagement

KB Short circuit L1 Fill signal is ON when command current is OFF
Fuel pressure is higher than maximum set
KK Drop in power source voltage, input L2 value
KQ Non match in model selection signal L3 Corresponding component cannot be controlled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
KT Abnormality inside controller L6 Engine signals do not match operating condi-

tion or stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit in power supply line LC Speed signals for 2 systems do not match
KZ Disconnection or short circuit LD Switch has been kept pressed for abnormally
long time
MA Function impossible LH Fill signal is OFF when command current is ON
MB Lower function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA150-5 20-307
(1)
TROUBLESHOOTING ERROR CODE [989F00]
Error Code [989F00] (HST motor protection caution (00))

Code Trouble HST motor protection caution (00)
E00 989F00 HST
• Not considered to be a failure.
Description • The travel speed exceeds the allowable speed the HST motor on down shifting.
of Trouble (When the travel speed is at 3rd or 4th speed (10 km/h), the display shows the speed shift down to 1st
or 2nd speed.)
Machine
monitor or • Activates an alarm.
controller
Reaction
Effect on • Shift down control cannot be applied.
Machine
Related
Information
20-308 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DHH1KX]
Error Code [DHH1KX] (HST oil pressure sensor input signal outside range (KX))

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

1) Turn starting switch OFF. 2) Disconnect connector T11.
3) Insert T-adapter.
Defective HST oil 4) Connect connector. 5) Turn starting switch ON
1 pressure sensor Between T11 (A) and (C) Voltage 0.5 - 4.5 V
Between T11 (A) and (B) Voltage 4-6V
1) Turn starting switch OFF. 2) Disconnect connectors L41 and T11.
3) Connect T-adapter
Wiring harness between L41 (Female) (3) Resistance Max. 1z
Wiring harness discon- and T11 (Female) (C)
2 tinuity (Disconnection
or defective contact) Wiring harness between L41 (Female) (4) Resistance Max. 1z
and T11 (Female) (A)
and T11 (Female) (B)
Wiring harness between Resistance between L41
Wiring harness ground L41 (Female) (3) and T11 (Female) (3), T11 (Female) Min. 1Mz
Possible 3 (Female) (C) (C) and chassis ground
Causes and fault
Standard Wiring harness between Resistance between L41
Values L41 (Female) (12) and T11 (Female) (12), T11 Min. 1Mz
(Female) (B) (Female) (B) and chassis
ground
3) Connect T-adapter. 4) Turn starting switch ON
Wiring harness between Voltage between L41
L41 (Female) (3) and T11 (Female) (3), T11 (Female) Max. 1V
(Female) (C) (C) and chassis ground
4 Hot short-circuiting Wiring harness between Voltage between L41
between harnesses L41 (Female) (4) and T11 (Female) (4), T11 (Female) Max. 1V
(Female) (A) (A) and chassis ground

L41 (Female) (12) and T11 (Female) (12), T11 Max. 1V
(Female) (B) (Female) (B) and chassis
ground
1) Turn starting switch OFF. 2) Disconnect connector L41.
Defective HST control- 4) Connect connector. 5) Turn starting switch ON
5 ler
Between L41 (3) and (4) Voltage 0.5 - 4.5 V
Between L41 (12) and (4) Voltage 4-6V
WA150-5 20-309
(1)
TROUBLESHOOTING ERROR CODE [DHH1KX]
9JF00512
20-310 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DLE2LC]
Error Code [DLE2LC] (Engine revolution sensor revolution speed signal mismatch
(LC))

Code Trouble Engine revolution sensor revolution speed signal mismatch
(LC)
E03 DLE2LC HST
Description • There is an abnormality in the speed calculated from the speed sensor signal and signal speed from
of Trouble the engine revolution signal.
Machine • Error is sent to machine monitor through CAN communications, and machine monitor turns HST
monitor or safety relay ON (cuts motor 1, clutch solenoid circuit).
controller
Reaction • Eorror code [DX19KZ] and [DX20KZ] occur at the same time.

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

1) Turn starting switch OFF. 2) Disconnect connector E12.
1 Defective engine revo- Between E12 (Male) (1) and (2) Resistance 500 -
lution sensor 1,000z
Between E12 (Male) (1), (2) and chassis
ground Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12.

2 Wiring harness ground
Possible fault Wiring harness between Resistance between L42
Causes and L42 (Female) (4) and E12 (Female) (4), E12 (Female) Min. 1Mz
Standard (Female) (1) (1) and chassis ground
Values 1) Turn starting switch OFF. 2) Disconnect Connectors L42, E12.
Hot short-circuiting 4) Connect connector. 5) Turn starting switch ON
3 between harnesses Wiring harness between Voltage between L42
L42 (Female) (4) and E12 (Female) (4), E12 (Female) Max. 1V
(Female) (1) (1) and chassis ground
4 Defective HST control- 4) Connect connector. 5) Turn starting switch ON
ler
Between L42 (Female) (4) and (11) Voltage Min. 0.5V
(AC range)
9JF00513
WA150-5 20-311
(1)
TROUBLESHOOTING ERROR CODE [DW26KZ]
Error Code [DW26KZ] (Motor 2 solenoid system discontinuity or short-circuiting (KZ))

Code Trouble Motor 2 solenoid system discontinuity or short-circuiting (KZ)
E03 DW26KZ HST
Description • Excessive electricity flows when output to motor 2 solenoid circuit is ON; no electricity flows when
of Trouble output is ON or electricity flows when output is ON.
controller
Reaction • Eorror code [DX19KZ] and [DX20KZ] occur at the same time.
Effect on • Travel speed does not increase.

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

1) Turn starting switch OFF. 2) Disconnect connector T07. 3) Connect T-
adapter
Defective motor 2 Between T07 (Female) (1) and (2) Resistance 10 - 30z
1 solenoid Between T07 (Female) (3) and (4) Resistance 10 - 30z
Between T07 (Female) (1), (3) and chassis Resistance Min. 1Mz
ground
1) Turn starting switch OFF.
2) Disconnect Connectors L41, T07 and fuse FS1 (12) terminal.
Wiring harness dis- 3) Connect T-adapter
2 continuity (Disconnec- Wiring harness between T07 (Female) (1)
tion or defective Resistance Max. 1z
contact) and L41 (Female) (5)
Wiring harness between T07 (Female) (2) Resistance Max. 1z
and chassis ground
Possible 2) Disconnect Connectors L41 and fuse FS1 (12).
Causes and 3) Connect T-adapter
Standard 3 Wiring harness
Values ground fault Wiring harness between Resistance between T07
T07 (Female) (1) and L41 (Female) (1), L41 (Female) Min. 1Mz
4) Connect connector. 5) Turn starting switch ON
Turn travel speed selector Voltage 20 - 30 V
switch 1st
Turn travel speed selector Voltage 20 - 30 V
Defective HST con- switch 2nd
4 Between
troller Turn travel speed selector
L41 (5) and switch 3rd Voltage 20 - 30 V
chassis
ground Turn travel speed selector
switch 4th Voltage 20 - 30 V
( Less than10km/h)
Turn travel speed selector Voltage Max. 2V
switch 4th (10 - 41km/h)
20-312 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DW26KZ]
WA150-5 20-313
(1)
TROUBLESHOOTING ERROR CODE [DX19KZ]
Error Code [DX19KZ] (Motor 1 solenoid system discontinuity or short-circuiting (KZ))

Code Trouble Motor 1 solenoid system discontinuity or short-circuiting (KZ)
E03 DX19KZ HST
Description • Excessive electricity flows when output to motor 1 solenoid circuit is ON; no electricity flows when out-
of Trouble put is ON or electricity flows when output is ON.
controller
Reaction • Error code [DX20KZ] occur at the same time.

Machine
Related • Motor 1 solenoid current can be checked in the monitoring function (Code:80000).
Information
Possible
Causes and Causes Standard Value in Normal State and Remarks on Troubleshooting
Standard
Values
Defective motor 1
1 solenoid Between T06 (Female) (1) and (2) Resistance 15 - 35z
ground
1) Turn starting switch OFF. 2) Interchange relay (L111) with normal relay.
3) Turn starting switch ON. 4) Operate FNR switch
The condi- Relay
tion is (L111) is
Does condition become normal when HST abnormal normal
safety relay (L111) is interchanged with nor-
mal relay? The condi- Defective
tion is nor- relay (L111)
mal
Defective HST safety 3) Solid part check
2 relay (L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
Possible 3) Solid part check.
Causes and 4) Applies impressed voltage between L111 (Male) (1) - (2)
Standard
Values Applies 24V impressed volt-
age between L111 (Male) Resistance Max. 1z
Between (1) - (2)
L111 (Male)
(3) and (5) Does not apply voltage
between L111 (Male) (1) - Resistance Min. 1Mz
(2)
2) Disconnect Connectors L23, L41, L111, T06 and fuse FS1 (12).
and L41 (Female) (6)
Wiring harness discon- Wiring harness between T06 (Female) (2) Resistance Max. 1z
3 tinuity (Disconnection and L111 (Female) (5)
or defective contact) Wiring harness between L111 (Female) (3) Resistance Max. 1z
and chassis ground
Wiring harness between fuse FS1 (12) and Resistance Max. 1z
L111 (Female) (1)
20-314 WA150-5
(1)

Wiring harness between Resistance between T06
Wiring harness
4 ground fault Wiring harness between Resistance between T06
Wiring harness between Resistance between fuse
fuse FS1 (12) and L111 FS1 (12), L111 (Female) (1) Min. 1Mz
Possible (Female) (1) * and chassis ground
Causes and In the above case of marked mark (*), the fuse is blown.
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L41.
Turn travel speed selector Voltage 2 - 20V
switch 1st
Defective HST con- Turn travel speed selector Voltage 2 - 20V

5 troller Between switch 2nd
L41 (6) and Turn travel speed selector
chassis switch 3rd and 4th Voltage 2 - 20V
ground (Less than 10km/h)
Turn travel speed selector
switch 3rd and 4th Voltage Max. 3V
(Min. 10km/h)
WA150-5 20-315
(1)
Error Code [DX20KZ] (Clutch solenoid system discontinuity or short-circuiting (KZ))

Code Trouble Clutch solenoid system discontinuity or short-circuiting (KZ)
E03 DX20KZ HST
Description • Excessive electricity flows when output to clutch solenoid circuit is ON; no electricity flows when out-
of Trouble put is ON or electricity flows when output is ON.
controller
Reaction • Error code [DX19KZ] occur at the same time
Effect on • Travel speed does not switch.

Machine
Related • The clutch solenoid current can be checked in the monitoring function (Code:80100).
Information

Defective clutch sole-
1 noid Between T05 (Female) (1) and (2) Resistance 15 - 35z
ground
The condi- Relay
tion is (L111) is
Does condition become normal when HST abnormal normal
safety relay (L111) is interchanged with nor-
tion is nor- relay (L111)
mal
Defective HST safety 3) Solid part check
2 relay (L111) Between L111 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L111.
Causes and 3) Solid part check,
Standard 4) Applies impressed voltage between L111 (Male) (1) - (2)
Values
Applies 24V impressed volt-
age between L111 (Male) Resistance Max. 1z
Between (1) - (2)
L111 (Male)
(2)
Wiring harness dis- Wiring harness between T05 (Female) (2)
continuity (Disconnec- Resistance Max. 1z
3 and L111 (Female) (5)
tion or defective
contact) Wiring harness between L111 (Female) (3) Resistance Max. 1z
and chassis ground
L111 (Female) (1)
20-316 WA150-5
(1)

2) Disconnect Connectors L23, L41, L111, Resistance Max. 1z
T05 and fuse FS1 (12).
Wiring harness between Resistance between T05
4 Wiring harness
ground fault Wiring harness between Resistance between T05
Possible (Female) (1) * and chassis ground
Causes and
Standard In the above case of marked mark (*), the fuse is blown.
Values
Turn travel speed selector Voltage 3 - 15V
switch 1st
Defective HST Turn travel speed selector Voltage 3 - 15V

5 controller Between switch 2nd
L41 (14) Turn travel speed selector
and chassis switch 3rd and 4th Voltage 3 - 15V
ground (Less than 10km/h)
Turn travel speed selector
switch 3rd and 4th Voltage Max. 4V
(Max. 10km/h)
9JF00522
WA150-5 20-317
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [HST-1]
Troubleshooting Code [HST-1] (Defective HST controller power source (HST controller
does not function))
Controller
Action Code Error Code Code Defective HST controller power source (HST controller does
Trouble
not function)
- - -
Description of • HST controller power source system is defective, so HST controller does not work.
Trouble
Machine mon-
itor or control- • No action.
ler Reaction
Machine • Machine monitor announces error code DAJOKR for defective HST controller communications
Related
Information

2) Disconnect Connectors L41, L102 and fuse FS1 terminal.
Wiring harness between L41 (Female) (8) and
L102 (Female) (5) Resistance Max. 1z
Wiring harness Wiring harness between fuse FS1 (3) and L102
discontinuity (Dis- Resistance Max. 1z
1 (Female) (3)
connection or
defective contact) Wiring harness between fuse FS1 (12) and Resistance Max. 1z
L102 (Female) (1)
Wiring harness between L102 (Female) (2) and Resistance Max. 1z
chassis ground
chassis ground
Does condition become nor- The condition
is abnormal Relay (L102) is normal
mal when HST safety relay
(L102) is interchanged with The condition
normal relay? Defective relay (L102)
is normal
Possible Defective HST 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check
Causes and 2 power source Between L102 (Male) (1) and (2) Resistance 200 - 400z
Standard safety relay (L102)
Values 1) Turn starting switch OFF. 2) Disconnect connector L102. 3) Solid part check.
4) Applies impressed voltage between L102 (Male) (1) - (2)
Between age between L102 (Male) (1) - Resistance Max. 1z
L102 (Male) (2)
between L102 (Male) (1) - (2) Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Replace diode (D12) to correct diode.
3) Turn starting switch START
The condition is abnormal Diode (D12) is normal
The condition is normal Defective diode (D12)
Measure at diode range
D12 (Male) (1) o (2) Continuity
Defective diode
3 (D12) D12 (Male) (3) o (2) Continuity
D12 (Male) (1) o (3) Discontinuity
a Connect the (+) pole of the tester to the left side of D12 ( ) o ( ).
20-318 WA150-5
(1)


L41 (Female) (8) and L102 (Female) (8), L102 Min. 1Mz
(Female) (5) (Female) (5) and chassis
ground
4 Wiring harness
Possible ground fault Wiring harness between Resistance between fuse
Causes and fuse FS1 (3) and L102 FS1 (3), L102 (Female) (3) Min. 1Mz
Standard (Female) (3) and chassis ground
Values
(Female) (1) and chassis ground
a In the above case, the all fuses are blown.

Defective HST con- 3) Insert T-adapter.
5 troller 4) Connect connector. 5) Turn starting switch ON
Between L41 (8) and (16) Voltage 20 - 30V
9JF00531
WA150-5 20-319
(1)
Troubleshooting Code [HST-2] (Travel speed does not shifted)

Code Trouble Travel speed does not shifted
- - -
Description • The speed selector switch system is defective, so the travel speed cannot be changed.
of Trouble
Machine
monitor or • No action.
controller
Reaction
Effect on • Travel speed does not shifted
Machine
Related
Information

2nd Resistance Max. 1z
Between L03 (Female) (1)
and (2) Other than Resistance Min. 1Mz
the above
1st Resistance Min. 1Mz
Between L03 (Female) (1) 2nd Resistance Min. 1Mz
Defective travel and (3) 3rd Resistance Max. 1z
1 speed selector
switch 4th Resistance Max. 1z
4th Resistance Max. 1z
and (4) Other than Resistance Min. 1Mz
the above
1st Resistance Max. 1z
Possible 2nd Resistance Min. 1Mz
Causes and Between L03 (Female) (3)
Standard and (4) 3rd Resistance Min. 1Mz
Values
The condi- Relay
Does condition become normal when shift tion is (L103) is
control relay (L103) is interchanged with nor- abnormal normal
tion is normal relay (L103)
Defective shift
2 control relay 1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check
(L103) Between L103 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L103. 3) Solid part check,
Applies 24V impressed voltage Resistance Max. 1z
Between between L103 (Male) (1) - (2)
L103 (Male)
(3) and (5) Does not apply voltage Resistance Min. 1Mz
between L103 (Male) (1) - (2)
20-320 WA150-5
(1)

3 Defective travel speed Between L54 (Female) (1) and (3) Resistance 4 - 6 kz
potentiometer
Between L54 (Female) (1) and (2) Resistance 0.25 - 5 kz
Between L54 (Female) (2) and (3) Resistance 0.25 - 5 kz
2) Disconnect Connectors L42, L103, J07 and fuse FS1 terminal.
Wiring harness dis- L103 (Female) (3)
continuity (Disconnec-
4 tion or defective Wiring harness between fuse FS1 (12) and Resistance Max. 1z
contact) L103 (Female) (1)
and J07 (Female) (1)
and J07 (Female) (18)
Possible 1) Turn starting switch OFF.

Causes and 2) Disconnect Connectors L42, L103 and fuse FS1 terminal.
Standard 3) Connect T-adapter
Values Resistance between L42
Wiring harness between
ground
Wiring harness
5 ground fault Wiring harness between Resistance between fuse
1) Turn starting switch OFF. 2) Disconnect Connectors L42, L103.

4) Turn starting switch ON
6 Hot short-circuiting
between harnesses Voltage between L42
Wiring harness between (Female) (12), L103
L42 (Female) (12) and L103 (Female) (5) and chassis Max. 1V
(Female) (5) ground
7 Defective HST con-
troller Between Travel "1st", "4th" Voltage 20 - 30V
L42 (12) speed
and chassis selector "2nd", "3rd" Voltage Max. 1V
ground switch
WA150-5 20-321
(1)
9JF00532
20-322 WA150-5
(1)
Troubleshooting Code [HST-3] HST Output Control (Traction control) cannot be con-
trolled

Code Trouble HST output control (Traction control) cannot be controlled
- - -
Description • The traction control switch system is defective, so the HST output control cannot be controlled.
of Trouble
Machine
monitor or • No action.
controller
Reaction
Effect on • The HST output control (Traction control) cannot be controlled.
Machine
Related • Traction control ON-OFF output signal can be checked in the monitoring function (Code: 80200).
Information

3) Connect T-adapter.
Defective traction Between Traction control switch ON Resistance Max. 1z
1 control switch L56
(Female) (3) Traction control switch OFF Resistance Min. 1Mz
and (2)
Wiring harness dis- 3) Connect T-adapter.
2 continuity (Discon- Wiring harness between L42 (Female) (3)
nection or defective and L56 (Female) (2) Resistance Max. 1z
contact)
Wiring harness between fuse FS1 (12) and
L56 (Female) (3) Resistance Max. 1z

Possible
Causes and Wiring harness between Resistance between L42
Standard L42 (Female) (3) and L56 (Female) (3), L56 (Female) Min. 1Mz
Values 3 Wiring harness (Female) (3) (2) and chassis ground
ground fault
1) Turn starting switch OFF. 2) Disconnect connectors L41 and L56.

3) Connect T-adapter. 4) Turn starting switch ON.
Hot short-circuiting
4 between harnesses Wiring harness between Voltage between L42
L42 (Female) (3) and L56 (Female) (3), L56 (Female) Max. 1V
1) Turn starting switch OFF. 2) Disconnect Connector L42.
4) Connect connector. 5) Turn starting switch ON.
Defective HST con-
5 troller Between Traction control switch ON Voltage 20 - 30V
L42 (3) and
chassis Traction control switch OFF Voltage Max. 1V
ground
WA150-5 20-323
(1)
9JF00533
20-324 WA150-5
(1)
HST-4 Travel speed limit cannot be changed when gear speed selector switch is in
"1st" position

Code Trouble Travel speed cannot be changed when gear speed selector
switch is in "1st" position
- - -
Description • Speed potentiometer signals are not input because of disconnection, grounding fault, or short circuit
of Trouble with power source in the speed potentiometer system.
Machine
monitor or • None in particular.
controller
Reaction
Effect on • When the gear speed selector switch is set in the "1st" position, the travel speed cannot be changed
Machine (The travel speed is fixed to 4 km/h or 13 km/h).
Related • The speed potentiometer is indicated by real-time monitor code "50302" [Speed limit: Max. (13 km/h =
information 100%) / Min. (4 km/h = 0%)]

2) Disconnect connector L54.
1 Defective speed
potentiometer Between L54 (female) (1) and (3) Resistance 4 - 6kz
Between L54 (female) (1) and (2) Resistance 0.25 - 5kz
Between L54 (female) (2) and (3) Resistance 0.25 - 5kz
2) Disconnect connector L03
2nd Resistance Max. 1z
Between L03 (female)
(1) and (2) Other than
above Resistance Min. 1Mz
1st Resistance Min. 1Mz
Between L03 (female) 2nd Resistance Min. 1Mz

Possible (1) and (3) 3rd Resistance Max. 1z
2 Defective gear speed
Causes and selector switch
Standard 4th Resistance Max. 1z
Values 4th Resistance Max. 1z
(1) and (4) Other than
above Resistance Min. 1Mz
1st Resistance Max. 1z

Between L03 (female) 2nd Resistance Min. 1Mz
(3) and (4) 3rd Resistance Min. 1Mz
2) Disconnect connectors L41, L54, and L03.
Disconnection in wir-
ing harness (Discon- Wiring harness between L41 (female)
(10) and L54 (female) (1) Resistance Max. 1z
3 nection in wiring
harness or defective Wiring harness between L41 (female)
contact) Resistance Max. 1z
(1) and L54 (female) (2)
Wiring harness between L41 (female) Resistance Max. 1z
(2) and L54 (female) (3)
WA150-5 20-325
(1)

Wiring harness between Resistance betweenL41
L41 (female) (10) and (female) (10) and chassis Min. 1Mz
L54 (female) (1) ground
Grounding fault in wir- Wiring harness between
4 ing harness Resistance between L41
L41 (female) (1) and L54
(female) (2) and L03 (female) (1) and chassis Min. 1Mz
(female) (1) ground

L41 (female) (2) and L54
(female) (3) and L03 (female) (2) and chassis Min. 1Mz
(female) (3) ground

Possible 3) Insert T-adapter.
Causes and 4) Turn starting switch ON.
Standard Wiring harness between
Values L41 (female) (10) and Voltage betweenL41 (female) Max. 1V
L54 (female) (1) (10) and chassis ground
Short circuit with
5 power source in wir- Wiring harness between
ing harness L41 (female) (1) and L54 Voltage between L41 (female)
(female) (2) and L03 (1) and chassis groun Max. 1V
(female) (1)
L41 (female) (2) and L54 Voltage between L41 (female) Max. 1V
(female) (3) and L03 (2) and chassis ground
(female) (3)
4) Connect connector.
Defective HST con- 5) Turn starting switch ON.
6 troller 6) Set gear speed selector switch in "1st".
Between L41 (10) and (2) Voltage 4 - 6V
Between L41 (1) and (2) Voltage 0.5 - 5V
20-326 WA150-5
(1)
WA150-5 20-327
(1)
HST-5 Travel speed is not increased

Code Travel speed is not increased (Abnormality in speed sensor
Trouble system)
- - -
Description • Signals are not input because of disconnection or grounding fault in the signal circuit of the speed
of Trouble sensor.
Machine
controller
Reaction
Effect on • The travel speed is not increased.
Machine • The speedometer pointer of the machine monitor does not move from "0 km/h".
Related
information

2) Disconnect connectors L41, L42, L102, and T09.
Wiring harness between T09 (female) (4) and L42 Resistance Max. 1z
(female) (5)
Wiring harness between T09 (female) (3) and L41 Resistance Max. 1z
(female) (13)
Disconnec-
tion in wir- Wiring harness between T09 (female) (2) and chassis Resistance Max. 1z
ing harness ground
1 (Disconnec- Wiring harness between T09 (female) (1) and L41
tion in wir- Resistance Max. 1z
ing harness (female) (7), (8) and L102 (female) (5)
or defective Wiring harness betweenL102 (female) (3) and fuse
contact) Resistance Max. 1z
(F1) (3)
Wiring harness between L102 (female) (2) and chas- Resistance Max. 1z
sis ground
Wiring harness between L102 (female) (1) and D12 Resistance Max. 1z
(female) (2)
Wiring harness between D12 (female) (3) and fuse Resistance Max. 1z
Possible (FS1) (12)
Causes and
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connectors L41, L42, L102, and T09.
Wiring harness between T09 Resistance between T09 (female) (4)
(female) (4) and L42 (female) - L42 (female) (5) wiring harness and Min. 1Mz
(5) chassis ground
(female) (3) and L41 (female) - L41 (female) (13) wiring harness Min. 1Mz
(13) and chassis ground
Grounding (female) (1) and L41 (female) - L41 (female) (7) - (8) - L102 Min. 1Mz
2 fault in wir- (7), (8) and L102 (female) (5) (female) (6) wiring harness and
ing harness (A) chassis ground
Wiring harness between L102 Resistance between L102 (female)
(female) (3) and fuse (FS1) (3) (3) - fuse (FS1) (3) wiring harness Min. 1Mz
(A) and chassis ground
Wiring harness between L102 Resistance between L102 (female)
(female) (1) and D12 (female) (1) - D12 (female) (2) wiring harness Min. 1Mz
(2) (A) and chassis ground
Wiring harness between D12 Resistance between D12 (female)
(female) (3) and fuse (FS1) (3) - fuse (FS1) (12) wiring harness Min. 1Mz
(12) ( A) and chassis ground
In the case of (A), fuse is broken.
20-328 WA150-5
(1)

2) Disconnect connector T09.
4) Turn starting switch ON.
6) Move machine a little, stop it, and measure voltage. Repeat this operation.
Between T09 (1) and (2) Voltage 20 - 30V
Defective Min. 5 V
Between T09 (3) and (2) Voltage (Pulse)
3 speed sen-
sor a Both voltages must be measured, depending on stopping position of machine.
While measuring, move Voltage Max. 2V
machine forward.
Between T09 (4) and (2)
While measuring, move
machine in reverse. Voltage Min. 5V
Possible [Warning] When moving the machine forward or in reverse while measuring the volt-
Causes and age, take care of safety extremely.
Standard
Values 1) Turn starting switch OFF.
6) Move machine a little, stop it, and measure voltage. Repeat this operation.
Between L41 (7), (8) and chassis ground Voltage 20 - 30V
Defective Between L41 (13) and chassis ground Voltage Min. 5 V
4 HST control- (Pulse)
ler
a Both voltages must be measured, depending on stopping position of machine.9.
While measuring, move
machine forward. Voltage Max. 2V
Between L42 (5) and
chassis ground While measuring, move
machine in reverse. Voltage Min. 5V
[Warning] When moving the machine forward or in reverse while measuring the volt-
age, take care of safety extremely.
WA150-5 20-329
(1)
20-330 WA150-5
(1)
TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM
(ECSS MODE)
Related circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402

Troubleshooting code [ECSS-1] Travel damper does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-403
WA150-5 20-401
(1)
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAM
RELATED ELECTRICAL CIRCUIT DIAGRAM

a For the connection table of the fuse box, see HST-mode, MON-mode, E-mode, etc.
a For how to read the troubleshooting table, see HST-mode, MON-mode, E-mode, etc.
a Before carrying out the troubleshooting, understand the contents of the related circuit diagram.
20-402 WA150-5
(4)
TROUBLESHOOTING ECSS-1 MALFUNCTION OF TRAVEL DAMPER
ECSS-1 MALFUNCTION OF TRAVEL DAMPER

a For how to read the troubleshooting table, see HST-mode, MON-mode, E-mode, etc. Before carrying out
the troubleshooting, understand the contents of the troubleshooting table.
Malfunction of travel damper
a) Travel damper does not operate
Controller
Action Code Error Code Code Malfunction of travel damper
Trouble a) Travel damper does not operate
- - -
Description • The travel damper does not operate.
of Trouble
Machine
controller
Reaction
Effect on • The travel damper does not operate.
Machine
Related infor- • If the fuse is broken, check for grounding fault.
mation

Defective 3) Connect T-adapter.
travel
1 damper Travel damper switch: Resistance Max. 1z
switch Between L09 ON
(male) (2) and (3) Travel damper switch: Resistance Min. 1Mz
OFF
2) Relay: Replace L110 with normal relay.
4) Operate travel damper switch.
When relay L110 is replaced, No Relay L110 is normal.
does condition become nor-
mal? Yes Relay L110 is defective.
2) Disconnect relay L110.
Defective 3) Check relay unit.
Possible travel
Causes and 2 damper Between relay L110 (male) (1) and (2) Resistance 200 - 400z
Standard relay
(L110) 1) Turn starting switch OFF.
Values 2) Disconnect relay L110.
3) Check relay unit.
4) Apply normal voltage between relay L110 (male) (1) and (2).
When 24 V is applied
between and (1) and Resistance Max. 1z
Between L110 (2)
(male) (3) and (5) When normal voltage
is not applied between Resistance Min. 1Mz
and (1) and (2)
2) Replace travel damper solenoid (F07) with normal solenoid.
Defective When solenoid (F07) is No Travel damper solenoid is normal.
travel replaced, does condition
3 damper become normal? Yes Travel damper solenoid is defective.
solenoid
(F07) 1) Turn starting switch OFF.
2) Disconnect connector F07.
Between F07 (male) (1) and (2) Resistance 21 - 24z
WA150-5 20-403
(4)

2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal.
Condition becomes normal. Diode (D05) is defective.
1) Check diode unit.
Defective Check continuity from (2) to (1) in diode range. There is continuity.
4 diode
(D05) Check continuity from (2) to (3) in diode range. There is continuity.
Check continuity from (1) to (2) in diode range. There is not continuity.
a Apply (+) pin of circuit tester to left line.
Defective 4) Turn starting switch ON.
travel
5 damper Travel speed:
controller 0 - 5 km/h Voltage Max. 1V
Between L14 (4) and
chassis ground Travel speed:
Above 6 km Voltage 20 - 30V

Causes and 2) Disconnect connectors L09, L110, L14, LT1, T09, D05, FL2, and F07 and fuse ter-
Standard minal FS1
Values 3) Connect T-adapter.
Wiring harness between fuse FS1 (13) and J05
(1), (6) and L14 (female) (1) Resistance Max. 1z
Wiring harness between fuse FS1 (13) and J05

(1), (7) and L09 (female) (2) Resistance Max. 1z
Wiring harness between L09 (female) (3) and

L110 (female) (3) Resistance Max. 1z
Discon- Wiring harness between L14 (female) (2) and Resistance Max. 1z
nection in chassis ground
wiring Wiring harness between L14 (female) (3) and
harness LT1 (male) (2) Resistance Max. 1z
(Discon-
6 nection in Wiring harness between L14 (female) (4) and
wiring L110 (female) (1) Resistance Max. 1z
harness or
defective Wiring harness between L110 (female) (2) and
chassis ground Resistance Max. 1z
contact)
Wiring harness between L110 (female) (5) and Resistance Max. 1z
J08 (14), (15) and D06 (female) (1)
Wiring harness between L110 (female) (5) and
J08 (14), (16) and FL2 (male) (4) Resistance Max. 1z
Wiring harness between LT1 (female) (2) and

T09 (female) (3) Resistance Max. 1z
Wiring harness between FL2 (female) (4) and

F07 (female) (1) Resistance Max. 1z
Wiring harness between F07 (female) (2) and

20-404 WA150-5
(1)

2) Disconnect connectors L09, L110, L14, LT1, T09, J08, D05, FL2, and F07 and fuse
terminal FS1
Wiring harness between Between this wir-
fuse FS1 (13) and J05 (1), ing harness and Resistance Min. 1Mz
(6) and L14 (female) (1) chassis ground
fuse FS1 (13) and J05 (1), ing harness and Resistance Min. 1Mz
(7) and L09 (female) (2) chassis ground
Wiring harness between L09 Between this wir-
(female) (3) and L110 ing harness and Resistance Min. 1Mz
(female) (3) chassis ground
Wiring harness between L14 Between this wir-
(female) (3) and LT1 (male) ing harness and Resistance Min. 1Mz
Possible (2) (A) chassis ground
Causes and Ground-
Standard 7 ing fault in Wiring harness between L14 Between this wir-
Values wiring har- (female) (4) and L110 ing harness and Resistance Min. 1Mz
ness (female) (1) chassis ground
L110 (female) (5) and J08 Between this wir-
(14), (15) and D05 (female) ing harness and Resistance Min. 1Mz
(1) chassis ground

L110 (female) (5) and J08 ing harness and Resistance Min. 1Mz
(14), (16) and FL2 (male) (4) chassis ground
Wiring harness between LT1 Between this wir-
(female) (2) and T09 ing harness and Resistance Min. 1Mz
(female) (3) (A) chassis ground
FL2 (female) (4) and F07 ing harness and Resistance Min. 1Mz
(female) (1) chassis ground
When grounding fault occurs in a wiring harness other than the ones marked with ( A),
the fuse is broken.
WA150-5 20-405
(1)
b) Travel damper is not reset

Controller
Action Code Error Code Code Malfunction of travel damper
Trouble a) Travel damper is not reset
- - -
Description • The travel damper is not reset.
of Trouble
Machine
controller
Reaction
• The travel damper is not reset when the travel speed is above 6 km/h and the travel damper switch is
turned OFF.
Effect on • The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is
Machine turned ON.
• The travel damper is not reset when the travel speed is below 5 km/h and the travel damper switch is
turned OFF. (The travel damper is not reset under any condition.)
Related infor-
mation

Defective 3) Connect T-adapter.
1 travel Travel damper switch:
damper Resistance Max. 1z
switch Between L09 ON
(male) (2) and (3) Travel damper switch: Resistance Min. 1Mz
OFF
2) Relay: Replace L110 with normal relay.
4) Operate travel damper switch.
When relay L110 is replaced, No Relay L110 is normal.

does condition become normal? Yes Relay L110 is defective.
Possible 2) Disconnect relay L110.
Defective 3) Check relay unit.
Causes and travel
Standard 2 damper Between relay L110 (male) (1) and (2) Resistance 200 - 400z
Values relay
(L110) 1) Turn starting switch OFF.
2) Disconnect relay L110.
4) Apply normal voltage between relay L110 (male) (1) and (2).
between and (1) and Resistance Max. 1z
Between L110 (2)
(male) (3) and (5) When normal voltage
is not applied between Resistance Min. 1Mz
and (1) and (2)
Defective 1) Turn starting switch OFF.
travel 2) Replace travel damper solenoid (F07) with normal solenoid.
damper 3) Turn starting switch ON.
3 solenoid
(F07) (Not When solenoid (F07) is No Travel damper solenoid is normal.
reset replaced, does condition
under any become normal?
condition) Yes Travel damper solenoid is defective.
20-406 WA150-5
(1)

2) Replace diode (D05) with normal one.
Condition does not become normal. Diode (D05) is normal.
Condition becomes normal. Diode (D05) is defective.
1) Check diode unit.
Defective Check continuity from (2) to (1) in diode range. There is continuity.
4 diode
(D05) Check continuity from (2) to (3) in diode range. There is continuity.
a Apply (+) pin of circuit tester to left line.
Defective 4) Turn starting switch ON.
5 travel
Possible damper Travel speed: Voltage Max. 1V
Causes and controller Between L14 (4) and chassis 0 - 5 km/h
Standard ground Travel speed:
Values Above 6 km Voltage 20 - 30V

2) Disconnect connectors L09, L110, L14, J08, D05, FL2, and F07.
Max. 1V
Wiring harness between L09 Between this wir- (Travel damper is not reset
(female) (3) and L110 ing harness and when hot short-circuiting occurs
Discon- (female) (3) chassis ground and speed is above 6 km/h and
nection in switch is OFF)
wiring Max. 1V
harness Wiring harness between L14 Between this wir- (Travel damper is not reset
(Discon- (female) (4) and L110 ing harness and when hot short-circuiting occurs
6 nection in (female) (1) chassis ground and speed is below 5 km/h and
wiring har- switch is ON)
ness or
defective Wiring harness between L110 Between this wir- Max. 1 V
contact) (female) (5) and J08 (14), (15) ing harness and (Travel damper is not reset
and D05 (female) (1) chassis ground under any condition)
Wiring harness between L110 Between this wir- Max. 1 V
(female) (5) and J08 (14), (16) ing harness and (Travel damper is not reset
and FL2 (male) (4) chassis ground under any condition)
Wiring harness between FL2 Between this wir- Max. 1 V
(female) (4) and F07 (female) ing harness and (Travel damper is not reset
(1) chassis ground under any condition)
WA150-5 20-407
(4)
TROUBLESHOOTING OF MONITOR SYSTEM
(MON MODE)
Monitor system circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502
Before troubleshooting code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
Error Code [15B0NX] (HST oil filter clogged (NX)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
Error Code [2G42ZG] (Decreased brake oil pressure (ZG)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
Error Code [989F00] (HST motor protection caution (00)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
Error Code [989FN1] (HST overrunning (N1)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
Error Code [AB00L6] (Defective battery charging circuit (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
Error Code [AB00MA] (Defective battery charging circuit (MA)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
Error Code [B@BAZG] (Degreased engine oil pressure (ZG)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
Error Code [B@BCNS] (Engine water temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-517
Error Code [B@BCZK] (Alarm indicating low coolant level (ZK)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
Error Code [B@C7NS] (Axle oil temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-519
Error Code [B@CRNS] (HST oil temperature overheating (NS)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-520
Error Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
Error Code [DAF0KT] (Controller inside failure (KT)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
Error Code [DAJ0KR] (HST controller communication failure (KR)). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-526
Error Code [DD15LD] (Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)). . . . 20-528
Error Code [DD16LD] (Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)) . . . 20-529
Error Code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)) . . . . 20-530
Error Code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)) . . . . 20-531
Error Code [DDK3KB] (Multiple directional lever FR signal input (KB)) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-532
Error Code [DDS5L6] (Decreased steering oil pressure (L6)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-534
Error Code [DGE2KX] (Engine water temperature (High temperature) sensor system failure (KX)) . . . . 20-535
Error Code [DGE3L6] (Engine water temperature (Low temperature) sensor system failure (L6)) . . . . . 20-536
Error Code [DGH1KX] (HST oil temperature sensor system failure (KX)). . . . . . . . . . . . . . . . . . . . . . . . . 20-537
Error Code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA)). . . . . . . . . . . . . . . . . . . . 20-538
Error Code [DGR4KX] (Axle oil temperature sensor system failure (KX)). . . . . . . . . . . . . . . . . . . . . . . . . 20-539
Error Code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6)). . . . . . . . . . . . . . . . . . . . . 20-540
Troubleshooting Code [MON-1] (The parking brake indicator lamp does not light ON) . . . . . . . . . . . . . . 20-542
Troubleshooting Code [MON-2] (The brake oil pressure caution lamp does not light ON) . . . . . . . . . . . . 20-546
Troubleshooting Code [MON-3] (The engine water temperature caution lamp does not light ON, or after the
engine starts, the engine water temperature gauge does not rise. ). . . . 20-547
Troubleshooting Code [MON-4] (The HST oil temperature caution lamp does not light ON, or after the
engine starts, the HST oil temperature gauge does not rise. ) . . . . . . . . 20-548
Troubleshooting Code [MON-5] (The fuel level gauge does not rise or decrease. ) . . . . . . . . . . . . . . . . . 20-549
Troubleshooting Code [MON-6] (The radiator coolant level caution lamp does not light ON) . . . . . . . . . . 20-550
Troubleshooting Code [MON-7] (The steering oil pressure caution lamp does not light ON) . . . . . . . . . . 20-551
Troubleshooting Code [MON-8] (The emergency steering oil pressure indicator lamp does not light ON) . 20-552
Troubleshooting Code [MON-9] (Input failure in monitor panel mode selector switch 1 [t]
(Panel switch 1)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
Troubleshooting Code [MON-10](Input failure in monitor panel mode selector switch 1 [U]
(Panel switch 2)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-554
Troubleshooting Code [MON-11](Input failure in monitor panel mode selector switch 2 [<]
(Panel switch 3)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555
Troubleshooting Code [MON-12]Input failure in monitor panel mode selector switch 2 [>]
(Panel switch 4)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
Troubleshooting Code [MON-13](The alarm buzzer does not sound or stop) . . . . . . . . . . . . . . . . . . . . . . 20-558
Troubleshooting Code [MON-14]The wiper does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-560
Troubleshooting Code [MON-15]The lamps do not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-560
WA150-5 20-501
(1)
TROUBLESHOOTING MONITOR SYSTEM CIRCUIT DIAGRAM
MONITOR SYSTEM CIRCUIT DIAGRAM
20-502 WA150-5
(1)
WA150-5 20-503
(1)
20-504 WA150-5
(1)
WA150-5 20-505
(1)
(1)
monitor
Error
Code
989F00
989F00
989FN1
AB00L6
DHE4L6
DDS5L6
DLE2LC
15B0NX
D5ZHL6
2G42ZG
DGE3L6
DX20KZ
DX19KZ
DAF0KT
DD18LD
DD17LD
DD16LD
DD15LD
DAJ0KR
B@CRN
AB00MA
DDK3KB
DW26KZ
DGE2KX
DHH1KX
DGR4KA
DGR1KX
DGH1KX
B@C7NS
B@BCZK
B@BAZG
B@BCNS
20-506
HST controller
E03
E03
E01
E03
E02
E01
E01
E01
E01
E03
E02
E02
E01
E01
E01
E01
E01
E01
E01
E03
E03
E01
E02
E03
E00
E01
E03
E03
E03
E03
E03
E00
Failures related to
Failures related to
Code
Action
Defective machine monitor
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q
q q
q q
Defective HST controller
q
q
q
q
q
q
TROUBLESHOOTING
q
q
Defective monitor panel mode switch 1 [t]
Defective monitor panel mode switch 1 [U]
q
q
Defective monitor panel mode switch 2 [<]
q
Defective monitor panel mode switch 2 [>]
q
Defective derectional lever
q
q
Battery is deteriorated
q q
Defective fuse, fusible link
Defective alternator
q
q
Defective engine revolution sensor
ERROR CODE AND POSSIBLE CAUSES TABLE
q
q
q q
q
Defective clutch solenoid
Engine oil pressure drops
q
q q
Defective engine oil pressure sensor
Engine coolant temperature overheating
q
q q
Defective engine coolant temperature sensor (high temperature)
q
Defective engine coolant temperature sensor (low temperature)
Possible Causes
Engine coolant level lacks
q q
Defective coolant level sensor
q
Defective HST oil pressure sensor
HST oil filter clogging
q q
Defective HST oil filter sensor
HST oil temperature overheating
q q
q
Defective HST oil temperature sensor
Brake oil pressure drops
q q
Defective brake oil pressure sensor
Axle oil temperature overheating
q q
q
q
Defective axle oil temperature sensor
Steering oil temperature overheating
q q
Defective steering oil temperature sensor
Defective relay
q q
q
q
q
q q
q
q q
q
q
Wiring harness discontinuity
q
q
q q
q
q
q
q
q
q
q
q q q
q q
q
q
Wiring harness ground fault
q
q
q q q q
q q q
q
q q
q
q
q
Wiring harness hot short-circuiting
WA150-5


2 10A Hazard lamp
3 10A HST control A
Permanent power source 4 10A Parking brake 1
(Fuse box 1)
5 10A Meter, panel
8 10A Head lamp
9 — (Spare 1)

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 10A —
5 10A Load-meter
7 10A DC converter
(Fuse box 2)
9 10A Horn
10 10A Side marker lamp (left side)
11 — (Spare 2)
14 — (Spare 3)
15 — (Spare 4)
WA150-5 20-507
(1)

Code
Trouble Trouble displayed in trouble data
Panel display Panel display Panel dis-
play
Description of • Condition when machine monitor or controller detected trouble.
Trouble
Machine moni-
tor or controller • Action to take to protect system or equipment when machine monitor or controller detected trouble.
Reaction

Information

<Data to fill in>
1 • Normal standard values used to judge probable cause

• Disconnection
There is defective connection of connector or disconnection in wir-
ing harness
2 Wiring harness not wired to ground (GND) circuit is in contact with
ground (GND) circuit
Wiring harness not wired to power supply (24 V) circuit is in contact
with power supply (24 V) circuit
Possible Causes Probable cause when trou-
ble occurred <Points to remember when troubleshooting>
and Standard 1) Method of displaying connector No. and handling T-adapter
Values (the numbers are index
numbers and do not indi- Unless there is special instruction, insert or connect the T-adapter
cate the order of priority) 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 con-
nector No., disconnect the connector and connect the T-
3 adapter to only the terminal indicated (either the male terminal
or female terminal)
Unless there is a special instruction, connect tester (+) lead and (-)
lead as follows to carry out troubleshooting
• Connect the (+) lead to the wiring harness for the pin No. given
first
• Connect the (-) lead to the wiring harness for the pin No. given
last
20-508 WA150-5
(1)
Phenomena code table
a For problem codes marked "See list", see the list below.
Phenom- Details Discon- Details
ena code nection
KA Disconnection L0 Double engagement
Fill signal is ON when command current is
KB Short circuit L1 OFF
KK Drop in power source voltage, input L2 Fuel pressure is higher than maximum set
value
Corresponding component cannot be con-
KQ Non match in model selection signal L3 trolled
KR Defective communication L4 ON/OFF signals for 2 systems do not match
KT Abnormality inside controller L6 Engine signals do not match operating condi-

tion or stopped condition of machine
KX Input signal outside range L8 Analog signals for 2 systems do not match
KY Short circuit in power supply line LC Speed signals for 2 systems do not match
KZ Disconnection or short circuit LD Switch has been kept pressed for abnormally
long time
Fill signal is OFF when command current is
MA Function impossible LH ON
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA150-5 20-509
(1)
TROUBLESHOOTING ERROR CODE [15B0NX]
Error Code [15B0NX] (HST oil filter clogged (NX))

Code Trouble HST oil filter clogged (NX)
E01 15B0NX MON
Description of • When HST oil temperature went above 50°C: signal circuit of HST oil filter clogging sensor
Trouble changed to CLOSE (connected to GND)
Machine moni-
tor or control- • Trigger an alarm.
ler Reaction
Effect on • If it is used as it is, there is danger that dirt will circulated in the HST circuit
Machine
Related
Information

1 HST oil filter clogged • Clean or replace
Defective HST oil filter Between Filter is normal Resistance Min. 1Mz
2 T13 and
clogging sensor
chassis Filter clogged Resistance Max. 1z
ground
Possible 1) Turn starting switch OFF. 2) Disconnect connector T13.
Causes and
Standard Wiring harness ground Resistance between L23
3 fault Wiring harness between
Values (Female) (6), T13 and Min. 1Mz
L23 (Female) (6) and T13 chassis ground
4 Defective machine moni- Filter is
tor normal Voltage 20 - 30V
and chassis ground Filter
clogged Voltage Max. 1V
20-510 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [2G42ZG]
Error Code [2G42ZG] (Decreased brake oil pressure (ZG))

Code Trouble Decreased brake oil pressure (ZG)
E03 2G42ZG MON
Description of • When engine was running (continuously for more than 30 seconds), signal from accumulator oil
Trouble pressure sensor went below 4.4 MPa {45 kg/cm²}.
Machine moni-
tor or control- • Trigger an alarm.
ler Reaction
Effect on • If it is used as it is, there is danger that the brake will have no effect.
Machine
Related
Information

Accumulator (Brake) oil pressure is normal
1 Decrease brake a If the oil pressure is not normal, carry out troubleshooting for the hydraulic,
oil pressure
mechanical system.
1) Turn starting switch OFF. 2) Disconnect connector T12. 3) Connect T-
adapter.
Defective brake Oil pressure is normal (6MPa
2 oil pressure sen- Resistance Max. 1z
sor
Between T12 {61.2kg/cm2})
(Male) (1) and
(2) Oil pressure is low (4MPa Resistance Min. 1Mz
{40.8kg/cm2})
Turn starting switch OFF. 2) Disconnect Connectors T12, T23. 3) Connect T-
Wiring harness adapter.
Possible discontinuity
3 (Disconnection Wiring harness between T12 (Female) (1) and Resistance Max. 1z
Causes and L23 (Female) (19)
Standard or defective con-
Values tact) Wiring harness between T12 (Female) (2) and
1) Turn starting switch OFF. 2) Disconnect Connectors T12, L23. 3) Connect T-

adapter.
4 Wiring harness Resistance between L23
ground fault Wiring harness between L23 (Female) (19), T12
(Female) (19) and T12 (Female) Min. 1Mz
(1) (Female) (1) and chassis
ground
1) Turn starting switch OFF. 2) Disconnect connector L23. 3) Insert T-adapter.
5 Defective Between L23 Oil pressure is normal Voltage Max. 1V

machine monitor (Female) (19) (5.88MPa {60kg/cm2})
and chassis Oil pressure is low (3.92MPa
ground {40kg/cm2}) Voltage 20 - 30V
WA150-5 20-511
(1)
TROUBLESHOOTING ERROR CODE [989F00]
Error Code [989F00] (HST motor protection caution (00))

Code Trouble HST protection caution (00)
E00 989F00 MON
Description of • Not considered to be a failure.

Trouble • The travel speed exceeds 42km/h.
Machine moni-
tor or control- • Activates an alarm.
ler Reaction
Effect on • If travel speed exceeds 42km/h, speed is automatically reduced.
Machine
Related
Information
20-512 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [989FN1]
Error Code [989FN1] (HST overrunning (N1))

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

Trouble • Automatic speed reduction when travel speed exceeds 42 km/h does not work.
Machine moni-
ler Reaction
Effect on • If the machine is driven as it is, HST motor may be broken (seized).
Machine
Related
Information

2) Operate machine monitor
1 ---
Other code is displayed at Carry out troubleshooting for applica-
same time ble code displayed
When machine was used in
2 Overrunning HST way that would cause HST Inspect and repair cause of problem
Possible to overrun and damage to HST.
Causes and
Standard 1) Start engine.
Values 2) Operate machine monitor
3) Travel on flat ground.
Defective machine moni- Travel speed goes above Carry out troubleshooting for HST con-
3 troller system failure codes DW26KZ
tor 42 km/h. and DX19KZ.
Travel speed does not go
above 42 km/h. (Less than Inspect and repair cause of problem
42 km/h) and damage to HST.
WA150-5 20-513
(1)
TROUBLESHOOTING ERROR CODE [AB00L6]
Error Code [AB00L6] (Defective battery charging circuit (L6))
Action Code Error Code Controller Defective battery charging circuit (L6)
Code Trouble (Alternator terminal R signal detected when engine
E03 AB00L6 MON stopped)
Description of • The alternator terminal R signal input voltage is 12V or higher before the engine started.
Trouble
Machine moni-
ler Reaction
Effect on • The engine cannot be started.

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

Engine started
Between alternator termi- (Throttle 1/2 or Voltage 28 - 29V
1 Defective alternator nal R [E02 (1)] and chas- more).
sis ground
Engine stopped. Voltage Max. 1.5V
Possible Hot short-circuiting Voltage between L23
Causes and 2 between harnesses Wiring harness between
L23 (Female) (12) and (Female) (12), E02 Max. 1V
Standard (Female) (1) and chassis
Values E02 (Female) (1) ground
3 Defective machine moni- Engine started
tor (Throttle 1/2 or Voltage 28 - 29V
Between L23 (Female)
(12) and chassis ground more).
20-514 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [AB00MA]
Error Code [AB00MA] (Defective battery charging circuit (MA))
Action Code Error Code Controller Defective battery charging circuit (MA)
Code Trouble (No signal from alternator terminal R when engine
E03 AB00MA MON stopped, Abnormal detection)
Description of • During engine operation, the input voltage to the alternator terminal R signal is below 5V.
Trouble
Machine moni-
ler Reaction
• The battery is deteriorated.
Effect on • The engine cannot be started.
Machine
• The service meter does not work.
Related
Information

1 Battery is deteriorated. ---
Engine started
Between alternator ter- (Throttle 1/2 or Voltage 28 - 29V
2 Defective alternator minal R [E02 (1)] and more).
chassis ground
Wiring harness discontinu- 3) Connect T-adapter.
3 ity (Disconnection or
defective contact) Wiring harness between L23 (Female)
Possible (12) and E02 (Female) (1) Resistance Max. 1z
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E02.
4 Wiring
fault
harness ground
L23 (Female) (12) and (Female) (12), E02 (Female) Min. 1Mz
E02 (Female) (1) (1) and chassis ground
5 Defective machine monitor Engine started
Between L23 (Female) (Throttle 1/2 or Voltage 28 - 29V
(12) and chassis ground more).
WA150-5 20-515
(1)
TROUBLESHOOTING ERROR CODE [B@BAZG]
Error Code [B@BAZG] (Degreased engine oil pressure (ZG))

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

Degrease engine oil
1 pressure ---

Defective engine oil pres- Engine
2 sure sensor (switch) Between engine oil pres- stopped. Resistance Max. 1z
sure sensor terminal (E15)
and chassis ground Engine Resistance Min. 1Mz
rotating.
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect Connectors L23, E15.
Standard 3) Connect T-adapter.
Values 3 Wiring harness ground
fault Resistance between L23
Wiring harness between (Female) (10), E15 and Min. 1Mz
L23 (Female) (10) and E15 chassis ground
4 Defective machine moni- Engine
tor stopped. Voltage Max. 1V
and chassis ground Engine
rotating. Voltage 20 - 30V
20-516 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [B@BCNS]
Error Code [B@BCNS] (Engine water temperature overheating (NS))

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

Overheating engine
1 water temperature ---

Defective engine water Normal tem-
2 temperature sensor (high perature Resistance 35 - 50kz
temperature) Between E14 (Male) (1)
and (2) (25°C).
When 100°C Resistance 3.1 - 4.5kz
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L21, E14.
Causes and 3) Connect T-adapter.
Standard
Values Wiring harness ground Resistance between L21
L21 (Female) (16) and (Female) (16), E14 Min. 1Mz
(Female) (1) and chassis
E14 (Female) (1) ground
4 Defective machine moni- Normal tem-
tor perature Resistance 35 - 50kz
(16) and chassis ground (25°C).
When 100°C Resistance 3.1 - 4.5kz
WA150-5 20-517
(1)
TROUBLESHOOTING ERROR CODE [B@BCZK]
Error Code [B@BCZK] (Alarm indicating low coolant level (ZK))

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

1 Decrease coolant level. ---
1) Turn starting switch OFF. 2) Disconnect connector B05.
Defective coolant level Reserve tank low level and
2 sensor Between B above (normal). Resistance Max. 1z
(Male) (1)
and (2) Reserve tank low level and
below (abnormal). Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05.

Possible 3) Connect T-adapter.
Causes and
Standard Wiring harness disconti- Wiring harness between L23 (Female) (8)
Values 3 nuity (Disconnection or and B05 (Female) (1) Resistance Max. 1z
defective contact)
Wiring harness between B05 (Female) (2) Resistance Max. 1z
and Chassis ground
Defective machine moni- Between Reserve tank low level and
4 tor Voltage Max. 1V
L23 above (normal).
(Female) (8)
and chassis Reserve tank low level and Voltage 20 - 30V
ground below (abnormal).
20-518 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [B@C7NS]
Error Code [B@C7NS] (Axle oil temperature overheating (NS))

Code Trouble Axle oil temperature overheating (NS)
E02 B@C7NS MON
Description of • The axle oil temperature is overheating.

Trouble {Min. 120°C (35km/h and below) or Min. 115°C (Min. 35km/h)}
Machine moni-
ler Reaction
Effect on • The brake may be damaged if operation continues.
Machine
Related • This error code is displayed if the probability of a failure in the electrical system is low.
Information • The axle oil temperature is displayed by monitoring code 30202.

Overheating axle oil tem-
1 perature. ---
1) Turn starting switch OFF. 2) Disconnect connector F14.

2 Defective axle oil temper- Normal temperature
Possible ature sensor Between F14 Resistance 35 - 50kz
(Male) (1) and (25°C).
Causes and
Standard (2) When 100°C Resistance 3.1 - 4.5kz
Values
3 Defective machine moni-
tor Between L21 Normal temperature
(Female) (8) (25°C). Resistance 35 - 50kz
and chassis
ground When 100°C Resistance 3.1 - 4.5kz
WA150-5 20-519
(1)
TROUBLESHOOTING ERROR CODE [B@CRNS]
Error Code [B@CRNS] (HST oil temperature overheating (NS))

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

Overheating HST oil tem-
1 perature. ---

2 Defective HST oil tem- Normal temperature
Possible perature sensor Between T10 Resistance 35 - 50kz
(Male) (1) and (25°C).
Causes and
Standard (2) When 100°C Resistance 3.1 - 4.5kz
Values
and chassis
20-520 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [D5ZHL6]
Error Code [D5ZHL6] (Starting switch "C" (IGN "C") input failure (L6))

Code Trouble Starting switch "C" (IGN "C") input failure (L6)
E01 D5ZHL6 MON
Description of • When engine was running, starting switch C (IGN C) terminal signal turned ON, or did not turn ON
Trouble when starting switch was at START
Machine moni-
ler Reaction
Effect on • No reaction.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect starting switch terminals.
Between Starting switch START. Resistance Max. 1z
1 Defective starting switch starting
switch ter-
minal B and Other than the above. Resistance Min. 1Mz
C
2) Interchange relay (L106) with normal relay
The condi- Relay
tion is (L106) is
Does condition become normal when abnormal. normal.
neutral safety relay (L106) is inter-
changed with normal relay? The condi-
tion is nor- Defective
mal. relay (L106)

Defective neutral safety 3) Solid part check.
2 relay (L106)
Possible Between L106 (Male) (1) and (2) Resistance 200 - 400z
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L106.
Values 3) Solid part check.
Applies 24V impressed
voltage between L106 Resistance Max. 1z
Between (Male) (1) - (2)
L106 (Male)
between L106 (Male) Resistance Min. 1Mz
(1) - (2)
2) Disconnect Connectors L02, L15, L23 and fuse L106.
Wiring harness between L02 (Female)
(3) and L106 (Female) (3) Resistance Max. 1z
Wiring harness disconti-
3 nuity (Disconnection or Wiring harness between L23 (Female) Resistance Max. 1z
defective contact) (3) and L106 (Female) (5)
Wiring harness between L106
(Female) (2) and chassis ground Resistance Max. 1z
Wiring harness between L106 Resistance Max. 1z

(Female) (1) and L15 (Female) (3)
20-522 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [D5ZHL6]

2) Disconnect Connectors L02, L15, L23 and L106.

ground
Wiring harness ground Resistance between L23
4 fault Wiring harness between (Female) (3), L106
L23 (Female) (3) and L106 (Female) (5) and chassis Min. 1Mz
(Female) (5) ground
Possible L106 (Female) (1) and L15 (Female) (1), L15 (Female) Min. 1Mz
Causes and (Female) (3) (3) and chassis ground
Standard
Values a In the above case, the fuse is blown.

Hot short-circuiting Voltage between L23
5 between harnesses Wiring harness between
L23 (Female) (3) and L106 (Female) (3), L106 Max. 1V
(Female) (5) ground
6 Defective machine mon-
itor Between L23 Starting switch START. Voltage 20 - 30V
(Female) (3)
and Chassis Other than the above. Voltage Max. 1V
ground
WA150-5 20-523
(1)
TROUBLESHOOTING ERROR CODE [DAF0KT]
Error Code [DAF0KT] (Controller inside failure (KT))

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

Causes and Abnormality inside machine monitor, so troubleshooting cannot be
Standard 1 Defective machine moni- carried out.
Values tor (Abnormality may be repaired by initializing machine monitor.)
20-524 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DAJ0KR]
Error Code [DAJ0KR] (HST controller communication failure (KR))

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

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

Effect on • Speed range display does not switch.
Machine
• Speedometer always displays 0 km/h.
Related
Information

Wiring harness between Resistance between
L22 (Female) (6), L42 L22 (Female) (2) and 40 - 80z
(Female) (16) (6)
L22 (Female) (2), L42 L22 (Female) (2) and 40 - 80z
(Female) (8) (6)
1 Defective wiring harness Wiring harness between Resistance between
L22 (Female) (6), L42 L22 (Female) (2) and Min. 1Mz
(Female) (16) chassis ground
L22 (Female) (2), L42 L22 (Female) (2) and Min. 1Mz
Possible (Female) (8) chassis ground
Causes and
Standard a Check that terminal resistances CAN1, CAN 2 are connected.
Values a Resistance value of terminal resistances CAN1, CAN 2: 120z
1) Turn starting switch OFF. 2) Replace HST controller.

Communication is HST control-
2 Defective HST controller When HST controller is abnormal. ler is normal.
replaced, do communica-
tions become normal? Communication is nor- Defective HST
mal. controller
1) Turn starting switch OFF. 2) Disconnect Connectors CAN1, CAN2.
3 Defective terminal resis- Wiring harness between CAN1 (A) Resistance 100 - 130z
tance and (B)
Wiring harness between CAN2 (A)
and (B) Resistance 100 - 130z
20-526 WA150-5
(4)
TROUBLESHOOTING ERROR CODE [DAJ0KR]

1) Turn starting switch OFF. 2) Replace machine monitor.
Possible Communication is Machine monitor

When machine monitor is abnormal. is normal.
Causes and replaced, do communica-
Standard Defective machine moni- Communication is Defective
4 tor tions become normal?
Values normal. Machine monitor
a When replacing the machine monitor, carry out adjustments.
For details, see TESTING AND ADJUSTING, Adjusting machine
monitor.
WA150-5 20-527
(1)
TROUBLESHOOTING ERROR CODE [DD15LD]
Error Code [DD15LD] (Monitor panel mode selector switch 1 [ ] (Panel switch 1) input
error (LD))

Code Trouble Monitor panel mode selector switch 1 [t] (Panel
switch 1) input error (LD)
E01 DD15LD MON
Description of • The monitor panel mode selector switch 1 [t] (Panel switch 1) input circuit is always in the CLOSE
Trouble state for more thirty seconds.
Machine moni-
ler Reaction
Effect on • The monitor does not work.
Machine
Related
Information

Defective monitor panel When monitor panel mode
1 mode selector switch 1 Between
[t] L10 selector switch 1 [t] is Resistance Max. 1z
(Female) (2) turned ON.
and (3) Other than above. Resistance Min. 1Mz
Possible 3) Connect T-adapter. 4) Turn starting switch ON.
Causes and Hot short-circuiting Voltage between L21
Standard 2 between harnesses Wiring harness between (Female) (1), L10
Values L21 (Female) (1) and L10 (Female) (3) and chassis Max. 1V
(Female) (3) ground
Defective machine moni- Between When monitor panel mode
3 tor L21 selector switch 1 [t] is Voltage 20 - 30V
(Female) (1) turned ON.
and chassis
ground Other than above. Voltage Max. 1V
20-528 WA150-5
(1)
Error Code [DD16LD] (Monitor panel mode selector switch 1 [ ] (Panel switch 2) input
error (LD))

Code Trouble Monitor panel mode selector switch 1 [U] (Panel
E01 DD16LD MON
Description of • The monitor panel mode selector switch 1 [U] (Panel switch 2) input circuit is always in the CLOSE
Machine moni-
ler Reaction
Machine
Related
Information

Defective monitor panel When monitor panel
1 mode selector switch 1 Between L10 mode selector switch 1 Resistance Max. 1z
[U] (Female) (2) [U] is turned ON.
and (1)
Other than above. Resistance Min. 1Mz
Causes and Hot short-circuiting
Standard 2 Wiring harness between Voltage between L21
between harnesses (Female) (2), L10
Values L21 (Female) (2) and L10 Max. 1V
(Female) (1) ground
3 Defective machine moni- When monitor panel
tor Between L21
(Female) (2) mode selector switch 1 Voltage 20 - 30V
and chassis [U] is turned ON.
WA150-5 20-529
(1)
Error Code [DD17LD] (Monitor panel mode selector switch 2 [<] (Panel switch 3) input
error (LD))

Code Trouble Monitor panel mode selector switch 2 [<] (Panel
E01 DD17LD MON
Description of • The monitor panel mode selector switch 2 [<] (Panel switch 3) input circuit is always in the CLOSE
Machine moni-
ler Reaction
Machine
Related
Information

[<] (Female) (2) [<] is turned ON.
and (3)
Causes and Wiring harness ground
Standard 2 Wiring harness between Resistance between L21
fault (Female) (4), L11
Values L21 (Female) (4) and L11 Min. 1Mz
(Female) (3) and chas-
(Female) (3) sis ground
tor Between L21
(Female) (4) mode selector switch 2 Voltage Max. 1V
and chassis [<] is turned ON.
ground Other than above. Voltage 20 - 30V
20-530 WA150-5
(1)
Error Code [DD18LD] (Monitor panel mode selector switch 2 [>] (Panel switch 4) input
error (LD))

Code Trouble Monitor panel mode selector switch 2 [>] (Panel
E01 DD18LD MON
Description of • The monitor panel mode selector switch 2 [>] (Panel switch 4) input circuit is always in the CLOSE
Machine moni-
ler Reaction
Machine
Related
Information

[>]. (Female) (2) [>] is turned ON.
and (1)
Standard 2 Wiring harness between L21 Resistance between L21
fault (Female) (5), L11
Values (Female) (5) and L11 Min. 1Mz
tor Between L21
and chassis [>] is turned ON.
WA150-5 20-531
(1)
TROUBLESHOOTING ERROR CODE [DDK3KB]
Error Code [DDK3KB] (Multiple directional lever FR signal input (KB))

Code Trouble Multiple directional lever FR signal input (KB)
E03 DDK3KB MON
Description of • Multiple signals (F and R signal) are input due to short-circuited directional lever.
Trouble
• Input signal is displayed as it is (F and R light up at same time).
Machine moni- • Activates an alarm.
tor or control-
ler Reaction • When the engine is started, the machine moves, even if the forward-reverse lever is in the N posi-
tion.
Effect on • Does not travel.

Machine • The power train may be damaged.
Related
Information


(Female) (10), L15
Hot short-circuiting L22 (Female) (10) and L15 (Female) (2) and chassis Max. 1V
1 between harnesses (Female) (2) ground

(Female) (8), L15
L22 (Female) (8) and L15 (Female) (4) and chassis Max. 1V
(Female) (4) ground
Possible Between L15 When directional lever is
Causes and turned F. Resistance Max. 1z
Defective directional (Female) (1)
Standard 2 and (2)
Values lever Other than above. Resistance Min. 1Mz
Between L15 When directional lever is Resistance Max. 1z
(Female) (1) turned R.
and (4) Other than above. Resistance Min. 1Mz
Between L15 When directional lever is

turned F. Voltage 20 - 30V
3 Defective machine moni- (Female) (1)
tor and (2) Other than above. Voltage Max. 1V
Between L15 When directional lever is Voltage 20 - 30V
(Female) (1) turned R.
and (4) Other than above. Voltage Max. 1V
20-532 WA150-5
(4)
TROUBLESHOOTING ERROR CODE [DDK3KB]
WA150-5 20-533
(1)
TROUBLESHOOTING ERROR CODE [DDS5L6]
Error Code [DDS5L6] (Decreased steering oil pressure (L6))

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

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

2 Defective steering oil Steering oil pressure is low Resistance Max. 1z

pressure sensor (switch) Between (Engine stopped).
F11 (Male)
(A) and (C) Steering oil pressure is nor- Resistance Min. 1Mz
mal (Engine started).
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L22, F11.

Wiring harness ground
Standard 3 fault Wiring harness between Resistance between L22
Values L22 (Female) (3) and F11 (Female) (3), F11 (Female) Min. 1Mz
(Female) (C) (C) and chassis ground
Steering oil pressure is nor-
Between mal.
4 Defective machine moni- Voltage 20 - 30V
tor L22 [0.9 MPa {9.2 kg/cm²}] and
(Female) above
(3) and Steering oil pressure is
Chassis
ground abnormal (low). Voltage Max. 1V
[0.5 MPa {5.1 kg/cm²}] and
below
20-534 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DGE2KX]
Error Code [DGE2KX] (Engine coolant temperature (High temperature) sensor system
failure (KX))

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

Defective engine coolant
1 temperature (High tem- Between E14 Normal temperature Resistance 35 - 50kz
perature) sensor (Male) (1) and (25°C).
(2) When 100°C Resistance 3.1 - 4.5kz
Causes and Wiring harness ground Resistance between
Standard 2 fault Wiring harness between
Values L21 (Female) (16) and E14 L21 (Female) (16), E14 Min. 1Mz
and chassis
WA150-5 20-535
(1)
TROUBLESHOOTING ERROR CODE [DGE3L6]
Error Code [DGE3L6] (Engine coolant temperature (Low temperature) sensor system
failure (L6))

Code Trouble Engine coolant temperature (Low temperature)
sensor system failure (L6)
E01 DGE3L6 MON
Description of • After starting the engine, and running it for more than 30 minutes, engine coolant temperature (low
Trouble temperature) sensor signal becomes abnormal 4.5V
Machine moni-
tor or control- • The Activates an alarm.
ler Reaction
Effect on • After starting switch is turned ON, system always carries out automatic preheating.
Machine
Related • The engine coolant temperature (low temperature) is displayed by real-time monitoring code
Information 04103.

Defective engine coolant
1 temperature (Low tem- Between E13 Normal temperature
perature) sensor (25°C). Resistance 3.1 - 5.7kz
(Male) (A) and
(B) When 100°C Resistance 0.2 - 0.7kz
Causes and Wiring harness disconti- 3) Connect T-adapter.
Standard 2 nuity (Disconnection or
defective contact) Wiring harness between L21 (Female)
Values (6) and E13 (Female) (A) Resistance Min. 1Mz

(Female) (6) (25°C). Resistance 3.1 - 5.7kz
and chassis
20-536 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DGH1KX]
Error Code [DGH1KX] (HST oil temperature sensor system failure (KX))

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

perature sensor Between T10 Resistance 35 - 50kz
(Male) (1) (25°C).
and (2) When 100°C Resistance 3.1 - 4.5kz
1) Turn starting switch OFF. 2) Disconnect Connectors L21, T10.
Causes and Wiring harness ground Resistance between L21
Standard 2 fault Wiring harness between (Female) (14), T10
Values L21 (Female) (14) and T10 (Female) (1) and chas- Min. 1Mz
tor Between L21 Normal temperature Resistance 35 - 50kz
(Female) (14) (25°C).
and chassis
WA150-5 20-537
(1)
TROUBLESHOOTING ERROR CODE [DGR4KA]
Error Code [DGR4KA] (Axle oil temperature sensor system discontinuity (KA))

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

ature sensor Between F13 Resistance 35 - 50kz
(Male) (1) and (25°C).
Possible 1) Turn starting switch OFF. 2) Disconnect Connectors L21, F13.
Values defective contact) Wiring harness between L21 (Female) Resistance Max. 1z
(8) and F13 (Female) (1)
Defective machine moni- 4) Connect connector. 5) Turn starting switch ON.
3 tor Between L21 Normal temperature
and chassis
20-538 WA150-5
(1)
TROUBLESHOOTING ERROR CODE [DGR4KX]
Error Code [DGR4KX] (Axle oil temperature sensor system failure (KX))

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

ature sensor Between F13 Resistance 35 - 50kz
(Male) (1) and (25°C).
1) Turn starting switch OFF. 2) Disconnect Connectors L21, F13.
Causes and Wiring harness ground Resistance between L21
Standard 2 fault Wiring harness between (Female) (8), F13
Values L21 (Female) (8) and F13 (Female) (1) and chas- Min. 1Mz
tor Between L21 Normal temperature Resistance 35 - 50kz
(Female) (8) (25°C).
and chassis
WA150-5 20-539
(1)
TROUBLESHOOTING ERROR CODE [DHE4L6]
Error Code [DHE4L6] (Engine oil pressure sensor system discontinuity (L6))

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

1 Defective engine oil pres- Engine Resistance Max. 1z

sure sensor (switch) Between engine oil pres- stopped.
sure sensor terminal E15
and chassis ground Engine
rotating. Resistance Min. 1Mz

Values defective contact) Wiring harness between L23 (Female)
(10) and E15 (Female) (C) Resistance Max. 1z

3 Defective machine moni- Engine
tor stopped. Voltage Max. 1V
(10) and Chassis ground Engine
rotating. Voltage 20 - 30V
20-540 WA150-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
Troubleshooting Code [MON-1] (The parking brake indicator lamp does not light ON)

Code Trouble The parking brake indicator lamp does not light ON
- - -
Description of • The parking brake indicator lamp does not light ON when the parking brake lever is pulled.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The parking brake indicator lamp does not light ON when the parking brake lever is pulled.
Machine
Related • If the parking brake does not work normally, carry out troubleshooting after carrying out the appli-
Information cable troubleshooting.

2) Interchange relay (L104) with normal relay.
3) Turn starting switch ON. 4) Operate parking brake switch.
Does condition become The condition is abnor- Relay (L104)
normal when parking mal. is normal.
brake indicator lamp relay
(L104) is interchanged The condition is nor- Defective
with normal relay? mal. relay (L104)
Defective parking brake 3) Solid part check.
1 indicator lamp relay Between L104 (Male) (1) and (2) Resistance 200 - 400z
(L104)
3) Solid part check.
Between voltage between L104 Resistance Max. 1z
L104 (Male) (1) - (2)
(Male) (3) Does not apply voltage
Possible and (5) between L104 (Male) Resistance Min. 1Mz
Causes and (1) - (2)
Standard
2) Replace L101 with normal relay.
4) Operate parking brake switch.
When mechanical parking The condition is abnor- Relay (L101)

brake relay (L101) is mal is normal.
replaced, does condition The condition is nor- Relay (L101)
becomes normal? mal is defective.
Defective mechanical 2) Disconnect connector L101.
2 parking brake relay 3) Check relay unit.
(L101)
Between L101 (male) (1) and (2) Resistance 200 - 400z
4) Apply normal voltage between L101 (male) (1) and (2).
Between Apply 24 V between (1)
and (2). Resistance Max. 1z
L101
(male) (3) Do not apply 24 V
and (4) between (1) and (2). Resistance Min. 1Mz
20-542 WA150-5
(1)

Defective parking brake
3 lever middle position Parking brake lever is placed Resistance Max. 1z
detection switch Between LOCK to MIDDLE.
(Mechanical type) L47 (Male)
(1) and (2) Parking brake lever is placed Resistance Min. 1Mz
MIDDLE to FREE.
Defective parking brake Set parking brake lever to bot-
4 lever lowest position tom position. Resistance Max. 1z
detection switch Between
(Mechanical type) L53 (Male) Set parking brake lever to any
(1) and (2) position other than bottom Resistance Min. 1Mz
position.
1) Turn starting switch OFF. 2) Disconnect Connectors L23, L47, L53,
L104 and fuse T18. 3) Connect T-adapter.
4) Check that connector L20 is connected to L18.
Wiring harness between L23 (Female) (18)
and L104 (Female) (6) Resistance Max. 1z
Wiring harness between L104 (Female) (3)

and chassis ground Resistance Max. 1z
Wiring harness disconti- Wiring harness between L104 (Female) (2) Resistance Max. 1z
5 nuity (Disconnection or and chassis ground
defective contact) Wiring harness between L104 (Female) (1)
and J12 (Female) (7) Resistance Max. 1z

J12 (Female) (5)
Wiring harness between J12 (Female) (6) and
Possible L47 (Female) (2) Resistance Max. 1z
Causes and
Standard Wiring harness between L47 (Female) (1) and Resistance Max. 1z
Values fuse FS1 (4)
2) Disconnect connector L23, L53, L47, L104. 3) Connect T-adapter.

L23 (Female) (18) and (Female) (18), L104 Min. 1Mz
L104 (Female) (5) * ground
L104 (Female) (1) and J12 (Female) (1) and chassis Min. 1Mz
(Female) (7) ground
Wiring harness ground Wiring harness between Resistance between L53
6 fault J10 (Female) (19) and L53 (Female) (2) and chassis Min. 1Mz
(Female) (2) ground
L53 (Female) (1) and J12 Resistance between L53
(Female) (5), (6) and L47 (Female) (1) and chassis Min. 1Mz
(Female) (2) ground

L47 (Female) (1) and fuse (Female) (1) and chassis Min. 1Mz
FS1 (4) ground
a In the above case (Other than marked mark (*)), the fuse is blown.
Defective junction con- Carry out inspection, and if any abnormality is found, repair or
7 nector (J10) and (J12) replace.
8 Defective machine moni- Parking brake lever is placed
tor Between L23 Voltage Max. 1V
(Female) (18) PARKING.
and chassis Parking brake lever is placed
ground other than FREE. Voltage 20 - 30V
WA150-5 20-543
(1)
20-544 WA150-5
(1)
WA150-5 20-545
(1)
Troubleshooting Code [MON-2] (The brake oil pressure caution lamp does not light
ON)

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

1) Turn starting switch OFF. 2) Disconnect connector T12. 3) Connect
T-adapter.
Brake oil pressure is nor-
Defective brake oil pres- mal (When 5.88MPa Resistance Max. 1z
1 Between {60kg/cm²} and above).
sure sensor
T12 (Male) Steering oil pressure is
(1) and (2) abnormal (When
3.92MPa {40kg/cm²} and Resistance Min. 1Mz
below).
Standard 2 Wiring harness between Resistance between L23
fault (Female) (19), T12
Values L23 (Female) (19) and Min. 1Mz
T12 (Female) (1) ground
4) Connect connector. 5) Start engine.
Brake oil pressure is nor-
Defective machine moni- Between mal (When 5.88MPa Voltage Max. 1V
3 tor L23 {60kg/cm²} and above).
(Female)
Chassis abnormal (When
3.92MPa {40kg/cm²} and Voltage 20 - 30V
ground
below).
20-546 WA150-5
(1)
Troubleshooting Code [MON-3] (The engine water temperature caution lamp does not
light ON, or after the engine starts, the engine water temperature gauge does not rise. )
Action Code Error Code Controller The engine water temperature caution lamp does
Code Trouble not light ON, or after the engine starts, the engine
- - - water temperature gauge does not rise.
Description of • The engine water temperature sensor circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Effect on • The engine water temperature caution lamp does not light ON.
Machine • After the engine starts, the engine water temperature gauge does not rise.
Related • The engine water temperature is displayed by real-time monitoring code 04101.
Information

1) Turn starting switch OFF. 2) Disconnect connector E14. 3) Connect
T-adapter.
1 Defective engine water Normal temperature
temperature sensor Between Resistance 35 - 50kz
E14 (Male) (25°C)
(1) and (2) When 100°C Resistance 3.1 - 4.5kz
1) Turn starting switch OFF. 2) Disconnect Connectors L21, E14. 3)
Connect T-adapter.
Possible Wiring harness disconti-
Causes and Wiring harness between L21 (Female)
2 nuity (Disconnection or (16) and E14 (Female) (1) Resistance Min. 1Mz
Standard defective contact)
Values Wiring harness between E14 (Female)
(2) and chassis ground Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect connector L21. 3) Connect

T-adapter.
Between Normal temperature Resistance 35 - 50kz
3 Defective machine moni- L21 (25°C)
tor (Female)
(16) and
Chassis When 100°C Resistance 3.1 - 4.5kz
ground
WA150-5 20-547
(1)
Troubleshooting Code [MON-4] (The HST oil temperature caution lamp does not light
ON, or after the engine starts, the HST oil temperature gauge does not rise. )
Action Code Error Code Controller The HST oil temperature caution lamp does not
Code Trouble light ON, or after the engine starts, the HST oil tem-
- - - perature gauge does not rise.
Description of • The HST oil temperature sensor circuit is always in the OPEN state.
Trouble
Machine moni-
ler Reaction
Effect on • The HST oil temperature caution lamp does not light ON.
Machine • After the engine starts, the HST oil temperature gauge does not rise.
Related • The HST oil temperature is displayed by real-time monitoring code 30100.
Information

perature sensor Between T10 Resistance 35 - 50kz
(Male) (1) and (25°C).
Causes and Wiring harness disconti-
Standard Wiring harness between L21 (Female)
2 nuity (Disconnection or (14) and T10 (Female) (1) Resistance Min. 1Mz
Values defective contact)
Wiring harness between T10 (Female)

Defective machine moni- Between L21 Normal temperature
3 tor Resistance 35 - 50kz
(Female) (14) (25°C).
and Chassis
20-548 WA150-5
(1)
Troubleshooting Code [MON-5] (The fuel level gauge does not rise or decrease. )

Code Trouble The fuel level gauge does not rise or decrease.
- - -
Description of • An abnormality has occurred in the fuel level sensor circuit.
Trouble
Machine moni-
ler Reaction
Effect on • The fuel level gauge does not rise or decrease.
Machine
Related • The fuel level is displayed by real-time monitoring code 04202.
Information

1) Turn starting switch OFF. 2) Disconnect connector R21.
1 Defective fuel level sen- FULL Resistance 1 - 5z
sor Between R21 (Male) (1) 1/2 LEVEL Resistance 29 - 36z
and (2)
EMPTY Resistance 103 - 117z
1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21.
Wiring harness disconti- Wiring harness between L23 (Female)
2 nuity (Disconnection or (13) and R21 (Female) (1) Resistance Min. 1Mz
Possible defective contact)
Causes and Wiring harness between R21 (Female)
Standard
Values 1) Turn starting switch OFF. 2) Disconnect Connectors L23, R21.
3 Wiring harness ground Resistance between L23
fault Wiring harness between (Female) (13), R21
L23 (Female) (13) and (Female) (1) and chassis Max. 1z
R21 (Female) (1) ground
4 Defective machine moni- FULL Resistance 1 - 5z

tor Between L23 (Female)
(13) and Chassis ground 1/2 LEVEL Resistance 29 - 36z
EMPTY Resistance 103 - 117z
WA150-5 20-549
(1)
Troubleshooting Code [MON-6] (The radiator coolant level caution lamp does not light
ON)

Code Trouble The radiator coolant level caution lamp does not light
ON
- - -
Description of • The radiator coolant level sensor signal circuit is always in the CLOSE state.
Trouble
Machine moni-
ler Reaction
Effect on • The radiator coolant level caution lamp does not light ON, when the radiator coolant level (Coolant
Machine water volume) is insufficient.
Related • The radiator water level caution lamp does not light up until the sensor circuit is kept OPEN for 30
Information seconds.

1) Turn starting switch OFF. 2) Disconnect connector B05.
Defective radiator cool- Between B05 Reserve tank low level
1 ant level sensor or more (Normal). Resistance Max. 1z
(Male) (1) and
chassis Reserve tank low level
ground or less (Abnormal). Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect Connectors L23, B05.

Causes and
Standard Wiring harness ground Wiring harness Resistance between
2 between L23
Values fault L23 (Female) (8), B05
(Female) (8) Resistance Max. 1z
and B05 (Female) (1) and chas-

Defective machine moni- Between L23 Reserve tank low level
3 tor or more (Normal). Resistance Max. 1z
(Female) (8)
and Chassis Reserve tank low level
ground or less (Abnormal). Resistance Min. 1Mz
20-550 WA150-5
(1)
Troubleshooting Code [MON-7] (The steering oil pressure caution lamp does not light
ON)

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

Defective steering oil Steering oil pressure is
1 pressure sensor (switch) Between low (Engine stopped). Resistance Max. 1z
F11 (Male)
(A) and (C) Steering oil pressure is Resistance Min. 1Mz
normal (Engine started).
Causes and 2 nuity (Disconnection or Wiring harness between L22 (Female) Resistance Max. 1z
Standard (3) and F11 (Female) (C)
defective contact)
Values Wiring harness between F11 (Female)
(A) and chassis ground Resistance Max. 1z

Defective machine moni- Between Steering oil pressure is
3 L22 low (Engine stopped). Voltage Max. 1V
tor
(Female)
Chassis normal (Engine started). Voltage 20 - 30V
ground
WA150-5 20-551
(1)
Troubleshooting Code [MON-8] (The emergency steering oil pressure indicator lamp
does not light ON)

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

Steering oil pressure is low.
1 Defective steering oil Between (While engine is stopped) Resistance Min. 1Mz
pressure sensor (switch) F12
(Male) (A) Steering oil pressure is nor-
and (B) mal. Resistance Max. 1z
(While engine is running)
Causes and Wiring harness disconti- Wiring harness between L22 (Female) (5)
Standard 2 nuity (Disconnection or and F12 (Female) (B) Resistance Max. 1z
Wiring harness between F12 (Female) (A)
and chassis ground Resistance Max. 1z

Defective machine moni- Between Steering oil pressure is low. Voltage 20 - 30V
3 L22 (While engine is stopped)
tor
(Female)
(5) and Steering oil pressure is nor-
Chassis mal. Voltage Max. 1V
ground (While engine is running)
20-552 WA150-5
(1)
Troubleshooting Code [MON-9] (Input failure in monitor panel mode selector switch 1
[ ] (Panel switch 1))

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

Defective monitor panel
1 mode selector switch 1 When monitor panel
Between L10 mode selector switch 1 Resistance Max. 1z
[t] (Female) (2) [t] is turned ON.
and (3)
2) Disconnect Connectors L21, L10, fuse FS1 (5).
2 nuity (Disconnection or Wiring harness between L21 (Female) (1) Resistance Max. 1z
defective contact) and L10 (Female) (3)
and fuse FS1 (5)
Causes and 2) Disconnect Connectors L21, L10, fuse FS1 (5).
Standard 3) Connect T-adapter.
Values
Wiring harness between L21 Resistance between
(Female) (1) and L10 L21 (Female) (1), L10 Min. 1Mz
Wiring harness ground (Female) (3) (Female) (3) and chas-
3 sis ground
fault
Wiring harness between L10 Resistance between
(Female) (2) and fuse FS1 L10 (Female) (2), fuse Min. 1Mz
(5) FS1 (5) and chassis
ground
a In the above case, the fuse is blown.
3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch ON.
4 Defective machine moni- Between L21 When monitor panel

tor (Female) (1) mode selector switch 1 Voltage 20 - 30V
and chassis [t] is turned ON.
WA150-5 20-553
(1)
[ ] (Panel switch 2))

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

1 mode selector switch 1 Between L10
[U] mode selector switch 1 Resistance Max. 1z
(Female) (2) [U] is turned ON.
and (1)
2) Disconnect Connectors L21, L10, fuse FS1 (5).
2 nuity (Disconnection or Wiring harness between L21 (Female) (2) Resistance Max. 1z
defective contact) and L10 (Female) (1)
Possible and fuse FS1 (5)
Causes and
Standard 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L10, fuse
Values FS1 (5). 3) Connect T-adapter.
Wiring harness between L21 Resistance between L21

(Female) (2) and L10 (Female) (2), L10 Min. 1Mz
Wiring harness ground (Female) (1) (Female) (1) and chas-
3 fault sis ground
Wiring harness between L10 Resistance between L10
(Female) (2) and fuse FS1 (Female) (2), fuse FS1 Min. 1Mz
(5) (5) and chassis ground
4 Defective machine moni- Between L21 When monitor panel

tor (Female) (2) mode selector switch 1 Voltage 20 - 30V
and chassis [U] is turned ON.
20-554 WA150-5
(1)
[<] (Panel switch 3))

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

[<] (Female) (2) [<] is turned ON.
and (3)
Wiring harness disconti- Wiring harness between L21 (Female) (4)
2 nuity (Disconnection or and L11 (Female) (3) Resistance Max. 1z
defective contact)
Possible Wiring harness between L11 (Female) (2)
Causes and and chassis ground Resistance Max. 1z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L11.
Hot short-circuiting Voltage between L21
3 between harnesses Wiring harness between L21
(Female) (4) and L11 (Female) (4), L11 Max. 1V
(Female) (3) ground
tor Between L21
and chassis [<] is turned ON.
WA150-5 20-555
(1)
[>] (Panel switch 4))

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

1 mode selector switch 2 Between L11
[>] mode selector switch 2 Resistance Max. 1z
(Female) (2) [>] is turned ON.
and (1)
2 nuity (Disconnection or Wiring harness between L21 (Female) Resistance Max. 1z
Possible Wiring harness between L11 (Female)
Causes and Resistance Max. 1z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect Connectors L21, L11.
3 Hot short-circuiting Voltage between L21
between harnesses Wiring harness between (Female) (5), L11
L21 (Female) (5) and L11 Max. 1V
(Female) (1) (Female) (1) and chas-
sis ground
Defective machine moni-
4 tor Between L21 When monitor panel
and chassis [>] is turned ON.
20-556 WA150-5
(1)
WA150-5 20-557
(1)
Troubleshooting Code [MON-13] (The alarm buzzer does not sound or stop)
Controller
Action Code Error Code Code Trouble The alarm buzzer does not sound or stop
- - -
Description of • The alarm buzzer does not sound or stop.
Trouble
Machine moni-
ler Reaction
Effect on • The alarm buzzer does not sound or stop.
Machine
Related
Information

1 nuity (Disconnection or (11) and L46 (Female) (2) Resistance Max. 1z
defective contact)
Wiring harness between L46 (Female) Resistance Max. 1z
(1) and fuse FS1 (5)
L46 (Female) (1) and fuse (Female) (1), fuse FS1 (5) Min. 1Mz
FS1 (5) and chassis ground
Wiring harness ground a In the above case, the fuse is blown and the alarm buzzer does
2 fault not sound.

(Female) (2), L21
L46 (Female) (2) and fuse (Female) (11) and chassis Min. 1Mz
L21 (11) ground
Possible a In the above case, the alarm buzzer does not stop.
Causes and 1) Turn starting switch OFF. 2) Disconnect connector L46.
Standard 3) Insert T-adapter.
Values 4) Connect connector.
5) 5 seconds lapsed after the starting switch was turned ON.
Alarm
3 Defective alarm buzzer The alarm buzzer sounds. buzzer is
Between L46 (Female) (2) normal.
and chassis ground Defective
The alarm buzzer does alarm
not sound. buzzer.
Turn starting switch ON. Voltage 20 - 30V
For 2 seconds after the
Defective machine moni- Between starting switch was turned Voltage 20 - 30V
4 L21 ON. (The alarm buzzer
tor
(Female) does not sound.)
(11) and For 1 second after 2 sec-
chassis onds lapsed after the
ground starting switch was turned Voltage Max. 1V
ON. (The alarm buzzer
sounds.)
20-558 WA150-5
(1)
WA150-5 20-559
(1)
Troubleshooting Code [MON-14] The wiper does not function

a Defects in the wiper system is given in the TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE),
so see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).
Troubleshooting Code [MON-15] The lamps do not work properly

a Defects in the lamp system (lamps do not work properly) is given in the TROUBLESHOOTING OF ELEC-
TRICAL SYSTEM (E MODE), so see the section for TROUBLESHOOTING OF ELECTRICAL SYSTEM (E
MODE).
20-560 WA150-5
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602
Parking brake related diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-606
Before troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-608
Information contained in troubuleshooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-610
Troubleshooting Code [E-1] (The engine does not start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
Troubleshooting Code [E-2] (The engine does not stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
Troubleshooting Code [E-3] (Preheating is impossible or constant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function) . . . . . . . . . . . . . . 20-625
Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation) . . . . . . . . . . . . . . . . . . 20-630
Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation) . . . . . . . . . . . . . . . 20-633
Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and cancellation) . . . . . . . . 20-636
Troubleshooting Code [E-8] (Travel direction is not changed normally) . . . . . . . . . . . . . . . . . . . . . . . . . 20-638
Troubleshooting Code [E-9] (The wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-645
Troubleshooting Code [E-10] (The window washer does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-650
Troubleshooting Code [E-11] (Lamps do not work properly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-653
Troubleshooting Code [E-11] (The horn does not sound) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-664
Troubleshooting Code [E-13] (Defective the air conditioner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-666
WA150-5 20-601
(1)
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
ELECTRICAL SYSTEM DIAGRAM
20-602 WA150-5
(1)
WA150-5 20-603
(1)
20-604 WA150-5
(1)
TROUBLESHOOTING PARKING BRAKE RELATED DIAGRAM
PARKING BRAKE RELATED DIAGRAM
20-606 WA150-5
(1)
TROUBLESHOOTING PARKING BRAKE RELATED DIAGRAM
WA150-5 20-607
(1)


2 10A Hazard lamp
3 10A HST control A
Permanent power source 4 10A Parking brake 1
(Fuse box 1)
5 10A Meter, panel
8 10A Head lamp
9 — (Spare 1)

14 10A Wiper
15 10A Car radio B
3 10A Beacon lamp
4 10A —
5 10A Load-meter
7 10A DC converter
(Fuse box 2)
9 10A Horn
10 10A Side marker lamp
11 — (Spare 2)
14 — (Spare 3)
15 — (Spare 4)
20-608 WA150-5
(1)

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
Information
Causes Standard Value in Normal State and Remarks on

Troubleshooting
<Data to fill in>
1 • Normal standard values used to judge probable cause

• Disconnection
There is defective connection of connector or disconnection
in wiring harness
2 Wiring harness not wired to ground (GND) circuit is in contact
with ground (GND) circuit
Wiring harness not wired to power supply (24 V) circuit is in
contact with power supply (24 V) circuit
Possible
Causes and Probable cause when trouble
occurred <Points to remember when troubleshooting>
Standard 1) Method of displaying connector No. and handling T-adapter
Values (the numbers are index num-
bers and do not indicate the Unless there is special instruction, insert or connect the T-
order of priority) 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., disconnect the connector and connect the
3 T-adapter to only the terminal indicated (either the male
terminal or female terminal)
Unless there is a special instruction, connect tester (+) lead
and (-) lead as follows to carry out troubleshooting
• Connect the (+) lead to the wiring harness for the pin No.
given first
• Connect the (-) lead to the wiring harness for the pin No.
given last
20-610 WA150-5
(1)
WA150-5 20-611
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [E-1]
Troubleshooting Code [E-1] (The engine does not start)

a) Defective starting motor system

Code The engine does not start
Trouble a) Defective starting motor system
- - -
Description of • The engine does not start due to defective starting motor system.
Trouble
Machine moni-
ler Reaction
Effect on • The engine does not start.
Machine
• If the error code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshoot-
Related ing first for the applicable code.
Information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

Specific gravity Min. 1.26V
1 Defective battery
Voltage Min. 24V
1) Turn starting switch OFF. 2) Replace battery relay with normal relay.
The condition Battery relay is normal.
When battery relay is is abnormal
replaced, does condition
becomes normal? The condition Battery relay is defec-
is normal tive.
1) Turn starting switch OFF. 2) Disconnect battery relay.
2 Defective battery relay
Between battery relays R15 and R16 Resistance 30 - 70z
1) Turn starting switch OFF. 2) Disconnect battery relay.
4) Apply normal voltage between battery relays R15 and R16.
Between Apply 24 V between R15 Resistance Max. 1z
battery and R16.
relays R04 Do not apply 24 V between
Possible and R01 Resistance Min. 1Mz
R15 and R16.
Causes and
Standard 1) Turn starting switch OFF.
Values 2) Interchange relay (L106) with normal relay.
Relay
Does condition become The condition is abnormal. (L106) is
normal when neutral normal.
safety relay (L106) is
interchanged with nor- Defective
mal relay? The condition is normal. relay
(L106)
Defective neutral safety 3) Solid part check.
3 relay (L106) 200 -
Between L106 (Male) (1) and (2) Resistance 400z
Between age between L106 (Male) Resistance Max. 1z
L106 (1) - (2)
and (5) between L106 (Male) (1) - Resistance Min. 1Mz
(2)
20-612 WA150-5
(1)

4 Defective directional Between When directional lever is
lever L15 turned N. Resistance Max. 1z
(Female)
(1) and (3) Other than above. Resistance Min. 1Mz
2) Replace both diodes (D08, D15) with normal diodes.
3) Turn starting switch START.
Defective diode (D08,
D15) The condition is abnormal. Diode (D08, D15) is
a Only when defect normal.
5
occurs in both at the Defective diode
The condition is normal. (D08, D15)
same time
Measure from (2) end with diode range Continuity
Measure from (1) end with diode range Discontinuity
2) Replace diode (D07) with normal diode.
The condition is abnormal. Diode (D07) is normal.
The condition is normal. Defective diode (D07)
Measure between (1) o (2) with diode
range Continuity
Measure between (3) o (2) with diode Continuity
range
6 Defective diode (D07) Measure between (2) o (3) with diode
range Discontinuity
Measure between (2) o (1) with diode Discontinuity
Possible range
Causes and Measure between (1) o (3) with diode
Standard range Discontinuity
Values
Measure between (3) o (1) with diode Discontinuity
range
a Put (+) pole of tester in contact with left side.
2) Disconnect connector L106, D08, D15, terminal E01, R01 and E10.
(5) and D08 (Female) (2)
nuity (Disconnection or Wiring harness between L106 (Female)
(5) and D15 (Female) (2) Resistance Max. 1z
7 defective contact)
a Starting motor related Wiring harness between D08 (Female)
harness (1) and E01 (Female) (1) Resistance Max. 1z
Wiring harness between D15 (Female) Resistance Max. 1z
(1) and E01 (Female) (1)
Wiring harness between R01 and start- Resistance Max. 1z
ing motor terminal B (E10)
2) Disconnect connector D07, E02, terminal R16, R15, R07, R04, R02
and R05. 3) Connect T-adapter.
Wiring harness between R16 and chas- Resistance Min. 1z
sis ground
nuity (Disconnection or Wiring harness between R15 and D07 Resistance Min. 1z
8 defective contact) (Female) (2)
a Battery relay related Wiring harness between E02 (Female)
(2) and R15 Resistance Min. 1z
harness
Wiring harness between R04 and R02 Resistance Min. 1z
Wiring harness between R01 and R05 Resistance Min. 1z
Wiring harness between battery and Resistance Min. 1z
R04
WA150-5 20-613
(1)

2) Disconnect connector L02, D07, L23, terminal R03 and fuse FS1.
nuity (Disconnection or Wiring harness between L02 (Female) Resistance Max. 1z
9 defective contact) (1), FS1 (1) and R03
a Starting switch Wiring harness between L02 (Female)
related harness Resistance Max. 1z
(2) and D07 (Female) (1)
(2) and L23 (Female) (1)
2) Disconnect connector L15, L106, terminal R06, R11 and fuse FS1.
nuity (Disconnection or Wiring harness between L15 (Female)
(1), FS1 (2) and R06 Resistance Max. 1z
a Directional lever Wiring harness between L15 (Female)
related harness (3) and L106 (Female) (1) Resistance Max. 1z
Wiring harness disconti- 1) Turn starting switch OFF. 2) Disconnect connector TEL.
nuity (Disconnection or 3) Connect T-adapter.
Possible a Defective short con- Wiring harness between TEL (Female) Resistance Max. 1z
Causes and nector TEL (7) and (8)
Standard
Values Wiring harness disconti- 1) Turn starting switch OFF. 2) Disconnect connector MF3.
nuty (Disconnection or 3) Connect T-adapter.
a Defective short con- Wiring harness between MF3 (Male) (2)
and (5) Resistance Max. 1z
nector MF3
1) Turn starting switch OFF. 2) Disconnect connector E01, E02, D07.
13 Hot short-circuiting
between harnesses
Wiring harness between Voltage between E01
E01 (Female) (2), E02 (Female) (2), E02
(Female) (1) and D07 (Female) (1) and chassis Max. 1V
(Female) (3) ground
1) Disconnect starting switch terminal. 2) Solid part check.
14 Defective starting switch Turn starting switch
START. Between terminal B and C Max. 1z
15 Defective starting motor • If the check of the individual part shows that it is normal, the start-
ing motor is normal.
Between Engine started (Throttle 1/
alternator 2 and above) Voltage 26.5 - 29V
terminal R
16 Defective alternator [E02 (1)]
and chas- Engine stopped Voltage Max. 1V
sis ground
20-614 WA150-5
(4)
WA150-5 20-615
(1)
b) Defective fuel cut solenoid system

Code Trouble The engine does not start
b) Defective fuel cut solenoid system
- - -
Description of • The fuel cut solenoid system is defective, so the engine does not start.
Trouble
Machine moni-
ler Reaction
Effect on • The engine does not start.
Machine
• If the error code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshoot-
Related ing first for the applicable code.
Information
• If the fuses are blown, check the wiring harness is short-circuited with the ground.

2) Interchange relay (R13) with normal relay.
Relay
Does condition become The condition is abnormal.(R13) is
normal when pull relay normal.
(R13) is interchanged with
normal relay? The condition is normal. Defective
relay (R13)
Defective fuel cut sole- 3) Solid part check.
1
noid pull relay (R13) Between R13 (Male) (1) and (2) Resistance 50 - 90z
4) Applies impressed voltage between R13 (Male) (1) - (2)
voltage between R13 Resistance Max. 1z
R13 (Male)
Possible between R13 (Male) (1) - Resistance Min. 1Mz
Causes and (2)
Standard
Values 1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24.
Defective fuel cut sole- 3) Connect T-adapter. 4) Solid part check.
2 noid Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
Between Turn starting switch ON. Voltage 20 - 30V
3 Defective fuel cut sole- R08 (1)
noid timer and (2) Turn starting switch OFF. Voltage Max. 1V
Between 2 - 4 sec after turning Voltage Min. 16V
R08 (3) starting switch ON
and (4) Other than above. Voltage Max. 1V
2) Replace diode (D03 or D04) with a normal diode.
4 Defective diode
(D03 or D04) The condition is Diode (D03 or D04) is normal.
abnormal.
The condition is normal. Defective diode (D03 or D04)
20-616 WA150-5
(1)

2) Disconnect connector L02, D03, D04, D08, D15, terminal E01, E03,
E11, E23, E24, R05, R08, R09, R10, R12 and R13.
Wiring harness between E24 and chas-
sis ground Resistance Max. 1z

Wiring harness between E03 and R09 Resistance Max. 1z
Possible 5 nuity (Disconnection or Wiring harness between E23 and L02
Causes and (Female) (4) Resistance Max. 1z
defective contact)
Standard Wiring harness between E23 and R08
Values (Female) (1) Resistance Max. 1z
Wiring harness between R08 (Female)
(2) and chassis ground Resistance Max. 1z
Wiring harness between R08 (Female) Resistance Max. 1z

(3) and R13 (Female) (1)
(4) and R13 (Female) (2) Resistance Max. 1z
Wiring harness between R10 and R12 Resistance Max. 1z
Wiring harness between R11 and R06 Resistance Max. 1z
1) Disconnect starting switch terminal. 2) Solid part check.
6 Defective starting switch Turn starting switch Between terminal B and
START. ACC Max. 1z

a See "TROUBLESHOOTING CODE [E-1 (a)]"
WA150-5 20-617
(1)
Troubleshooting Code [E-2] (The engine does not stop)

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

1) Turn starting switch OFF. 2) Disconnect terminal E03, E23, E24.
3) Connect T-adapter. 4) Solid part check.
Defective fuel cut sole-
1 noid Between E23 and E24 Resistance 43 - 53z
Between E03 and E24 Resistance 0.8 - 1.2z
Defective fuel cut sole- 4) Connect connector.
Possible 2 noid timer
Causes and Between Turn starting switch ON. Voltage 20 - 30V
Standard R08 (1)
Values and (2) Turn starting switch OFF. Voltage Max. 1V
2) Disconnect connector L02, D03, D08, terminal E03, E23 and R09.
3) Connect T-adapter. 4) Turn starting switch OFF.
3 Hot short-circuiting E03, R09 and D03 (Harness side) and chas- Max. 1V
between harnesses (Female) (1) sis ground
E23, L02 (Female) (4) (Harness side) and chas- Max. 1V
and R08 (Female) (1) sis ground
20-618 WA150-5
(1)
WA150-5 20-619
(1)
Troubleshooting Code [E-3] (Preheating is impossible or constant)

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

2) Disconnect heater relay terminal E06, E07, E08. 3) Solid part check.
Between E06 and chassis ground Resistance 19 - 25z
1 Defective intake air When relay is ON (impressed
heater relay voltage 24V between E08 - Resistance Max. 1z
Between
E07 and chassis ground).
E08 When the relay OFF (Other
than above). Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Disconnect heater terminal E09.

Defective intake air 3) Solid part check.
2
heater (Ribbon heater) Between heater terminal E09 and chassis 0.17 -
Resistance
ground 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay
Condition Relay
Does condition become normal when auto- is abnor- L115 is
matic preheating relay L115 is replaced with mal. normal.
normal relay? Condition Defective
is normal. relay L115.
Possible 1) Turn starting switch OFF. 2) Disconnect connector L115.
Causes and Defective auto-preheat- 3) Solid part check.
Standard 3 ing relay (L115)
Between L115 (Male) (1) and (2) Resistance 200 -
Values 400z
Between Applies 24V impressed voltage Resistance Max. 1z
L115 between L115 (Male) (1) - (2)
and (5) Resistance Min. 1Mz
between L115 (Male) (1) - (2)
1) Turn starting switch OFF. 2) Replace diode (D05) with normal diode.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D05)
Measure between (2) o (1) with diode range Continuity
4 Defective diode (D05) Measure between (2) o (3) with diode range Continuity
Measure between (1) o (2) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-620 WA150-5
(1)

2) Disconnect connector L115, L22, fuse FS2 (5), E06, E07 and E08.
Wiring harness between E08 and E09 Resistance Max. 1z
Wiring harness between R07 and E07 Resistance Max. 1z
Wiring harness disconti- Wiring harness between E06, J08 and
5 nuity (Disconnection or L115 (Female) (5) Resistance Max. 1z
defective contact)
Wiring harness between fuse FS2 (5) Resistance Max. 1z
Wiring harness between fuse FS2 (5)

2) Disconnect connector D05, L115, L22, fuse FS2 (5), E06, E07 E08,
E09 and R07.
Wiring harness between Resistance between E08,
E08 and E09 * E09 and chassis ground Min. 1Mz
Wiring harness between Resistance between R07, Min. 1Mz

R07 and E07 * E07 and chassis ground
Wiring harness between Resistance between E06,
E06, J08 and L115 J08, L115 (Female) (5) Min. 1Mz
(Female) (5) * and chassis ground
Possible fuse FS2 (5) and L115 FS2 (5), L115 (Female) Min. 1Mz
Causes and (Female) (3) * (3) and chassis ground
Standard Wiring harness between Resistance between fuse
Values 6 Wiring harness ground
fault fuse FS2 (5) and L115 FS2 (5), L115 (Female) Min. 1Mz
(Female) (1) * (1) and chassis ground
Resistance between J08
Wiring harness between (Female) (12), D05
J08 (Female) (12) and (Female) (3) and chassis Min. 1Mz
D05 (Female) (3) * ground
a Item 6 above is wiring harness related to intake air heater (ribbon
heater)

L21 (Female) (6) and E13 (Female) (6), E13 (A) and Min. 1Mz
(A) chassis ground
a The above is wiring harness related to the engine water tempera-
ture (low temperature) sensor
a If it is marked * , the fuse is blown

Defective engine water
7 temperature (Low tem- Between Normal temperature
perature) sensor (25°C). Resistance 3.1 - 5.7kz
E13 (Male)
(A) and (B) When 100°C Resistance 0.2 - 1.0kz
2) Replace junction connector (J06, J09, J11) with normal junction
connector
8 Defective junction con- Junction connector (J06, J09, J11) is
nector (J06, J09, J11) Condition is abnormal.
normal.
Condition is normal. Defective junction connector (J06, J09,

J11).
WA150-5 20-621
(1)
20-622 WA150-5
(1)
b) Preheating is constant

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

2) Disconnect heater relay terminal E06, E07, E08.
Between E06 and chassis ground Resistance 19 - 25z
Defective intake air When relay is ON
1 heater relay (impressed voltage 24V
Between between E08 - chassis Resistance Max. 1z
E07 and ground).
E08
When the relay OFF
(Other than above). Resistance Min. 1Mz
1) Turn starting switch OFF. 2) Replace relay L115 with normal relay.
Condition Relay L115
Does condition become normal when is abnor-
mal. is normal.
automatic preheating relay L115 is
replaced with normal relay? Condition Defective
Possible is normal. relay L115.
Standard 3) Solid part check.
Values Defective auto-preheat-
2 Between L115 (Male) (1) and (2) Resistance 200 - 400z
ing relay (L115)
L115 (Male) (1) - (2)
(2)
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.
3 Hot short-circuiting Wiring harness between Voltage between E08, Max. 1V

between harnesses E08 and E09 E09 and chassis ground
Wiring harness between Voltage between E06,
E06, J06 and L115 J08, L115 (Female) (5) Max. 1V
WA150-5 20-623
(1)

1) Turn starting switch OFF. 2) Disconnect connectors L22 and L115.
4 Short circuit with chassis Resistance between L22
Possible ground in wiring harness Wiring harness between
Causes and L22 (female) (4) and L115 (female) (4), L115 Min. 1Mz
Standard (female) (2) (female) (2) and chassis
Values ground
Defective mechanical 3) Insert T-adapter.
5 4) Connect connector. 5) 1 minute after starting switch is turned ON.
monitor
Voltage between L22 (4) and chassis ground Min. 16 V

20-624 WA150-5
(1)
Troubleshooting Code [E-4] (The parking brake (Mechanical type) does not function)
a) Parking brake dragging prevention does not function (mechanical type)
Action Code Error Code Controller The parking brake (Mechanical type) does not func-
Code Trouble tion
a) Parking brake dragging prevention does not
- - - function (mechanical type)
Description of • Parking brake dragging prevention does not function
Trouble
Machine moni-
ler Reaction
Effect on • Parking brake dragging prevention does not function
Machine
Related
Information

3) Turn starting switch ON. 4) Operate parking brake switch.
Condition is Relay L112
Does condition become normal when abnormal. is normal.
parking brake neutral safety relay L112 is
replaced with normal relay? Condition is Defective
normal. relay L112.
1 Defective parking brake
neutral safety relay (L112)
Between L112 (Male) (1) and (2) Resistance 200 - 400z
L112 (Male)
(2)
Possible Causes 1) Turn starting switch OFF.
and Standard 2) Disconnect connector D01, L19, L112, T01. 3) Connect T-adapter.
Values
L112 (Female) (5) and J08 (Female) (5), T01 (Female) Min. 1Mz
2 Wiring
fault
harness ground (7), (9) and T01 (Female)
(2), (4) (4) and chassis ground

L112 (Female) (5) and J08 (Female) (5), T01 (Female) Min. 1Mz
(7), (8) and T01 (Female) (2) and chassis ground
(2)
1) Turn starting switch OFF. 2) Replace diode D01 with normal diode.
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
WA150-5 20-625
(1)
20-626 WA150-5
(1)
WA150-5 20-627
(1)
b) Parking brake "non-applied" indicator does not light up (mechanical type)
Action Code Error Code Controller The parking brake (Mechanical type) does not func-
Code Trouble tion
b) Parking brake "non-applied" indicator does not
- - - light up (mechanical type)
Description of • Parking brake "non-applied" indicator does not light up
Trouble
Machine moni-
ler Reaction
Effect on • Parking brake "non-applied" indicator does not light up
Machine
Related
Information

1 Defective parking brake Place parking brake lever Resistance Miin 1Mz
lowest switch Between LOCK.
L53 (Male)
(3) and (2) Place parking brake lever Resistance Max. 1z
FREE.
2 Defective parking brake Place parking brake lever Resistance Min. 1Mz
middle switch Between LOCK to MIDDLE.
L47 (Male)
(3) and (1) Place parking brake lever Resistance Max. 1z
MIDDLE to FREE.
Possible 3) Turn starting switch ON. 4) Operate parking brake switch.
Causes and
Standard Does condition become Condition is abnormal. Relay L101
Values normal when parking is normal.
brake relay L101 is
replaced with normal Condition is normal. Defective
relay? relay L101.
Defective mechanical
3 type parking brake relay Between L101 (Male) (1) and (2) Resistance 200 - 400z
(L101)
L101 (Male) (1) - (2)
(2)
20-628 WA150-5
(1)

2) Disconnect connector L47, L53, fuse FS1 terminal.
(2) and J12 (6), (7) and L53 (Female) (1) Resistance Max. 1z

(2) and J10 (19), (18) and L21 (Female) Resistance Max. 1z
Wiring harness disconti- (13)
4 nuity (Disconnection or Wiring harness between L53 (Female)
defective contact) (2) and J10 (Female) (19), (20) and J05 Resistance Max. 1z
(14), (16) and L101 (Female) (1)
(2) and J10 (Female) (19), (20) and J05 Resistance Max. 1z
(14), (17) and L101 (Female) (5)

(2) and J12 (Female) (6), (4) and L101 Resistance Max. 1z
(Female) (3)
Causes and 2) Disconnect connector L101, L47, L53, both ends of fuse FS1 termi-
Standard nal.
fuse FS1 (4) and L47 (Female) (1) and chassis Min. 1Mz
(Female) (1) ground
Wiring harness ground Wiring harness between Resistance between L47
5 fault L47 (Female) (2) and J12 (Female) (2), L53
(6), (5) and L53 (Female) (Female) (1) and chassis Min. 1Mz
(1) ground
L47 (Female) (2) and J12 (Female) (2), L101
(6), (4) and L101 (Female) (3) and chassis Min. 1Mz
(Female) (3) ground
Defective junction con- • Carry out inspection, and if any abnormality is found, repair or
6 nector (J05), (J10) and
(J12) replace.

4) Connect connector. 5) Turn starting switch
7 Defective machine moni- Place parking brake lever
tor Between Voltage Max. 1V
L21 (13) LOCK to MIDDLE.
and chas- Place parking brake lever
sis ground FREE. Voltage 20 - 30V

WA150-5 20-629
(1)
Troubleshooting Code [E-5] (Defective boom kick-out function and cancellation)

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
Trouble switch system, lift arm PPC detent system and lift arm detent relay system.
Machine moni-
tor or control- ----
ler Reaction
Effect on • Boom kick-out does not function or cannot be cancelled.
Machine
Related
Information

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.
Defective lift arm detent Between L113 (Male) (1) and (2) Resistance 200 - 400z
1 relay 1) Turn starting switch OFF. 2) Disconnect connector L113.
Possible Applies 24V impressed
Causes and Between voltage between L113 Resistance Max. 1z
Standard L113 (Male) (1) - (2)
Values (Male) (3) Does not apply voltage
(2)
2 Defective lift arm PPC 3) Connect T-adapter.
detent
3) Interchange lift arm positioner proximity switch (F04) with bucket
positioner proximity switch (F03).
4) Operate boom kick-out.
Defective lift arm posi-
3 tioner proximity switch Defective boom kick-out
Boom kick-out function is normal. proximity switch F04
Boom kick-out proximity
Boom kick-out does not function. switch F04 is normal.
20-630 WA150-5
(1)

2) Disconnect connector F04, L113, L36 and fuse FS1 terminal.
Wiring harness between F04 (Female) Resistance Max. 1z
(A) and fuse FS1 (13)
Wiring harness between F04 (Female)
(B) and L113 (Female) (2) Resistance Max. 1z

(C) and chassis ground Resistance Max. 1z
defective contact) (1) and fuse FS1 (13) Resistance Max. 1z


a With all the above items, the boom kick-out does not function
Resistance between F04
Wiring harness between (Female) (B), L113
Possible F04 (Female) (B) and (Female) (2) and chassis Min. 1Mz
Causes and L113 (Female) (2) ground
Standard
Values Resistance between L113
L113 (Female) (5) and (Female) (1) and chassis Min. 1Mz
L36 (Female) (1) ground
a In this case, the boom kick-out detent does not function (lever
Wiring harness ground returns to neutral)
5 fault
Wiring harness between Resistance between F04
F04 (Female) (A) and (Female) (A), FS1 (13) Min. 1Mz
fuse FS1 (13) and chassis ground
L113 (Female) (1) and (Female) (1), fuse FS1 Min. 1Mz
fuse FS1 (13) (13) and 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 L113, L36.

Voltage between L113
Hot short-circuiting L113 (Female) (5) and Max. 1V
6 between harnesses (Female) (1) and chassis
a In this case, the boom kick-out does not function (lever does not
return to neutral)
WA150-5 20-631
(1)
20-632 WA150-5
(1)
Troubleshooting Code [E-6] (Defective bucket positioner function and cancellation)

Code Defective bucket positioner function and cancella-
Trouble tion
- - -
Description of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner prox-
Trouble imity switch system, bucket PPC detent system and bucket detent relay system.
Machine moni-
ler Reaction
Effect on • Bucket positioner does not function or cannot be cancelled.
Machine
Related
Information

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.
Defective bucket detent Between L114 (Male) (1) and (2) Resistance 200 - 400z
1 relay (L114) 1) Turn starting switch OFF. 2) Disconnect connector L114.
Possible Applies 24V impressed
Causes and Between voltage between L114 Resistance Max. 1z
Standard L114 (Male) (1) - (2)
Values (Male) (3) Does not apply voltage
(2)
2 Defective bucket PPC 3) Connect T-adapter.
detent
3) Interchange bucket positioner proximity switch (F03) with lift arm
positioner proximity switch (F04).
4) Operate bucket positioner.
Defective bucket posi-
3 tioner proximity switch Defective bucket positioner
Bucket positioner function is normal. proximity switch F03
Bucket positioner proxim-
Bucket positioner does not function. ity switch F03 is normal.
WA150-5 20-633
(1)

(A) and fuse FS1 (13)
(B) and L114 (Female) (2) Resistance Max. 1z

(C) and chassis ground Resistance Max. 1z
defective contact) (1) and fuse FS1 (13) Resistance Max. 1z


a With all the above items, the bucket positioner does not function
Resistance between F03
Wiring harness between (Female) (B), L114
F03 (Female) (B) and (Female) (2) and chassis Min. 1Mz
Possible
Causes and a In this case, the bucket positioner detent does not function (lever
Standard
Values does not return to neutral)
Resistance between L114
Wiring harness ground
5 fault a In this case, the bucket positioner does not function (lever returns
to neutral)
Wiring harness between Resistance between F03

F03 (Female) (A) and (Female) (A), FS1 (13) Min. 1Mz
fuse FS1 (13) and chassis ground
a In this case, the fuse is blown and no detents function (lever
returns to neutral)


Hot short-circuiting L114 (Female) (5) and (Female) (5), L37 Max. 1V
6 between harnesses (Female) (1) and chassis
a In this case, the bucket positioner does not function (lever does
not return to neutral)
20-634 WA150-5
(1)
WA150-5 20-635
(1)
Troubleshooting Code [E-7] (Defective lift arm FLOATING holding function and
cancellation)

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
Trouble FLOATING PPC detent system.
Machine moni-
ler Reaction
Effect on • Lift arm FLOATING holding does not function or cannot be cancelled.
Machine
Related
Information

1 Defective lift arm FLOAT- 3) Connect T-adapter.
ING PPC detent
Possible
Causes and 1) Turn starting switch OFF.
Standard 2) Disconnect connector L35 and fuse FS1 terminal.
2 nuity (Disconnection or Wiring harness between fuse FS1 (13)
defective contact) and L35 (Female) (1) Resistance Max. 1z

20-636 WA150-5
(1)
WA150-5 20-637
(1)
Troubleshooting Code [E-8] (Travel direction is not changed normally)

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

2) Disconnect connector F15
1 Defective directional lever When directional
lever is in "F" Resistance Max. 1z
(1) and (2) When directional
lever is not in "F" Resistance Min. 1Mz

4) Operate parking brake.
The
condition is Relay (L112)
Possible causes When parking brake neutral safety relay abnormal is normal.
and standard (L112) is replaced, does condition become
value in normal normal? The Relay (L112)
state condition is
normal is defective.

2 Defective parking brake 2) Disconnect connector L112.
neutral safety relay (L112) 3) Check relay unit.
between and (1) and (2) Resistance Max. 1z
Between
L112 (male) When normal voltage is
(3) and (5) not applied between and Resistance Min. 1Mz
(1) and (2)
20-638 WA150-5
(1)

The Relay (L108)
condition is is normal.
When forward relay (L108) is replaced, abnormal
does condition become normal? The Relay (L108)
condition is is defective.
normal
3 Defective
(L108)
forward relay 3) Check relay unit.
2) Disconnect connector L108
When 24 V is applied Resistance Max. 1z
Between between and (1) and (2)
(1) and (2)
Possible causes 1) Turn starting switch OFF.
and standard
value in normal 2) Disconnect connector T01.
state 3) Connect T-adapter.
4 Defective forward solenoid
Between T01 (male) (1) and (2) Resistance 30 - 60z
Between T01 (male) (1), (2) and chassis Resistance Min. 1Mz
ground
2) Disconnect connectors T01, L15, L108, and L112 and fuse (FS1).
Wiring harness between L15 (female) (2) Resistance Max. 1z
and L108 (female) (1)
Disconnection in wiring Wiring harness between L108 (female) (2) Resistance Max. 1z
5 harness (Disconnection in and chassis ground
wiring harness or defective
contact) Wiring harness between fuse FS1 (12) Resistance Max. 1z
and T01 (female) (1)
Wiring harness between T01 (female) (2) Resistance Max. 1z
Disconnection in wiring 1) Turn starting switch OFF.
harness (Disconnection in 2) Disconnect connector MF3.
6 wiring harness or defective
contact)
a Disconnection in short Wiring harness between MF3 (male) (1)

Resistance Max. 1z
connector (MF3) and (4)
WA150-5 20-639
(1)

2) Disconnect connectors T01, L15, L22, and L108
Wiring harness Resistance between L15
between L15 (female) (female) (2), L22 (female) (10) Min. 1Mz
(2) and L22 (female)

Possible causes (2) and L108 (female)
and standard (1) and chassis ground
value in normal Grounding fault in wiring
7 harness Wiring harness Resistance between L108
state
between L108 (female) (female) (5), D01 (female) (1) Min. 1Mz
(5) and D01 (female) (1) and chassis ground
between L108 (female) (female) (5), T01 (female) (1) Min. 1Mz
(5) and T01 (female) (1) and chassis ground
Wiring harness Resistance between fuse (FS1)
between fuse (FS1) (12), L15 (female) (1), L108
(12) and L15 (female) (female) (3) and chassis Min. 1Mz
(1), L108 (female) (3) ground
a In all of these cases, the fuse is broken.
20-640 WA150-5
(1)
WA150-5 20-641
(1)
b) When directional lever is set in "R", machine does not travel in reverse
Action Code Error Code Controller Travel direction is not changed normally
Code Trouble b) When directional lever is set in "R", machine
- - - does not travel in reverse
Contents of • The machine does not travel in reverse since the directional lever system, reverse relay system, or
trouble reverse solenoid valve system is defective.
Action of
machine moni- ----
tor
Problem that
appears on • The machine does not travel in reverse.
machine
• If error code "DDK3KB" is displayed to indicate simultaneous input of directional lever FR signals,
carry out the troubleshooting for it first.
Related • When the parking brake lever is pulled, if the parking brake omission caution lamp goes off and the
information
parking brake indicator lamp does not light up, carry out the troubleshooting for "MON-1 Parking
brake indicator lamp does not light up" before carry out the following troubleshooting.

2) Disconnect connector F15
1 Defective directional lever When directional
lever is in "R" Resistance Max. 1z
(1) and (4) When directional
lever is not in "R" Resistance Min. 1Mz

4) Operate parking brake.
The
Possible causes When parking brake neutral safety relay abnormal is normal.
and standard (L112) is replaced, does condition become
value in normal normal? The
state is defective.
normal
2 Defective parking brake 2) Disconnect connector L112.
neutral safety relay (L112) 3) Check relay unit.
(1) and (2)
20-642 WA150-5
(1)

The Relay (L107)
condition is is normal.
When forward relay (L107) is replaced, abnormal
does condition become normal? The Relay (L107)
condition is is defective.
normal
3 Defective reverse relay 1) Turn starting switch OFF.
(L107) 2) Disconnect connector L107
(5) and (6)
Possible causes L107 (male) When normal voltage is
and standard (3) and (4) not applied between and Resistance Min. 1Mz
value in normal (5) and (6)
state
2) Disconnect connector T01.
4 Defective reverse solenoid
Between T01 (male) (3) and (4) Resistance 30 - 60z
Between T01 (male) (3), (4) and chassis Resistance Min. 1Mz
ground
2) Disconnect connectors T01, L15, L107, and L112 and fuse (FS1).
Disconnection in wiring Wiring harness between L107 (female) (6)
harness (Disconnection in Resistance Max. 1z
5 wiring harness or defective and chassis ground
and T01 (female) (3)
Wiring harness between T01 (female) (4) Resistance Max. 1z
Disconnection in wiring 1) Turn starting switch OFF.
harness (Disconnection in 2) Disconnect connector MF3.
6 wiring harness or defective
contact)
a Disconnection in short Wiring harness between MF3 (male) (3) Resistance Max. 1z
connector (MF3) and (6)
WA150-5 20-643
(1)

2) Disconnect connectors T01, L15, L22, and L107
(4) and L22 (female) (8) and chassis ground
Possible causes Wiring harness Resistance between L15

and standard between L15 (female) (female) (4), L107 (female) (5) Min. 1Mz
(4) and L107 (female)
value in normal 7 Grounding fault in wiring (5)
and chassis ground
state harness
between L107 (female) (female) (4), D01 (female) (3) Min. 1Mz
(4) and D01 (female) (3) and chassis ground
Wiring harness Resistance between fuse (FS1)
between fuse (FS1) (12), L15 (female) (1), L107 Min. 1Mz
(12) and L15 (female) (female) (1) and chassis
(1), L107 (female) (1) ground
a In all of these cases, the fuse is broken.

20-644 WA150-5
(1)
Troubleshooting Code [E-9] (The wiper does not function)

a) The rear wiper does not function

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

Between L57 (6) and chassis ground Voltage 20 - 30V
Between L57 (2) and Turn wiper Voltage 20 - 30V
1 Defective rear wiper chassis ground switch Lo.
motor
chassis 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.

chassis ground switch INT
2 Defective wiper timer
Turn wiper
Possible Between L48 (2) and switch Voltage 20 - 30V
Causes and chassis ground WASHER
Standard
Values
Between L48 (5) and chassis ground 20 - 30V o 0V
OV o
(The voltage is output intermittently by Voltage 20 - 30V
wiper switch INT) (Repeated)
Between Turn wiper switch Lo. Resistance Max. 1z
L05
(Male) (7) Other than above. Resistance Min. 1Mz
and (5)
Between Turn wiper switch Hi. Resistance Max. 1z
Defective rear wiper L05
3 (Male) (7) Other than above. Resistance Min. 1Mz
switch and (4)
Between Turn wiper switch INT Resistance Max. 1z
L05
and (2)
Between Turn wiper switch INT Resistance Max. 1z
L05
and (5)
WA150-5 20-645
(1)

2) Disconnect connector L05, L48, L57 and fuse FS1 terminal.

defective contact) (4) and L57 (Female) (1) Resistance Max. 1z



2) Disconnect connector L05, L48, L52, L57 and fuse FS1 terminal.
Possible Resistance between L05
Causes and Wiring harness between (Female) (2), L48
Standard L05 (Female) (2) and L48 (Female) (4) and chassis Min. 1Mz
Values (Female) (4) ground
(Female) (5) ground
(Female) (2) ground
Wiring harness ground Resistance between L05
5 fault Wiring harness between (Female) (4), L57
(Female) (1) ground
(Female) (5) ground
(Female) (7) ground
(Female) (3) ground
(Female) (6) ground
20-646 WA150-5
(1)
WA150-5 20-647
(1)
b) The rear wiper does not function

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

1 Defective rear wiper Between L52 (2) and Turn wiper
motor Voltage 20 - 30V
chassis 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.

Possible Between Turn wiper switch Lo. Resistance Max. 1z
Causes and 2 Defective rear wiper L05 (Male)
Standard switch (7) and (9) Other than above. Resistance Min. 1Mz
Values
Between Turn wiper switch OFF. Resistance Max. 1z
L05 (Male)
(8) and (9) Other than above. Resistance Min. 1Mz
2) Disconnect connector L05, L52 and fuse FS1 terminal.


20-648 WA150-5
(1)

2) Disconnect connector L05, L48, L52, L57 and fuse FS1 terminal.

ground
Possible
Causes and Wiring harness between Resistance between L05
Standard Wiring harness ground L05 (Female) (9) and L52 (Female) (9), L52 Min. 1Mz
4 (Female) (2) and chassis
Values fault (Female) (2)
ground
(Female) (7) ground
(Female) (4) ground
a In the all above cases, the fuse is blown.
WA150-5 20-649
(1)
Troubleshooting Code [E-10] (The window washer does not function)

Code Trouble The window washer does not function
- - -
Description of • The window washer does not function due defective window washer motor, switch, timer (Front
Trouble only) or wiring harness.
Machine moni-
ler Reaction
Effect on • The window washer does not function.
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector R25, R26.
• Front washer motor
1 Defective window washer
motor Between R25 (1) and chassis ground Voltage 20 - 30V
• Rear washer motor
Between R26 (1) and chassis ground Voltage 20 - 30V
• Common to front switch and rear switch.
Possible Between L05 (Male) (7) and chassis

ground Voltage 20 - 30V
Causes and
Standard
• Front switch
Between Turn washer switch ON. Resistance Max. 1z
2 Defective wiper switch L05
(Male) (7) Turn washer switch OFF. Resistance Min. 1Mz
and (6)
• Rear switch
Between Turn washer switch ON. Resistance Max. 1z
L05
(Male) (7) Turn washer switch OFF. Resistance Min. 1Mz
and (10)
Turn washer
Between L05 (Male) (7) and wiper Resistance Max. 1z
and (9), (10) low switch
ON.
20-650 WA150-5
(1)

Wiring harness between L48 (3) and Voltage 20 - 30V
chassis ground
3 Defective wiper timer Wiring harness between
(Relay) Turn washer
L48 (2) and chassis switch ON. Voltage 20 - 30V
ground
Wiring harness between L48 (5) and
chassis ground Voltage 20 - 30V
(0.2 to 0.8 sec. after the washer switch
was turned ON)
2) Disconnect connector L05, L48, R25, R26 and fuse FS1 terminal.
• Front side
(6) and R25 (Female) (1) Resistance Max. 1z

Wiring harness disconti- (6) and L48 (Female) (2)
• Rear side

(10) and R26 (Female) (1)
Possible
Causes and • Common to front and rear side.
Standard
Values Wiring harness between fuse FS1 (14)

2) Disconnect connector L05, L48, L52, L57, R25, R26, D10, D13 and
fuse FS1 terminal.
• Front side

L05 (Female) (6) and (Female) (6), R25 (Female) Min. 1Mz
R25 (Female) (1) (1) and chassis ground
L05 (Female) (6) and (Female) (6), L48 (Female) Min. 1Mz
L48 (Female) (2) (2) and chassis ground
Wiring harness ground L05 (Female) (3) and (Female) (7), L48 (Female) Min. 1Mz
5 fault L48 (Female) (5) (5) and chassis ground
• Rear side

Wiring harness between (Female) (10), R26
R26 (Female) (1) ground
• Common to front and rear side.

(Female) (7) ground
a In the all above cases, the fuse is blown.
WA150-5 20-651
(1)
20-652 WA150-5
(1)
Troubleshooting Code [E-11] (Lamps do not work properly)

a) Neither high beam nor low beam of headlamp light up
Action Code Error Code Controller 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 har-
Trouble ness (Ground fault) in the head lamp system.
Machine moni-
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
Related fuse and relay, between fuse and lamp)
Information
• When circuits for other lamp systems are normal

2) Disconnect connector HEAD L, HEAD R.
Between
HEAD L (3) Turn lamp switch STEP 2
and chas- and dimmer switch Lo. Voltage 20 - 30V
sis ground
Between
HEAD L (3) Turn lamp switch STEP 2
and chas- and dimmer switch Hi. Voltage 20 - 30V
1 Defective head lamp sis ground
Between
HEAD R
(3) and Turn lamp switch STEP 2 Voltage 20 - 30V
chassis and dimmer switch Lo.
Possible ground
Causes and
Standard Between
Values HEAD R Turn lamp switch STEP 2
(3) and Voltage 20 - 30V
chassis and dimmer switch Hi.
ground
Turn lamp switch OFF. Resistance Min. 1Mz
Between
L04 (Male) Turn lamp switch 1 STEP. Resistance Min. 1Mz
Defective lamp switch (2) and (3)
2 Turn lamp switch STEP 2. Resistance Max. 1z
and dimmer switch
Between Turn dimmer switch Lo. Resistance Max. 1z
L04 (Male)
(4) and (3) Turn dimmer switch Hi. Resistance Min. 1Mz
Between Turn dimmer switch Lo. Resistance Min. 1Mz
L04 (Male)
(5) and (3) Turn dimmer switch Hi. Resistance Max. 1z
WA150-5 20-653

Does condition become Condition is abnormal. Relay L120
normal when the head- is normal.
lamp relay (left) L120 is
relay? relay L120.
Defective head lamp
3 relay (Left side) (L120) Between L120 (Male) (1) and (2) Resistance 200 - 400z
L120 (Male) (1) - (2)
(2)

normal when headlamp is normal.
relay L119 is replaced Defective
with normal relay? Condition is normal. relay L119.
4 Defective head lamp Between L119 (Male) (1) and (2) Resistance 200 - 400z
Possible relay (Right side) (L119)
Standard 3) Solid part check.
Values 4) Applies impressed voltage between L119 (Male) (1) - (2)
L119 (Male) (1) - (2)
(2)
2) Disconnect connector L04, L120, L119, HEAD L, and fuse FS1 ter-
minal (8), (9). 3) Connect T-adapter.
(5) and HEAD L (Female) (3)
Wiring harness between fuse FS1 termi- Resistance Max. 1z
nal (8) and L120 (Female) (1), (3)
Wiring harness disconti- (2) and L04 (Female) (2)
5 nuity (Disconnection or
defective contact) 1) Turn starting switch OFF.
2) Disconnect connector L04, L119, HEAD R, and fuse FS1 terminal
(9). 3) Connect T-adapter.
(5) and HEAD R (Female) (3)
Wiring harness between fuse FS1 termi- Resistance Max. 1z
nal (9) and L119 (Female) (1), (3)
20-654 WA150-5
(1)
WA150-5 20-655
(1)
b) Head lamp (Lo beam) does not light ON

Code Trouble Each lamps does not function
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
Trouble fault) in the head lamp system.
Machine moni-
ler Reaction
Effect on • Head lamp (Lo beam) does not light ON when the lamp switch is turned STEP 2.
Machine
Related fuse and lamp)
Information

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

(4) and HEAD R (Female) (1) Resistance Max. 1z

a See "TROUBLESHOOTING CODE [E-10.(a)]".
20-656 WA150-5
(1)
c) Head lamp (Hi beam) does not light ON

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
Trouble fault) in the head lamp system.
Machine moni-
ler Reaction
Effect on • Head lamp (Hi beam) does not light ON when the lamp switch is turned STEP 2.
Machine
Information

Between
HEAD L (3) Turn lamp switch STEP 2 Voltage 20 - 30V
and chas- and dimmer switch Hi.
Between
HEAD R Turn lamp switch STEP 2
chassis and dimmer switch Hi.
ground
Possible Turn lamp switch OFF. Resistance Min. 1Mz
Causes and Between
Standard L04 (Male) Turn lamp switch 1 STEP. Resistance Min. 1Mz
Values Defective lamp switch (2) and (3)
and dimmer switch
L04 (Male)
L04 (Male)
2) Disconnect connector L04, HEAD L, HEAD R.
3 nuity (Disconnection or (5) and J03 (4), (2) and HEAD L Resistance Max. 1z
defective contact) (Female) (2)
(5) and J03 (4), (2) and HEAD R Resistance Max. 1z
(Female) (2)

WA150-5 20-657
(1)
d) Clearance lamp (Small lamp) does not light ON

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
Trouble (Ground fault) in the clearance lamp system.
Machine moni-
ler Reaction
Effect on • Clearance lamp (Small lamp) does not light ON when the lamp switch is turned STEP 1.
Machine
Information

Between
HEAD L (5) Turn lamp switch STEP 1. Voltage 20 - 30V
and chas-
1 Defective clearance lamp sis ground
Between
HEAD R
(5) and Turn lamp switch STEP 1. Voltage 20 - 30V
chassis
ground
2 Defective lamp switch Turn lamp switch OFF. Resistance Min. 1Mz
Between
L04 (Male) Turn lamp switch STEP 1. Resistance Max. 1z
Possible (2) and (3)
Causes and Turn lamp switch STEP 2. Resistance Max. 1z
Standard
Values 1) Turn starting switch OFF. 2) Replace relay L117 with normal relay.
Does condition become Relay L117
normal when small lamp Condition is abnormal. is normal.
relay (left) L117 is
relay? relay L117.
Defective small lamp 3) Solid part check.
relay (Left side) (L117)
a When left side is
defective 1) Turn starting switch OFF. 2) Disconnect connector L117.
L117 (Male) (1) - (2)
(2)
20-658 WA150-5
(1)

normal when small lamp is normal.
relay (right) L118 is
relay? relay L118.
Defective small lamp 3) Solid part check.
relay (Right side) (L118)
a When right side is
defective 1) Turn starting switch OFF. 2) Disconnect connector L118.
L118 (Male) (1) - (2)
(2)
2) Disconnect connector L04, L117, L118, HEAD L, and fuse FS2
terminal (10), (11).
Causes and Wiring harness between L04 (Female)
Standard (3) and chassis ground Resistance Max. 1z
Values
(5) and J10 (9), (10) and HEAD L Resistance Max. 1z
(Female) (5)
and L117 (Female) (1), (3)
Wiring harness disconti- Wiring harness between HEAD L Resistance Max. 1z

5 nuity (Disconnection or (Female) (4) and chassis ground
defective contact) 1) Turn starting switch OFF.
2) Disconnect connector L04, L118, HEAD R and fuse FS2 terminal
(11).
(5) and HEAD R (Female) (5)
and L118 (Female) (1), (3)
Wiring harness between HEAD R Resistance Max. 1z

WA150-5 20-659
(1)
e) Turn signal lamp does not blink

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
Trouble the turn signal lamp system.
Machine moni-
ler Reaction
Effect on • Turn signal lamp does not blink
Machine
Information

Turn turn-signal switch
Between RIGHT. Resistance Max. 1z
Defective turn-signal L04 (Male)
1 switch (6) and (7) Turn turn-signal switch Resistance Min. 1Mz
LEFT.
Turn turn-signal switch
Between RIGHT. Resistance Max. 1z
Possible L04 (Male)
Causes and (6) and (8) Turn turn-signal switch Resistance Min. 1Mz
Standard LEFT.
Between Turn hazard switch OFF. Resistance Max. 1z
L06 (Male)
(1) and (2),
or (4) and Turn hazard switch ON. Resistance Min. 1Mz
2 Defective hazard switch (5)
Between Turn hazard switch OFF. Resistance Max. 1z
L06 (Male)
(3) and (2),
or (6) and Turn hazard switch ON. Resistance Min. 1Mz
(5)
20-660 WA150-5
(1)

2) Disconnect connector L04, L119, L120, HEAD L, HEAD R and fuse
FS1 terminal (8), (9).
a When both sides are defective (in this case, headlamp also does
not light up)

a When left side is defective
(8) and J03 (10), (6) and HEAD L Resistance Max. 1z
(Female) (6)
Wiring harness between HEAD L
(Female) (4) and chassis ground Resistance Max. 1z

(8) and J03 (10), (9) and R22 (Female) Resistance Max. 1z
(1)
Wiring harness between J01 (Female) Resistance Max. 1z

(17) and D14 (2), (1) and J03 (7)
a When right side is defective
(7) and J03 (20), (16) and HEAD R Resistance Max. 1z
Possible (Female) (6)
Causes and Wiring harness disconti- Wiring harness between HEAD R
Standard 3 nuity (Disconnection or (Female) (4) and chassis ground Resistance Max. 1z
(7) and J03 (20), (19) and R23 (Female) Resistance Max. 1z
(1)
Wiring harness between J01 (Female) Resistance Max. 1z

(20) and D11 (2), (1) and J03 (17)
a When both sides are defective

and J10 (4), (1) and L06 (Female) (1)
(2) and L49 (Female) (B)
(E) and chassis ground
(L) and J01 (Female) (6)
(6) and J01 (Female) (4)
a When hazard switch does not function

(5) and J01 (Female) (4)
(6) and J01 (Female) (18) Resistance Max. 1z

WA150-5 20-661
(1)
f) Working lamp does not light ON

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
Trouble the clearance lamp system.
Machine moni-
ler Reaction
Effect on • Working lamp does not light ON.
Machine
Information • When circuits for other lamp systems are normal
• When side lamps do not light up, carry out troubleshooting first for side lamp system.

2) Disconnect connector C05, C06, B01 or B02.
6) Turn small lamp switch ON.
Between Turn front working lamp Voltage 20 - 30V
C05 (1) switch ON.
and chas- Turn front working lamp
sis ground switch OFF. Voltage Max. 1V
Between Turn front working lamp Voltage 20 - 30V

C06 (1) switch ON.
1 Defective working lamp and chas- Turn front working lamp
Between Turn rear working lamp Voltage 20 - 30V

Possible B01 (1) switch ON.
Causes and and chas- Turn rear working lamp
Standard sis ground switch OFF. Voltage Max. 1V
Values
Between Turn rear working lamp Voltage 20 - 30V
B02 (1) switch ON.
and chas- Turn rear working lamp

Turn front working lamp Resistance Max. 1z
Between switch ON.
L07 (Male)
Defective working lamp (2) and (3) Turn front working lamp
2 switch switch OFF. Resistance Min. 1Mz
Turn rear working lamp Resistance Max. 1z

Between switch ON.
L08 (Male)
(2) and (3) Turn rear working lamp
switch OFF. Resistance Min. 1Mz
20-662 WA150-5
(1)

1) Turn starting switch OFF.2) Replace relay L122 with normal relay.
Does condition become Relay L122
normal when working Condition is abnormal. is normal.
lamp relay L122 is
relay? relay L122.
3 Defective working lamp Between L122 (Male) (5) and (6) Resistance 200 - 400z
relay (L122)
L122 (Male) (5) - (6)
(6)
2) Disconnect connector L04, L119, L120, HEAD L, HEAD R and fuse
FS1 terminal (8), (9).
3) Connect T-adapter. 4) When small lamp (L•H) is normal.
a When all lamps are defective
Possible
Causes and Wiring harness between L117 (Female) Resistance Max. 1z
Standard (5) and L122 (Female) (1)
Values
a When front lamps are defective

defective contact) (3) and C05 (Female) (1), C06 (Female) Resistance Max. 1z
(1)
Wiring harness between C05 (Female)
(2), C06 (Female) (2) and chassis Resistance Max. 1z
ground
a When rear lamps are defective

(3) and B01 (Female) (1), B02 (Female) Resistance Max. 1z
(1)
Wiring harness between B01 (Female)
(2), B02 (Female) (2) and chassis Resistance Max. 1z
ground

WA150-5 20-663
(1)
Troubleshooting Code [E-12] (The horn does not sound)

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

Between Push horn switch ON Resistance Max. 1z
1 Defective horn switch L13 (Male)
(1) and
chassis Horn switch OFF Resistance Min. 1Mz
ground
Between L116 (1), (3) and chassis ground Voltage 20 - 30V
Between L116 (2) and Horn switch Voltage 20 - 30V
chassis ground OFF
Between L116 (2) and Push horn
chassis ground switch ON Voltage Max. 1V
Between L116 (5) and Push horn Voltage 20 - 30V

chassis ground switch ON

Possible Causes normal when horn and is normal.
and Standard 2 Defective horn relay (L116) lamp relay L116 is replaced
Values Defective
with normal relay? Condition is normal. relay L116.
L116 (Male)
(2)
1) Turn starting switch OFF. 2) Disconnect connector F01, F02.
3) Insert T-adapter. 4) Connect T-adapter. 5) Turn starting switch ON.
Between Push horn switch ON Voltage 20 - 30V
F01 (Male)
3 Defective horn (1) and (2) Horn switch OFF Voltage Max. 1V
Between Push horn switch ON Voltage 20 - 30V
F02 (Male)
(1) and (2) Horn switch OFF Voltage Max. 1V
20-664 WA150-5
(1)

2) Disconnect connector L05, L52 and fuse FS1 (9) terminal.
L116 (Female) (1), (3)
Wiring harness discontinu-
4 ity (Disconnection or Wiring harness between L116 (Female) Resistance Max. 1z
(5) and F01 (Female) (1), F02 (Female) Resistance Max. 1z
(1)
(2), F02 (Female) (2) and chassis ground
Possible Causes
and Standard 1) Turn starting switch OFF.
Values 2) Disconnect connector L116, F01, F02 and fuse FS2 (9) terminal.
fuse FS2 (9) and L116 FS2 (9), L116 (Female) (1), Min. 1Mz
(Female) (1), (3) *1 (3) and chassis ground
5 Wiring
fault
harness ground L116 (Female) (2) and L13 (Female) (2), L13 (Female) Min. 1Mz
(Female) (1) *2 (1) and chassis ground
L116 (Female) (5) and F01 (Female) (5), F01 (Female) Min. 1Mz
(Female) (1), F02 (Female) (1), F02 (Female) (1) and
(1) chassis ground
a In case of *1 above, fuse is blown
a In case of *2 above, horn does not stop sounding
WA150-5 20-665
(1)
Troubleshooting Code [E-13] (Defective the air conditioner)

a) The air conditioner does not work

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

2) Disconnect connector C03, fuse FS2 terminal.
Causes and 1 nuity (Disconnection or Wiring harness between fuse FS2 (2) Resistance Max. 1z
Standard defective contact) and C03 (Female) (8)
Values Wiring harness between C03 (Female) Resistance Max. 1z
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or
2
control panel replace.
20-666 WA150-5
(1)
WA150-5 20-667
(1)
b) Air does not flow out or amount of air cannot be adjusted.
Action Code Error Code Controller 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-
ler Reaction
Effect on • Air does not flow out or amount of air cannot be adjusted.
Machine
Related
Information

2) Disconnect connector A09, A10, A11, A13 and fuse FS2 terminal.
and A09 (Female) (1)
Power supply wiring har- Wiring harness between fuse FS2 (2)
ness discontinuity (Dis- Resistance Max. 1z
1 and A10 (Female) (1)
connection or defective
2) Disconnect connector C03, A09, A10, A11, A12 and fuse FS2 ter-
minal.
Wiring harness between C03 (Female) Resistance Max. 1z
Possible (7) and A09 (Female) (2)
Causes and Wiring harness between C03 (Female) Resistance Max. 1z
Standard (4) and A10 (Female) (2)
Values Wiring harness between C03 (Female)
(5) and A11 (Female) (2) Resistance Max. 1z
(6) and A13 (Female) (2)
Wiring harness between A09 (Female) Resistance Max. 1z
Wiring harness disconti- (4) and A01 (Female) (6)
2 nuity (Disconnection or Wiring harness between A10 (Female)
defective contact) (4) and A01 (Female) (5) Resistance Max. 1z
20-668 WA150-5
(1)

2) Disconnect connector A01, A05, A09, A10, A11,A12, A13, C03 and
fuse FS2 terminal.
fuse FS2 (2) and A09 FS2 (2), A09 (Female) (1) Min. 1Mz
fuse FS2 (2) and A11 FS2 (2) and A11 (Female) Min. 1Mz
(Female) (1) * (1) and chassis ground
fuse FS2 (2) and A12 FS2 (2), A12 (Female) Min. 1Mz
(Female) (1), (4) * (1), (4) and chassis
ground
ground
Wiring harness between Resistance between C03
C03 (Female) (7) and A09 (Female) (7), A09 Min. 1Mz
Possible ground
Causes and
Standard Wiring harness ground Wiring harness between Resistance between C03
3 fault (Female) (4), A10
Values C03 (Female) (4) and A10 Min. 1Mz
ground
ground
ground
Wiring harness between Resistance between A09
A09 (Female) (4) and A01 (Female) (4), A01 Min. 1Mz
ground
ground
ground
ground
A05 (Female) (2) and C03 (Female) (2), C03 Min. 1Mz
ground
a If marked * above, fuse is blown
WA150-5 20-669
(1)

1) Turn starting switch OFF. 2) Replace relay A09 with normal relay.
3) Turn starting switch ON. 4) Start air conditioner
Defective blower main Does condition become Condition is normal. Defective
4 relay A09 relay.
normal when relay is
replaced with normal Relay is
relay? Condition is abnormal.
normal.
Defective blower Hi relay Does condition become Condition is normal. Defective
5 A10 relay.
normal.
Defective blower M2 Does condition become Condition is normal. Defective
6 relay A11 relay.
Possible relay? Condition is abnormal.
normal.
Causes and
Standard 1) Turn starting switch OFF. 2) Replace relay A13 with normal relay.
Values 3) Turn starting switch ON. 4) Start air conditioner
Defective blower M1 Does condition become Condition is normal. Defective
7 relay A13 relay.
normal.
1) Turn starting switch OFF. 2) Replace motor with normal motor.
Does condition become Condition is normal. Defective
8 Defective blower motor motor.
normal when motor is
motor? Condition is abnormal.
motor.
1) Turn starting switch OFF. 2) Disconnect connector A01.
9 Defective blower resister Between A01 (Female) (1) and (3) Resistance 2.8z
Between A01 (Female) (1) and (4) Resistance 4.8z
Between A01 (Female) (1) and (5) Resistance 4.0z
a Check the control panel, and if any abnormality is found, repair or
10 Defective air conditioner

20-670 WA150-5
(1)
c) Does not cool or temperature cannot be adjusted.

Code Trouble c) Does not cool or temperature cannot be
- - - adjusted.
Description of • Does not cool or temperature cannot be adjusted.

Trouble
Machine moni-
ler Reaction
Effect on • Does not cool or temperature cannot be adjusted.
Machine
Related
Information

2) Disconnect connector A12, A15 and fuse FS2 terminal.
Power supply wiring har- 3) Connect T-adapter.
1 ness discontinuity (Dis- Wiring harness between fuse FS2 (2)
connection or defective and A12 (Female) (1), (4) Resistance Max. 1z
contact)
and A15 (Female) (1), (4)
2) Disconnect connector A02, A03, A05, A07, A08, A12, A15, B04,
C03, C04 and J06.
(2) and C03 (Female) (4)
(3) and B04 (Female) (2)
Wiring harness between A05 (Female)
(4) and A12 (Female) (2), A15 (Female) Resistance Max. 1z
(2)
Possible Wiring harness between A12 (Female) Resistance Max. 1z
Causes and (3) and B04 (Female) (1)
Standard Wiring harness between A15 (Female)
Values (3) and E16 (Female) (1) Resistance Max. 1z
Wiring harness between B04 (Female)
Wiring harness disconti- (3) and chassis ground Resistance Max. 1z
2 nuity (Disconnection or
defective contact) Wiring harness between compressor
magnet clutch (-) terminal and chassis Resistance Max. 1z
ground
Wiring harness between C03 (Female)
(16) and A03 (Female) (2) Resistance Max. 1z
(1) and J06 (16), (15) and C03 (Female) Resistance Max. 1z
(12)
(1) and J06 (16), (15) and A02 (Female) Resistance Max. 1z
(4)
(1) and C03 (Female) (9) Resistance Max. 1z
WA150-5 20-671
(1)

2) Disconnect connector A02, A03, A05, A12, A15, B04, C03, C04,
E16 and fuse FS2 terminal.
FS2 (2), A12 (Female)
fuse FS2 (2) and A12 (1), (4) and chassis Min. 1Mz
(Female) (1), (4) * ground
ground
(Female) (3), B04
A05 (Female) (3) and B04 (Female) (2) and chassis Min. 1Mz
(Female) (2) * ground
(Female) (4), A12
(Female) (2), A15 (Female) (2) and chassis
(Female) (2) ground
A12 (Female) (3) and B04 (Female) (3), B04 Min. 1Mz
ground
Resistance between A15
Wiring harness between (Female) (3), E16
A15 (Female) (3) and E16 (Female) (1) and chassis Min. 1Mz
(Female) (1) ground
Wiring harness ground Resistance between C03
Possible C03 (Female) (16) and (Female) (16), A03 Min. 1Mz
Causes and (Female) (2) and chassis
A03 (Female) (2) ground
Standard
Values Wiring harness between Resistance between A03
A03 (Female) (1) and J06 (Female) (1), C03 Min. 1Mz
(16), (15) and C03 (Female) (12) and chassis
(Female) (12) ground
A03 (Female) (1) and J06 (Female) (1), A02 Min. 1Mz
(16), (15) and A02 (Female) (4) and chassis
(Female) (4) ground
(Female) (9) ground
ground
(Female) (5), C03
A02 (Female) (5) and C03 (Female) (15) and chassis Min. 1Mz
(Female) (6), C04
(Female) (3) ground
a If marked * above, fuse is blown
Defective compressor Does condition become Defective
4 Condition is normal. relay.
clutch relay A15 normal when relay is
interchanged with normal Relay is
normal.
20-672 WA150-5
(1)

1) Turn starting switch OFF. 2) Disconnect connector A05.
Defective pressure Turn air conditioner
5 switch OFF. Resistance Min. 1Mz
switch Between
A05 (Male) When air conditioner
(1) and (2) switch is ON and cooling Resistance Max. 1z
is in operation
1) Turn starting switch OFF. 2) Disconnect connector ACTH.
3) Turn starting switch ON. 4) Start air conditioner.
6 Defective thermister Temperature: 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.
Defective temperature Does condition become Defective
7 Condition is normal. motor.
control servo motor normal when servo motor
Possible is interchanged with nor- Motor is
Causes and mal motor? Condition is abnormal.
normal.
Standard
2) Replace compressor with normal compressor.
Defective
air condi-
Defective air conditioner Does condition become Condition is normal. tioner com-
8 compressor normal when air condi- pressor.
tioner compressor is
replaced with normal Air condi-
compressor? Condition is abnormal. tioner com-
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
Condition is abnormal.
is normal.
10 control panel replace.

WA150-5 20-673
(1)
d) Impossible to switch between recirculated air and fresh air

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
Trouble air
Machine moni-
ler Reaction
Effect on • Impossible to switch between recirculated air and fresh air
Machine
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector C04, L51.
Wiring harness disconti- Wiring harness between C04 (Female)
1 nuity (Disconnection or (1) and L51 (Female) (2) Resistance Max. 1z
defective contact)
Possible 1) Turn starting switch OFF. 2) Disconnect connector C04, L51.

Standard Resistance between C04
Values Wiring harness between
C04 (Female) (1) and L51 (Female) (1), L51 Min. 1Mz
2 Wiring harness ground (Female) (2) (Female) (2) and chassis
fault ground

C04 (Female) (2) and L51 (Female) (2), L51 Min. 1Mz
ground
3 control panel replace.

20-674 WA150-5
(1)
e) Impossible to switch vents

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

2) Disconnect connector A03, A07, A08, C03, C04, J06.
Wiring harness between A07 (Female) (1)
and C03 (Female) (1) Resistance Max. 1z


Possible Wiring harness between A07 (Female) (8)

Causes and Wiring harness disconti-
Standard 1 nuity (Disconnection or Wiring harness between A08 (Female) (1)
Values defective contact) and C04 (Female) (5) Resistance Max. 1z




and J06 (16), (14) and A07 (Female) (6) Resistance Max. 1z

and J06 (16), (14) and A08 (Female) (6) Resistance Max. 1z
WA150-5 20-675
(1)

2) Disconnect connector ACP1, ACP2, ACM2. 3) Connect T-adapter.

A07 (Female) (1) and C03 (Female) (1), C03
(Female) (1) and chassis Min. 1Mz
(Female) (1)
ground

(Female) (2) ground
Wiring harness between (Female) (3), C04

(Female) (8), C03

Possible 2 Wiring harness ground (Female) (5)
Causes and fault ground
Standard Resistance between A08
Values Wiring harness between (Female) (2), C04
(Female) (6) ground
Wiring harness between (Female) (3), C04

(Female) (14)
ground
A03 (Female) (1) and J06 (Female) (1), A07
(16), (14) and A07 (Female) (6) and chassis Min. 1Mz
(Female) (6) ground
A03 (Female) (1) and J06 (Female) (1), A08
(16), (14) and A08 (Female) (6) and chassis Min. 1Mz
(Female) (6) ground
3

20-676 WA150-5
(1)
f) Defective cooling (Mechanical system)

Code Trouble Air conditioner is defective
f) Defective cooling (Mechanical system)
- - -
Description of • Cooling is defective because of abnormality in the mechanical system.
Trouble
Machine moni-
ler Reaction
Effect on • Cooling is defective because of abnormality in the mechanical system.
Machine
Related
Information

Gas leakage from pipe • Check. If abnormality is detected, repair or replace.
1 joint or piping part
Natural leakage from
hoses, etc. (Refrigerant • Check quantity of refrigerant. If insufficient, add proper amount of
2 has not been added for refrigerant.
long period)
3 Insufficient charge with • Charge with refrigerant to proper level.

refrigerant
• Check. If abnormality is detected, repair or replace.
4 Defective expansion a Check that the valve is not opened too wide. Check thermometer
valve
tube for defective contact.
5 Clogging of low-pressure • Check. If any part is clogged, repair or replace.

circuit or evaporator
Clogging of evaporator • Check. If evaporator fins are clogged, clean them.
6 fins
Possible
Causes and 7 Clogging of filter • Check, then clean or replace.
Standard
Values 8 Defective installation of • Check. If abnormality is detected, repair or replace.
thermistor
9 Air leakage from air con- • Check. If leakage is detected, repair or replace.
ditioner unit or duct joint
10 Insufficient set air flow • Increase the set air flow.
• Check quantity of refrigerant. If it is too much, reduce it to proper
11 Overcharging
erant
with refrig-
level.
• Evacuate the system, then charge it with proper quantity of refrig-
12 Air in system
erant and replace receiver drier.
Clogging of condenser • Check. If condenser fins are clogged, clean them.
13 fins
14 Defective compression
by compressor
• Check. If abnormality is detected, repair or replace.
• Evacuate the system, then charge it with proper quantity of refrig-

15 Water
cuit
in refrigerant cir-
erant and replace receiver drier.

WA150-5 20-677
(1)
g) Defective heating (Defective hot-water circuit)

g) Defective heating (Defective hot-water circuit)
- - -
Description of • Heating is defective (The hot-water circuit is defective).
Trouble
Machine moni-
ler Reaction
Effect on • Heating is defective (The hot-water circuit is defective).
Machine
Related • Check that water is not leaking from the hot-water circuit
Information • Check that air is blowing out of the air outlet.

• Check. If heater core fins are clogged, clean them.
1 Clogging of heater core a If this item is the cause, both temperatures at the heater core hot-
fins water inlet and outlet are high.
• Check. If leakage is detected, repair or replace.
2 Air leakage from air con- a If this item is the cause, both temperatures at the heater core hot-
ditioner unit water inlet and outlet are high.
Possible • Check. If clogging or defect is detected, repair or replace.
Causes and Defective waste valve a If this item is the cause, the temperatures at the heater core hot-
Standard 3 (Clogging or defect in water inlet is high and that at the heater core hot-water outlet is
Values valve) low.
• Check. If clogging is detected, repair or replace.
4 Clogging in heater core a If this item is the cause, the temperatures at the heater core hot-
water inlet is high and that at the heater core hot-water outlet is
low.
• Check. If clogging is detected, repair or replace.
5 Clogging up to heater a If this item is the cause, the temperatures at the heater core hot-
core hot-water inlet water inlet is low.
20-678 WA150-5
(1)
h) Abnormal sound comes out

h) Abnormal sound comes out
- - -
Description of • Abnormal sound comes out.
Trouble
Machine moni-
ler Reaction
Effect on • Abnormal sound comes out.
Machine
Related
Information

Defective installation of • Check. If abnormality is detected, repair.
1 case bolts (screws)
2 Interference of fan case • Check. If abnormality is detected, repair or replace.

or breakage of fan
Foreign matter in blower • Check. If abnormality is detected, remove foreign matter and
Possible 3 motor or defective blower
motor repair or replace.
Causes and
Standard • Check. If abnormal sound (blowing or leaking sound) comes out,
Values 4 Defective expansion
valve replace valve.
Looseness or wear of • Check. If looseness or wear is detected, repair or replace.
5 compressor V-belt
6 Improper quantity of • Check quantity of refrigerant, then adjust it properly, if necessary.

refrigerant
7 Defective compressor • Check. If abnormality is detected, repair or replace.
WA150-5 20-679
(1)
i) Water leaks

i) Water leaks
- - -
Description of • Water leaks.
Trouble
Machine moni-
ler Reaction
Effect on • Water leaks.
Machine
Related
Information

Clogging of water drain
1 opening in air condi- • Check. If abnormality is detected, repair.
tioner unit
Clogging, bend, defective
installation, or hole of • Check. If abnormality is detected, repair or replace.
2 drain hose of air condi-
tioner unit
Possible
Causes and 3 Breakage (Cracking) of • Check. If breakage (cracking) is detected, repair or replace.
Standard air conditioner unit case
Values
Defective mounting bolt
4 (screw) of air conditioner • Check. If abnormality is detected, repair or replace.
unit case
Defective joint of hot- • Check. If abnormality is detected, repair or replace.
5 water circuit piping
6 Defective heater core • Check. If abnormality is detected, repair or replace.
7 Defective water valve • Check. If abnormality is detected, repair or replace.
20-680 WA150-5
(1)
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
Method of using troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
Error 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
H-27 The travel damper does not operate and machine pitches and bounces . . . . . . . . . . . . . . . . . . . . . 20-724
WA150-5 20-701
(1)
TROUBLESHOOTING 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
troubleshooting swiftly.
Step 1. Ask operator questions 2) Find the matching cause in the Causes col-
The questions to ask the operator are given umn.
under the problem. If the answer to the question If a problem is found, the Q marks on the
matches the content given, the cause given after same line as the troubleshooting are the
the arrow is the probable cause. causes. (In Troubleshooting item 2 in the
Keeping the content of the questions in mind, same diagram on the right the cause is c or
read the matrix and proceed with Step 2 and e.)
Step 3 to pinpoint the correct cause. When there is one Q mark
Carry out troubleshooting for the other items
Example: Steering wheel will not turn marked with Q in the same Causes column
Ask the operator and check the following points. to check if the problem occurs, then make
• Did the problem suddenly start? repairs.
o Broken part in steering equipment When there are two Q marks
Go to Step 3) to narrow down the cause.
• Was the steering wheel heavy before?
o Internal wear, defective seal in steering 1. Steering wheel does not turn i Problem
related equipment (example)
Ask the operator the following questions.
Step 2. Checks before troubleshooting • Did the problem suddenly start?
Before measuring the oil pressure or starting the Yes = Equipment related to steering broken
troubleshooting, confirm the checks before start- • Was there previously any symptom, such as heavi-
ing items, check for leakage of oil, or for loose ness of the steering wheel?
bolts. Yes = Wear of equipment related to steering, defec-
This will prevent wasting time when trouble- tive seal
shooting.
The items given under Checks before trouble- Checks before troubleshooting (example)
shooting are checks that are particularly impor- • Is the oil level in the hydraulic tank correct? Is the
tant to make about the condition of the machine type of oil correct?
before starting the actual troubleshooting. • Is there any leakage of oil from the steering valve or
Orbit-roll?
Example: Checks before starting troubleshooting • Has the safety bar been removed from the frame?
• Is oil level and type of oil in hydraulic tank
correct? <Example 1>
• Is there any oil leakage from steering valve No. Problems Remedy
or demand valve?
• Is steering linkage adjusted properly? 1 Steering wheel does not turn in either direction
(left and right)
2 In Item 1, movement of work equipment is abnormal
Step 3. Method of reading matrix
1) Operate the machine when carrying out 3 Steering wheel turns only in one direction (left or right)
troubleshooting of the items in the Trouble- 4 Steering wheel is heavy and does not turn
shooting column. If any problems occur as
the result of the troubleshooting, put a check <Example 2>
against the item. Cause
a When carrying out the troubleshooting, a b c d e
check the easier items first. It is not nec- Remedy E
essary to follow the number order. X C A X
Problems X
1 Q Q Q Q
2 q q
3 Q Q
4 Q Q
5 Q Q
20-702 WA150-5
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART
3) Operate the machine and carry out trouble-

shooting of the items not checked in Step 1).
Operate the machine in the same way as in Cause
Step 1), and if any problem occurs, put a a b c d e
check against the item. (In Troubleshooting
Remedy E
item 5 in the diagram on the right, the prob- X C A X
lem was re-enacted.) Problems X
4) Find the matching cause in the cause col- 1 Q Q Q Q
umn.
o 2 q q
In the same way as in Step 2), if a problem is
found, the Q marks on the same line for the 3 Q Q
troubleshooting item are the causes. (In 4 Q Q
Troubleshooting item 5 in the diagram on the o 5 q q
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
same Cause column as each other) that a b c d e
have causes common with the problem Remedy E
items found in the troubleshooting in Step 1) X C A X
Problems X
and Step 3).
a The items that are not common (items 1 Q Q Q Q
that do not have Q marks in the same o 2 q q
cause common as each other) are prob- 3 Q Q
ably not the cause, so they can be elimi-
4 Q Q
nated.
(The causes for Troubleshooting item 2 o 5 q q
in the diagram on the right are c or e,
and the causes in Troubleshooting item Nature of remedy
5 are b or e, so Cause e is the common
cause.) Cause
6) Repeat the operation in Steps 3), 4), and 5) a b c d e
until the cause is narrowed down to 1 item (1 Remedy E
common item). X C A X
a If cause items are 2 or more, continue Problems X
until number of items becomes mini- 1 Q Q Q Q
mum. o 2 q q
3 Q Q
7) Remedy
After narrowing down the common causes, 4 Q Q
taken the action given in the remedy line. o 5 Q q
X: Replace E: Repair A: Adjust C: Clean
WA150-5 20-703
(1)
TROUBLESHOOTING ERROR CODE AND CAUSE TABLE
ERROR CODE AND CAUSE TABLE

Part causing problem HST HST
Damper
Inching valve
HST pump motor 2 motor
High pressure relief valve

High pressure cut-off valve
Low pressure relief valve (Charge relief
Angle stopper control solenoid valve

Angle stopper solenoid valve (SOL b)
Pump body (Charge pump end)
Mode selector solenoid valve (SOL a)

Pump body (Piston pump end)
Forward and reverse solenoid valve

DA valve
Motor body
Motor body
Failure Code
Does not travel forward or in reverse 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
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
Rimpull is weak in both forward and reverse Q Q Q Q Q
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 WA150-5
(1)
Inching valve linkage
Clutch solenoid
WA150-5
Q Q Q
Q Q
Clutch
Q Q Q Q
Q Q Q Q
Transfer
Q
Q
Q
Q
Q
Q
Q
Q
Work equipment and steering pump
Q
Brake pump
TROUBLESHOOTING
Q
Orbit-roll
Q
Q
Q
Q
Q
Q
Priority valve
valve
Q Q Q
Q Q Q
Relief valve
Steering
Safty valve
Q
Q
Q
Steering cylinder
Q Q Q
Tire inflation pressure
Accumulator charge valve
Brake valve
Slack adjuster
Brake disc and plate
Axle
Q Q Q
Brake piston
Q Q Q Q Q Q
Wheel brake linkage
Q
Q
Q
Main relief valve
Q Q
Q Q
Q Q
Q
Lift arm spool
Q
Bucket spool
Q Q
Q 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
Q
Bucket cylinder
Q
Q
Q
Lift arm PPC valve
Q Q
Q
Q
Q
Bucket PPC valve
Q
Bypass valve
Q
2-way restrictor 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
(1)
20-705
ERROR CODE AND CAUSE TABLE
Work equipment system Brake Steering wheel HST related

TROUBLESHOOTING H-1
H-1 The machine does not start
Ask the operator about the following: Cause

• Has the machine come not start suddenly? HST pump HST HST Others
o Breakage of HST pump and motor motor 2 motor 1
related equipment a b c d e f g h i j k l m n o
• Was there any problem of not traveling
Low pressure relief valve (Charge relief valve)
Motor body
Motor body
Forward and reverse solenoid valve
Transfer
Inching valve
Clutch
Clutch solenoid
Damper
DA valve
before?
o Internal wear of HST pump and motor
related equipment, defective seal
Inspection before diagnosis

• Are the oil level in the hydraulic tank and
the oil type 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 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 Q Q

normal)
Does not travel forward or in reverse, motor makes
4 sound of rotation Q Q Q
20-706 WA150-5
(1)
TROUBLESHOOTING H-2
H-2 The travel speed is slow

• Did the travel speed suddenly becomes HST pump HST
HST motor 2 motor Others
slower? 1
o Breakage of HST pump and motor a b c d e f g h i j k l m n o
related equipment
Low pressure relief valve (Charge relief valve)
Motor body
Motor body
forward and reverse solenoid valve

Mode selector solenoid valve (SOL a)
Inching valve
Clutch
Clutch solenoid
Angle stopper control solenoid valve

Angle stopper solenoid valve (SOL b)

DA valve
• Was there any problem of travel speed
becoming slower before?
o Internal wear of HST pump and motor
related equipment, defective seal
• Is the inching valve linkage adjusting appro-
priate?
• Is inching valve linkage properly adjusted?
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 Q Q

(Reverse is normal)
The travel speed is slow at reverse
3 (Forward is normal) Q Q
4 Maximum travel speed in both forward and reverse Q

is approx. 4 km/h
Maximum travel speed in both forward and reverse
5 is approx. 18 km/h Q
6 Abnormal sound comes from motor in both forward Q Q

and reverse when travel speed is 10 km/h or more
WA150-5 20-707
(1)
TROUBLESHOOTING H-3
H-3 The thrusting force is weak

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

Clutch
Inclination control solenoid valve
Transfer
Inching valve
Clutch solenoid
Motor body
Motor body

Remedy E E E E E E E E E E E
No. Diagnosis X 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 Q
2 The thrusting force is weak at forward

(Reverse is normal) Q
The thrusting force is weak at reverse
3 (Forward is normal) Q
4 Rimpull is weak in both forward and reverse, but Q Q Q Q

maximum travel speed is reached the linee.
20-708 WA150-5
(1)
TROUBLESHOOTING H-4
H-4 Engine stalls when traveling or engine speed drops excessively

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

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

excessively Q Q Q
Machine moves when the direction the lever is at F
2 or R and engine is at Li Q
WA150-5 20-709
(1)
TROUBLESHOOTING H-5
H-5 The gear is not shifted

a If the speed range switch and the monitor Cause
display do not match, check the electrical HST HST Others
wiring. motor 2 motor 1
a When the travel speed is slow, carry out a b c d
troubleshooting for H-2 first.
Inclination stopper solenoid valve (SOLb)
Clutch
Clutch solenoid
Remedy E E E E
No. Diagnosis X X X X
1 The gear is not shifted Q Q Q Q
20-710 WA150-5
(1)
TROUBLESHOOTING H-6
H-6 The steering wheel does not turn

• Did the problem suddenly start? Hydrau- Others
o Breakage of steering related equipment lic pump
• Was there previously any symptom, such a b c d e f
as heavy steering?
Emergency steering valve (*1)

Steering Defective hydraulic pump or PTO
Priority valve
2-way restrictor valve

Obit-roll
Internal defective steering cylinder (Defective piston seal)
Steering pump and switch pump
o Internal wear of steering related equip-
ment, defective seal
• Has the safety bar been removed from
frame?
Relief valve
Spool
Remedy E E E E
No. Diagnosis X X X X X X X
1 Steering
and right)
wheel does not turn in both directions (left Q Q Q Q Q Q
2 In condition in Item 1, movement of work equip-

ment is abnormal Q
In condition in Item 1, movement of work equip-
3 ment is normal Q
4 Steering wheel turns only in one direction (left or Q Q Q

right)
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no

pressure Q
7 Emergency steering does not function in both

directions (left and right) Q
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is
felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
WA150-5 20-711
(1)
TROUBLESHOOTING H-7
H-7 The steering wheel is heavy

• Did the problem suddenly start? Hydrau- Valve Others
o Breakage of steering related equipment lic pump
• Was there previously any symptom, such a b c d e f
as heavy steering?
The steering pump is defective The hydraulic pump is defective
Priority valve
Clogging of hydraulic oil return filter, defective bypass valve

Obit-roll internal defect
Clogging of oil cooler

Internal defective steering cylinder (Defective piston seal)
o Internal wear of steering related equip-
ment, defective seal
• Is the connection of the orbit-roll and the
serration of the steering column normal?
hydraulic piping, valve and cylinder?
• Is there any gouging of center hinge pin
bearing and steering cylinder pin, bushing?
Relief valve
Spool
• Is the tire inflation pressure correct?
Check for abnormalities

• Measure operating effort of steering wheel
and time taken to turn steering, and check
standard judgment value table to see if
there is any abnormality.
Remedy E E E E E E E
No. Diagnosis X X X X X X X
A C C
Steering wheel is heavy when turned in both direc-
1 tions (left and right) Q Q Q Q Q
Steering wheel is heavy when turned in one direc-
2 tion (left and right) Q Q
3 Steering wheel is heavy particularly when engine is Q Q Q Q

running at low speed
Lift arm lifting speed is slow when engine is run-
4 ning at full speed Q Q
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 Q Q

pressure
8 Pressure rises in return piping of steering cylinder Q
20-712 WA150-5
(1)
TROUBLESHOOTING 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 Valves Cylinder
of oil correct? a b c
• Is there any play in the center hinge pin
Defect inside drbitrol

Defective 2-way restrictor valve
Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)
bearing or steering cylinder pin or bushing?
• 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 shakes and under what con-
ditions.
a In cases where the steering wheel is
heavy but does not shake, go to "H-7
The steering wheel is heavy".
Remedy E E
No. Diagnosis X X X
Chassis shakes when traveling on rough road sur-

1 face Q Q
2 Shakes when steering is suddenly turned during

operation or travel Q Q Q
3 Chassis shakes when accelerating during travel Q Q

operations
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
WA150-5 20-713
(1)
TROUBLESHOOTING H-10
H-10 The brake does not work or does not work well

• Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Defective operation of accumulator charge valve

Metal contact due to complete wear of brake lining in axle
Defective brake pump (For charge)

Brake linkage
Defective operation of brake piston in axle
Defect inside brake valve

Defective brake piston seal in axle
Defective seal of accumulator piston, insufficient gas pressure

Mixing of air in brake circuit
Defective slack adjuster
Wear or abnormality of brake lining in axle
• Has the brake come not to work gradually?
o Wear of lining and disc, defective seal

• Is the oil level in the hydraulic tank appropri-
ate?
• 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 refer-
ring to the standard 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 Q Q Q Q Q

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

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

from the axle brake
When the four wheels are jacked up, the axle is
4 placed on a table and the brake is applied at the Q Q Q Q
first forward speed, only a specific wheel rotates
An airflow is observed in bleeding air from brake
5 circuit, and the brake returns to normal after the Q
bleeding
6 Brake oil leaks abnormally from the axle during Q

inspection
7 Much metal powders are mixed in the axle oil Q
8 The brake pedal leg-power and stroke are normal, Q Q Q Q Q Q Q Q Q

but the brake does not work well
9 The brake does not work often when the engine is Q Q Q Q Q Q

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

sounds
11 The brake works after some time lag Q Q Q
20-714 WA150-5
(1)
H-11 The brake is not released or is dragged

• Has the brake pedal returned completely? a b c d
• Is the parking brake released completely?
Defective operation of brake piston in axle

Defective brake piston seal in axle
Defective slack adjuster

Wear or abnormality of brake lining 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 Q Q Q Q

applied
When the brake pedal is released, oil is drained
2 from the air bleeder, the circuit oil pressure drops Q Q
and the brake is released
When the four wheels are jacked up, the axle is
3 placed on a table, the engine is stopped, the park- Q Q Q
ing brake is released and the tires are rotated by
hand but a specific tire hardly rotates
WA150-5 20-715
(1)
H-12 The lift arm does not rise or lower

• Has the lift arm come not to work suddenly? Work
o Seizure or breakage of each equipment Tank to Pump Priority HST PPC
valve pump valve equipment Cylinder
valve
Did any abnormal noise occur at the time
a b c d e f g h i j
(And where)?
Defective operation of main relief valve

Defective operation of spool

Defective work equipment pump
Damage of lift arm cylinder piston seal

Defective HST charge pump
Defective steering pump
Breakage inside valve body (Lift arm spool)

Clogging of pump suction port or mixing of much air in oil
Defective low-pressure relief valve

• Was there the phenomenon that the lift arm
worked slowly?
o Wear of parts or deformation of spring

• Is the oil level in the hydraulic tank appropri-
ate?
• Is the stroke of the lift arm control lever
appropriate?
• Is the engine speed appropriate?
Remedy C E E E E E E
No. Diagnosis E X X X X X X X X X
The bucket cannot operate and the lift arm cannot

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

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

5 Large hydraulic drift of lift arm cylinder Q Q
6 When the engine is at full throttle, the steering

operation is heavy and slow Q Q
20-716 WA150-5
(1)
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 Tank to Priority HST PPC Work equip- Cylinder
appropriate? Pump valve pump valve ment valve
a b c d e f g h
Check of Abnormality
Wear or breakage inside valve body (Lift arm spool)

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

Defective low-pressure relief valve
Defective operation or improper adjustment of main relief valve

• Rising force and speed problem are closely
related, and this problem occurs as insuffi-
cient rising speed at first. Measure the lift
arm rising speed when the lift arm is loaded
and make sure referring to the criterion
table that the speed is abnormal.
Remedy C E E E E A E
No. Diagnosis E X X X X X X X
1 The bucket tilting force and speed are abnormal, Q Q Q Q Q

and the lift arm rising speed is slow
The bucket tilting force and speed are normal, and
2 the lift arm rising speed is slow Q Q Q
3 When the oil temperature rises in No. 1, the lift arm

speed becomes very slow Q Q
4 The hydraulic pump causes an abnormal noise Q Q

5 Large hydraulic drift of lift arm cylinder Q Q
The relief oil pressure from the relief valve of the
6 work equipment valves is low Q
7 The relief oil pressure from the relief valve of the

work equipment valves is too high Q
WA150-5 20-717
(1)
H-14 When rising, the lift arm comes to move slowly at specific height

• Deformation of lift arm cylinder in appearance
Cause
• Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see "H-13. The lift arm moves slowly or the lift arm rising
force is insufficient."
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-13. The lift arm moves slowly or the lift arm rising force is insufficient."

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

• Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? o Wear of parts

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

• Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder
packing is defective
H-17 The lift arm wobbles during operation
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the "HOLD" position.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-15. Hydraulic drifts of the lift arm occur
often."
2. When the lift arm cylinder cannot lift the machine, see "H-15. The lift arm cylinder cannot hold down the
bucket."
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times with
the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vacuum gen-
erated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20-718 WA150-5
(1)
H-18 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls
temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the lift arm
falls temporarily due to its own weight. When the control lever is completely set to "RAISE," the lift arm
returns to normal.
Cause
• Improper adhesion of lift arm spool check valve of the work equipment valve
WA150-5 20-719
(1)
H-19 The bucket does not tilt back

• Has the bucket come not to work sud- Tank to Priority HST PPC Work Equip- Cylinder
denly o Seizure or breakage of each Pump Valve pump Valve ment Valve
equipment a b c d e f g h i
• Did any abnormal noise occur at the time
The low-pressure relief valve is defective

The HST charge pump (which is used as PPC pump, too) is defective
Defective operation of main relief valve
Damage of bucket cylinder piston seal

Breakage inside valve body (Bucket spool)
Work equipment and steering pump are defective
The spool is defective

(And where)?
• Was there the phenomenon that the bucket
worked slowly? o Wear of parts or defor-
mation of spring

• Is the stroke of the bucket control lever
appropriate?
Remedy C E E E E A
No. Diagnosis E X X X X X X X X
1 The lift arm cannot operate and the bucket cannot Q Q Q Q Q Q Q

tilt back
The bucket can lift the machine but cannot tilt back,
2 or the lift arm operates but the lift arm cannot tilt Q Q Q
back
3 The bucket can tilt back without load but cannot in Q Q Q

digging 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 Q Q

operation is heavy and slow
20-720 WA150-5
(1)
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 Tank to Priority HST PPC Work equipment valve Cylinder
appropriate? Pump valve pump valve
• Seizure of work equipment linkage bushing a b c d e f g h i
(Does any abnormal noise occur?)
The hydraulic pump and the switch pump are defective

Defective operation of low-pressure relief valve
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Wear or breakage inside valve body (Bucket spool)

Defective operation or improper adjustment of main relief valve
Damage of bucket cylinder piston seal

• 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 abnormal
Remedy C E E E E E E
No. Diagnosis E X X X X X X X X
A
The lift arm rising force and speed are abnormal,
1 and the bucket tilting force and speed are abnor- Q Q Q Q Q
mal
2 The lift arm rising force and speed are normal, and
the bucket tilting force and speed are abnormal Q Q Q Q
When the oil temperature rises in No. 1, the bucket
3 speed becomes worse Q Q
4 The hydraulic pump is causing an abnormal noise Q Q

5 Large hydraulic drift of bucket cylinder Q Q Q
6 The relief oil pressure from the relief valve of the

work equipment valves is low Q Q Q
The relief oil pressure from the relief valve of the
7 Q
work equipment valves is too high
WA150-5 20-721
(1)
H-21 The bucket comes to operate slowly in he midst of tilting-back

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

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

• Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? o Wear of parts

• Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the
spool detent is defective
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
20-722 WA150-5
(1)
H-24 The bucket wobbles during travel with cargo (The work equipment valve is set
to "HOLD")

• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
H-25 When the control lever is switched from "HOLD" to "TILT," the bucket falls tem-
porarily
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 PPC
if the lever operating efforts are large practi- valve
cally. a
Defective operation of relief valve
Remedy C
No. Diagnosis E
1 Becomes heavy in some places during operation Q

regardless of oil pressure and oil temperature
2 Becomes heavy overall during operation regard-
less of oil pressure and oil temperature Q
WA150-5 20-723
(1)
H-27 The travel damper does not operate and machine pitches and bounces
Check the following points with the operator. Cause

• Did the machine starts pitching and bounc- Solenoid Accumu- Controller Sensor
ing suddenly? o Breakage of related valve lator
device a b c d
Did abnormal sound come out when the
Gas leakage from accumulator or defective seal
Malfunction of controller
Malfunction of solenoid valve
Defective travel speed sensor

machine started pitching and bouncing?
From what part did the abnormal sound
come out?
• Did the machine starts pitching and bounc-
ing gradually? o Wear of related device or
defective seal
Check before troubleshooting

• Check that the hydraulic tank is filled with oil
of a proper type up to a proper level.
• Check that the travel damper switch is set
properly.
No. Remedy X X X X
Diagnosis
1 Travel speed to start operation of travel damper Q Q
(6 km/h) is changes largely
2 Travel damper does not work while machine is Q Q
loaded
Travel damper does not work while machine is
3 empty Q Q
4 Boom lowers more than 30 cm at maximum when Q

travel damper operated while machine is loaded
5 Travel damper does not work at all Q Q Q Q
20-724 WA150-5
(1)
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
WA150-5 20-801
(1)
TROUBLESHOOTING 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
information (A) that he has obtained from the user
and the results of (C) that he has obtained from his Causes
own 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 infor-
mation gained from [Questions] and [Check
items]. (b) (2) (3)
(a) w
Questions
(A) (b) w
(c) w
(d) Q
(e) Q
(B)
(C)
Check items
i q
shooting
Trouble-
ii q
iii q
20-802 WA150-5
(1)
The basic method of using the troubleshooting chart is as follows.

Items listed for [Questions] and [Check items] that have a relationship
with the Cause items are marked with Q, and these, causes that have a
high probability are marked with w.
Check each of [Questions] and [Check items] in turn, and marked the Q Causes
or T in the chart for items where the problem appeared. The vertical col-
Defective injection pump (excessive injection)

umn (Causes) that has the highest number of points is the most probable
cause, so start troubleshooting for that item to make final confirmation of
the causes.
*1. For [Confirm recent repair history] in the [Questions] Section, ask
Seized turbocharger, interference

the user, and mark the Cause column with E to use as reference
Clogged, seized injection nozzle

for locating the cause of the failure. However, do not use this
Clogged air cleaner element

Worn piston ring, cylinder
when making calculations to narrow down the causes.
Improper injection timing

*2. Use the E in the Cause column as reference for [Degree of use
(Operated for long period)] in the [Questions] section as refer-
ence. As a rule, do not use it when calculating the points for locat-
ing the causes, but it can be included if necessary to determine
the order for troubleshooting.
*1 Confirm recent repair history

*2 Degree of use of machine Operated for long period EEE
w
WA150-5 20-803
(1)
• 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
Defective fuel injection pump (rack, plunger seized)

Defective fuel injection pump (excessive injection)
• Excessive injection fuel
Leakage of air between turbocharger and head

Clogged fuel injection nozzle, defective spray
Defective contact of valve and valve seat

Improper fuel injection timing

Improper valve clearance

Crushed, clogged muffler
Legend
Q : Possible causes (judging from Questions and check items)
w : Most probable causes (judging from Questions and Check items)
t : Possible causes due to length of use (used for a long period)
q : Items to confirm the causes.
Confirm recent repair history

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

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

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

When air cleaner element is inspected directly, it is found to be clogged q
When compression pressure is measured, it is found to be low q q
Speed does not change when operation of certain cylin- q
ders is stopped
Troubleshooting
When check is made using delivery method, fuel injection

timing is found to be incorrect q
Fuel injection pump test shows that fuel injection amount is incor- q
rect
When valve clearance is checked directly, it is found to be q
outside standard value
When muffler is removed, exhaust color returns to normal q
When control rack is pushed, it is found to be heavy, or q
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-804 WA150-5
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of Q and w marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element:wQw
(2) Air leakage between turbocharger
and headQQ
(3) Clogged, seized injection nozzle:Q
(4) Defective contact of valve, valve seat:Q
(5) Worn position ring, cylinder:Q
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked q. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA150-5 20-805
(1)
TROUBLESHOOTING 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 Causes
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of -10°C or below, ASTM D975 No. 2 die-
sel fuel is used)
a Battery charging rate
Defective contact of valve, valve seat

Charging rate
Ambient 100% 90% 80% 75% 70%
Clogged feed pump gauze filter

temperature

20°C 1.28 1.26 1.24 1.23 1.22
Clogged fuel filter, strainer
Electrical intake air heater

0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the valve for the charging rate
of 70% in the above table.
• In cold areas the specific gravity must exceed the value for the
charging rate of 75% in the above table.
Degree of use of machine Operated for long period EE E
Gradually became worse w w Q Q Q
Ease of starting
Starts when warm w
Questions
Indicator lamp does not light up w

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

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

Is voltage 26 - 30V between alternator terminal B and termi- Yes
nal E with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
* Use a test stand
20-806 WA150-5
(1)
q
Replace Defective regulator
w w
q
Replace Defective alternator
q
w
w
Replace Defective or deteriorated battery
WA150-5
q
w
w
Q
Q
Replace Defective fuel injection nozzle
w
*Adjust Defective fuel injection timing
Q
Q
q
w
w
Replace Defective fuel injection pump (rack, plunger stuck)
Causes
Q w
q
Correct Defective Leakage, clogging, air in fuel piping
w Q
q
Q
Clean Clogged air breather hole in fuel tank
w
Replace Defective feed pump
TROUBLESHOOTING
w
Replace Defective boost compensator cancel
(1)
20-807
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start

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

• Internal parts of engine seized
a If internal parts of the engine are seized, carry
out troubleshooting for "Engine stops during
operations".
• Defective electrical system
Defective battery terminal connection

• Failure in power train
Defective wiring of starting circuit

Defective or deteriorated battery

Defective starting motor

Defective safety relay
Broken ring gear
Questions
Degree of use of machine Operated for long period E E

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

When battery is checked, battery electrolyte is found to be low w
Specific gravity of electrolyte, voltage of battery is low q

For the following conditions 1) - 4), turn the starting switch OFF,
connect the cord, and carry out troubleshooting
q
1) When terminal B and terminal C of starting switch are con-
Troubleshooting
nected, engine starts

2) When terminal B and terminal C of starting motor are con-
q
nected, engine starts
3) When terminal B and terminal C of starting safety relay are
q
connected, engine starts
4) There is no 24V between battery relay terminal b and termi-
q
nal E
When ring gear is inspected directly, tooth surface is found to be
q
chipped
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy -
20-808 WA150-5
(1)
TROUBLESHOOTING 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

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Broken, fuel injection pump drive shaft, key

a Standards for use of fuel
Clogged air breather hole in fuel tank

AMBIENT TEMPERATURE
KIND OF
Seized broken feed pump piston

FLUID -4 14 32 50 68°C
-20 -10 0 10 20°F
Clogged feed pump strainer
Clogged leaking fuel piping

Insufficient fuel in tank

ASTM D975 No. 2
Improper fuel used

Diesel fuel
ASTM D975 No. 1

Questions

Exhaust smoke suddenly stops coming out (when starting again) w w w
Replacement of filters has not been carried out according to Oper-
w w
ation Manual
Fuel tank is found to be empty w
There is leakage from fuel piping w
Mud is stuck to fuel tank cap w
When fuel filter is drained, fuel does not come out w
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is w Q Q Q
Check items
loosened
2) No fuel spurts out even when fuel injection pump piping
w w w
sleeve nut is loosened
Rust and water are found when fuel tank is drained Q Q Q
Inspect fuel injection pump directly q
When control rack is pushed, it is found to be heavy, or does not
q
Troubleshooting
return
Inspect feed pump directly q
When fuel filter, strainer are inspected directly, they are found to
q q
be clogged
When feed pump strainer is inspected directly, it is found to be
q
clogged
When fuel cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA150-5 20-809
(1)
TROUBLESHOOTING 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-
Defective, broken valve system (valve, rocker lever etc.)

Defective fuel injection pump (rack, plunger stuck)
tem

• Insufficient supply of fuel
Clogged air breather hole in fuel tank cap

Leakage, clogging, air in fuel system

• Improper selection of fuel and oil
Defective electrical intake air heater

Defective or deteriorated battery
Worn piston ring, cylinder liner

Improper fuel used

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

Replacement of filters has not been carried out according to Oper- w w w
ation Manual
Rust and water are found when fuel tank is drained w w
Indicator lamp does not light up w
Starting motor cranks engine slowly w
Mud is stuck to fuel tank cap Q
When fuel lever is placed at FULL position, it does not contact stopper Q
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when fuel filter air bleed plug is w
loosened
2) No fuel comes out even when fuel filter air bleed plug is w w Q
loosened
When exhaust manifold is touched immediately after starting w
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out w
Remove head cover and check directly q
When control rack is pushed, it is found to be heavy, or does not q
return
When compression pressure is measured, it is found to be low q
When fuel filter, strainer are inspected directly, they are found to q q
Troubleshooting
be clogged
When feed pump strainer is inspected directly, it is found to be q
clogged
Heater mount does not become warm q
Either specific gravity of electrolyte or voltage of battery is low q
When feed pump is operated, there is no response, or operation q
is too heavy
Speed does not change when operation of certain cylinders is stopped q
When fuel tank cap is inspected directly, it is found to be clogged q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-810 WA150-5
(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly Causes


• Improper fuel used
Clogged air breather hole in fuel tank cap

Seized fuel injection pump plunger
Seized turbocharger, interface
Clogged, leaking fuel piping


Degree of use of machine Operated for long period EE E E E
w w w
Questions
ation Manual
Non-specified fuel is being used w w w w
Engine pick-up suddenly became poor Q w Q Q
Rust and water are found when oil is drained w w
Blue under light load Q w
Color of exhaust gas
Black w w w Q
Check items

High idling speed under no load is normal, but speed suddenly
w w Q
drops when load is applied
There is hunting from engine (rotation is irregular) Q w Q Q
When exhaust manifold is touched immediately after starting
w Q
When air cleaner element is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
Troubleshooting
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 return q
When valve clearance is checked directly, it is found to be outside q
standard value
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
WA150-5 20-811
(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stop during operations Causes

• Seized parts inside engine
Defective fuel injection pump (rack, plunger stuck)

Broken dynamic valve system (valve, rocker lever, etc.)
• Overheating
a If there is overheating and the engine stops,
Broken fuel injection pump drive shaft, key

Broken injection pump auxiliary equipment
carry out troubleshooting for overheating.
Broken, seized piston, connecting rod

• Failure in hydraulic pump
Broken, seized crankshaft bearing
Failure in hydraulic pump system

Broken, seized feed pump piston
a If the engine stops because of a failure in the
hydraulic pump system, carry out troubleshoot-

Broken, seized gear train
ing for "H-mode".

Degree of use of machine Operated for long period EE
Abnormal noise was heard and w w w w w w Q Q w
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q
w w
ation Manual
Non-specified fuel is being used Q Q Q Q
Fuel level lamp lights up w
When feed pump is operated, operation is too light or too heavy Q Q w
w
Check items
Engine rotates, but stops when power train is operated

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

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

When fuel filter, strainer are inspected directly, they are found to
q
be clogged
When feed pump strainer is inspected directly, it is found to be
q
clogged
Inspect feed pump directly q
When control rack is pushed, it is found to be heavy, or does not
q
return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy -
Add
20-812 WA150-5
(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (Hunting)
General causes why engine does not rotate smoothly Causes

• Air in fuel system
• Defective governor mechanism
Clogged air in circuit between fuel tank and feed pump

Clogged air in circuit between feed pump and nozzle
• Defective electric governor mechanism
(engine with electric governor)
a If hunting stops when electric governor rod is dis-

connected, carry out troubleshooting for the
Defective operation of control rack

Defective adjustment of governor
chassis.
Defective operation of governor

Low idling speed is too low

Degree of use of machine Operated for long period EE
Occurs at a certain speed range w w w Q
Occurs at low idling Q w Q Q Q Q
Questions
Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w
w w
ation Manual
Rust and water are found when tank is drained Q Q
Leakage from fuel piping w w
When feed pump is operated,
w
Check items
1) No response, light, return is quick

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

return
When fuel tank cap is inspected directly, it is found to be clogged q q
clogged
be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
WA150-5 20-813
(1)
TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output Causes

Bent fuel lever linkage, defective adjustment

• Improper fuel used
Defective boost compensator diaphragm

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

• Lack of output due to overtaking
Seized fuel injection pump plunger

a If there is overheating and lack of output, carry

out troubleshooting for overheating.


Degree of use of machine Operated for long period E EEE E
Suddenly w w
Questions
Power was lost

Gradually Q Q Q Q Q Q
Replacement of filters has not been carried out according to Oper- w w w
ation Manual
Non-specified fuel is being used w w w w
Black w w
Blow-by gas excessive w Q
Check items
Engine pickup is poor and combustion is irregular w Q Q Q

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

clogged
stopped
return
standard value
When level is placed at FULL position, it does not contact stopper q
When feed pump is operated, operation is too light or too heavy q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-814 WA150-5
(1)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes


Leakage of air between turbocharger and head

• Excessive injection of fuel

Improper fuel injection timing


Crushed, clogged muffler
Degree of use of machine Operated for long period EE E E
Suddenly became black w Q Q
Color of exhaust gas Gradually became black w Q Q
Questions

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

Timing lock on fuel injection pump does not match w
Exhaust noise is abnormal Q Q w
Muffler is crushed w
Leakage of air between turbocharger and head, loose clamp w
clogged
Troubleshooting
stopped
When check is made using delivery method, fuel injection timing q
is found to be incorrect
Fuel injection pump test shows that fuel injection amount is incor- q
rect
standard value
When muffler is removed, exhaust color returns to normal q
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
WA150-5 20-815
(1)
TROUBLESHOOTING 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)
Turbocharger
General causes why oil consumption is excessive
• Abnormal combustion of oil
Worn piston ring, cylinder (liner less engine)

• External leakage of oil
• Wear of lubrication system
Worn valve (stem, guide), broken seal

Leakage from oil pan or cylinder head
Worn, broken rear seal, seal surface

Clogged breather or breather hose
Dust sucked in from intake system

Leakage from oil filter or oil cooler
Leakage from oil drain plug
Worn seal at turbine end

Worn seal at blower end
Leakage from oil piping
Broken piston ring
Broken oil cooler

Degree of use of machine Operated for long period E EE E
Oil consumption suddenly increased w Q
Engine oil must be added more frequently w Q
Questions
Engine oil becomes contaminated quickly Q w Q

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

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

Pressure-tightness test of oil cooler shows there is leakage q
Excessive play of turbocharger shaft q q
Inspect rear seal directly q
When intake manifold is removed, dust is found inside q
When intake manifold is removed, inside is found to be dirty with q
oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-816 WA150-5
(1)
TROUBLESHOOTING 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
• Improper oil used
Defective seal at turbocharger turbine end

• Operation under excessive load
Clogged turbocharger oil drain tube

Clogged breather, breather hose
Worn valve, valve guide
Exhaust smoke is black

Clogged oil cooler
Clogged oil filter
Degree of use of machine Operated for long period E E E
Questions

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

Excessive
Check items
Amount of blow-by gas

None w
When oil filter is inspected, metal particles are found Q w Q
When exhaust pipe is removed, inside is found to be dirty with oil w
Engine oil temperature rises quickly w

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

When oil filter is inspected directly, it is found to be clogged q
When oil cooler is inspected directly, it is found to be clogged q
Turbocharger oil drain tube is clogged q
Excessive play of turbocharger shaft q
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy -
WA150-5 20-817
(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

• Leakage of fuel

• Excessive injection of fuel
Defective oil seal inside feed pump (piston)

Defective adjustment of fuel control linkage
External leakage from fuel piping, fuel filter
Defective fuel injection pump plunger
Leakage of fuel inside head cover

Defective nozzle holder spray
Defective fuel injection timing

More than for other machines of
Questions
w Q
Condition of fuel same model
consumption Gradually increased Q Q
Suddenly increased Q Q
Black w Q Q Q
Exhaust smoke color
White Q
There is irregular combustion w
Check items

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

return
When check is made using delivery method, injection timing is q
found to be incorrect
Remove feed cover and inspect directly q
When engine speed is measured, low and high idling speeds are q
found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-818 WA150-5
(1)
S-11 Oil is in cooling water, or water spurts back,

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

• Internal leakage in lubrication system
• Internal leakage in cooling system
Broken cylinder head, head gasket
Internal cracks in cylinder block

Broken oil cooler core, O-ring
Broken hydraulic oil cooler

Holes caused by pitting
Questions
Degree of use of machine Operated for long period E E

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

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

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

Remove oil pan and inspect directly q q
Replace
Replace
Replace
Replace
Replace
Remedy
WA150-5 20-819
(1)
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)
General causes why oil pressure lamp lights up Causes

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
Selection of SAE No. according to
Leaking, crushed hydraulic piping

Type of oil ambient temperature
Clogged strainer inside oil pan

Clogged oil pipe inside oil pan
Defective oil pressure sensor

-30 -20 -10 0 10 20 30 40°C
Broken suction pipe brazing
Defective oil level sensor

Defective regulator valve
SAE30CD
Worn bearing, journal
Defective relief valve

Lack of oil in oil pan
Defective oil pump
SAE10WCD
Clogged oil filter
Water, fuel in oil

Engine oil
SAE10W-30CD
SAE15W-40CD

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

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

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

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

Troubleshooting
Oil pump rotation is heavy, there is play q

There is catching of relief valve or regulator valve, spring or valve q q
"Oil level rises".
guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out q
When oil pressure is measured, it is found to be within standard q
valve
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy -
Add
20-820 WA150-5
(1)
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trouble- Causes

shooting for "Oil is in cooling water".
General causes why oil level rises
• Water in oil (milky white)
Leakage of fuel from piping inside head cover

• Fuel in oil (diluted, and smells of diesel fuel)
Defective pump auxiliary equipment seal

• Entry of oil from other component
Defective part inside injection pump

Worn, damaged rear seal surface
Defective nozzle holder sleeve
Broken oil cooler core, O-ring
Cracks inside cylinder block

Holes made by pitting
Defective thermostat
Questions
Degree of use of machine Operated for long period E EE E

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

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

When pump auxiliary equipment is removed, seal is found to be q
damaged
Remove fuel injection pump and inspect directly q
Defective contact with thermostat seal valve q
Remove oil pan and check directly q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA150-5 20-821
(1)
S-14 Water temperature becomes too high (Overheating)
General causes why water temperature becomes too Causes

high
Rise in torque converter oil temperature of hydraulic pump system

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in hydraulic pump system
a Carry out troubleshooting for "H-mode".
Defective thermostat (does not open)

Defective water temperature gauge

Fan belt slipping, worn fan pulley
Clogged, crushed radiator fins
Clogged, broken oil cooler

Defective pressure valve
Clogged radiator core
Holes made by pitting

Lack of cooling water
Broken water pump

Degree of use of machine Operated for long period EE EE
Suddenly overheated w Q Q
Questions
Condition of overheating
Always tends to overheat w w Q Q
Rise quickly w Q
Water temperature gauge
Does not go down from red range w
Radiator water level sensor lights up w
Fan belt whines under sudden load w
Cloudy white oil is floating on cooling water w
Cooling water flows out from overflow hose w
Excessive air bubbles inside radiator, water spurts back w
Engine oil level has risen, oil is cloudy white Q w
Check items
There is play when fan pulley is rotated w

Radiator shroud, inside of underguard are clogged with dirt or mud w w
When light bulb is held behind radiator, no light passes through w
Water is leaking because of cracks in hose or loose clamps w
When belt tension is inspected, it is found to be loose w
Hydraulic 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
slight
Troubleshooting
When water filler port is inspected, core is found to be clogged q

When function test is carried out on thermostat, it does not open q
When water temperature is measured, it is found to be normal q
When oil cooler is inspected directly, it is found to be clogged q
When measurement is made with radiator cap tester, set pressure q
is found to be low
Remove oil pan and inspect directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy -
Add
20-822 WA150-5
(1)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter- Causes

nal noise.
Broken dynamic valve system (valve, rocker lever, etc.)
Leakage of air between turbocharger and cylinder head

Excessive wear of piston ring, cylinder (liner less engine)
Defect inside muffler (dividing board out of position)

General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
Defective adjustment of valve clearance

• Air sucked in from intake system
Clogged, seized fuel injection nozzle
Deformed fan, fan belt interference

Improper gear train backlash

Missing, seized bushing
Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Black w Q Q
Metal particles found in oil filter w w
Check items
Engine pickup is poor and combustion is abnormal w

Abnormal noise is loud when accelerating engine Q Q Q Q Q Q
Clanging sound is heard from around cylinder head w w
Leakage of air between turbocharger and cylinder head, loose w
clamp
Vibrating noise is heard from around muffler w
Remove gear cover and inspect directly q
Troubleshooting
stopped
return
Fuel injection pump test shows that injection amount is incorrect q
Fan is deformed, belt is loose q
When valve clearance is checked, it is found to be outside q
standard value
Remove cylinder head cover and inspect directly q
When muffler is removed, abnormal noise disappears q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA150-5 20-823
(1)
S-16 Vibration is excessive
a If there are abnormal noise together with the Causes

vibration, carry out troubleshooting also for
Defective dynamic valve system (valve, rocker lever, etc. stuck)

Defective fuel injection pump (excessive fuel injection)
"Abnormal noise is made".
General causes why vibration is excessive
Loose engine mounting bolts, broken cushion

• Defective parts (abnormal wear, breakage)
Center of engine and power train misaligned

• Improper combustion
Broken part inside output shaft (damper)

• Abnormal combustion
Worn connecting rod, main bearing
Improper gear train backlash

Worn cam bushing
Degree of use of machine Operated for long period EEE
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are found in oil filter w w
Metal particles are found when oil is drained w w
Oil pressure is low at low idling Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q
Remove oil pan and inspect directly q
Remove side cover and inspect directly q
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion q

Inspect inside of output shaft (damper) directly q
When face runout and radial runout are inspected, they are found q
to be incorrect
Remove front cover and inspect directly q
Remove front head cover and inspect directly q
Fuel injection pump test shows that injection amount is incorrect q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-824 WA150-5
(1)

WA150-5 SEBM033805 Troubleshooting

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WA150-5 SEBM033805 Troubleshooting

Uploaded by

Copyright:

Available Formats

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

POINTS TO REMEMBER WHEN TROUBLESHOOTING

3. Check before troubleshooting.

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

1. PRECAUTIONS WHEN HANDLING ELECTRIC

Main failures occurring in wiring harness

(2) Defective compression or soldering of con-

12 (3) Disconnections in wiring

(4) High pressure water entering a connector

(5) Oil, grease or dirt stuck to connector

2) Removing, installing, and drying connectors and

(3) Action to take after removing connectors.

(2) Assemble the connector securely.

(3) Correct any protrusion of the boot and any

12 (4) When the wiring harness clamp of the con-

• Drying wiring harness

If water gets directly on the connector, do as fol-

(2) Dry the inside of the connector with a dryer.

(3) Carry out a continuity test on the connector.

3) Handling control box

(3) Do not place objects on top of the control

(6) Do not place the control box on oil, water, or

2. Points to remember when troubleshooting electric circuits

3. Points to remember when handling hydraulic

With the increase in pressure and precision of

1) Be careful of the operating environment

2) Disassembly and maintenance work in the field

4) Do not let any dirt, or dust get in during refilling

5) Change hydraulic oil when the temperature is

CHECK BEFORE TROUBLESHOOTING

2. Check for impurities in fuel - Drain

10. Check emergency steering - Repair

11. Check tire inflation pressure and damage - Air charge or

Tightening torque (See DIS-

22. Check operation of monitor panel - Adjust or repair

32. Check battery electrolyte level - Add

36. Check for blown, corroded fuses - Replace

CATEGORIES, PROCEDURE, AND METHOD OF USING

2. Procedure for troubleshooting

PHENOMENA CONSIDERED TO BE FAILURES AND

1 Error code is displayed on error code display unit q

2 Starting performance is poor (starting always takes S-1

4 Engine Engine rotates but no exhaust smoke S-2b)

6 Engine does not pick up smoothly (follow-up is S-3

11 Oil consumption is excessive (or exhaust smoke is S-8

14 Oil in cooling water (or water spurts back, or water

15 Oil pressure caution lamp light ON (drop in oil pres- S-12

20 Defective HST controller power source (HST con- HST-1

23 Travel speed limit cannot be changed when gear HST-4

31 The radiator coolant level caution lamp does not

32 The steering oil pressure caution lamp does not MON-7

33 The emergency steering oil pressure indicator lamp MON-8

34 Input fault in monitor panel mode switch 1 [t] (panel

35 Input fault in monitor panel mode switch 1 [U] MON-10

36 Input fault in monitor panel mode switch 2 [<] (panel

37 Input fault in monitor panel mode switch 2 [>] (panel MON-12

47 Defective lift arm FLOATING holding and cancella- E-7

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

67 When rising, the lift arm comes to move slowly at H-14

68 The lift arm cylinder cannot hold down the bucket

69 Hydraulic drifts of the lift arm occur often H-16