Komatsu PW168-11E1 Hydraulic Excavator Shop Manual VENBM75000 PDF

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Komatsu PW168-11E1 Hydraulic Excavator Shop Manual VENBM75000 – PDF DOWNLOAD

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Komatsu PW168-11E1 Hydraulic Excavator Shop Manual VENBM75000 – PDF DOWNLOAD

Language : English
Pages : 2420
Downloadable : Yes
File Type : PDF

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Komatsu PW168-11E1 Hydraulic Excavator Shop Manual VENBM75000 – PDF DOWNLOAD

• MACHINE MODEL PW168-11E1
• SERIAL NUMBER H68051 AND UP

VENBM75000 PW168-11E1 . 1
Contents 3
Foreword 21
Abbreviation List . 21
List of Abbreviations Used in the Text 21
List of Abbreviations Used in the Circuit Diagrams 25
Foreword, Safety, Basic Information . 26
How to Read the Shop Manual . 26
Composition of the Shop Manual 27
Symbols . 28
Signal Word . 28
Safety Notice for Operation . 28
Safety Considerations . 29
General Precautions . 29
Preparations for Work . 29
Precautions During Work . 30
Hoisting Instructions . 31
Hoisting 31
Wire Ropes 31
Coating Materials . 32
Standard Tightening Torque 34
Standard Tightening Torque of Bolts and Nuts 34
Tightening Torque of Hose Nuts 35
Tightening Torque of Split Flange Bolts . 35
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type) . 35
Tightening Torque for 107 Engine Series (bolts and nuts) 36
Tightening Torque for 107 Engine Series (Eye Joints) 36
Tightening Torque for 107 Engine Series (Tapered Screws) 36
Electric Wire Code 37
Classification by Thickness . 37
Classification by Color and Code 37
Conversion Tables . 38
Method of Using the Conversion Table 38
Units . 44
Specification . 45
Specification Dimension Drawings 46
Dimensions 46
Working Ranges 48
Working Range: 1-Piece Boom . 48
Working Range: 2-Piece Boom . 49
Weight Table 53
1-Piece Boom 54
2-Piece Boom 55
Fuel, Coolant, Lubricant 56
Structure and Function 59
UREA SCR System . 62
Layout Drawing of UREA SCR System . 62
Detailed Drawing of ATS Assembly 64
Detailed Drawing of DEF Tank 65
UREA SCR System Diagram . 66
Function of UREA SCR System . 67
Function of DEF System 68
DEF Injection Function 68
DEF Purge Function 69
Function of DEF Thawing and Preventing From Freezing 70
Inducement Strategy . 71
Component Parts of ATS System . 88
SCR Assembly 89
Structure of SCR Assembly . 89
KDPF 90
Structure of KDPF . 90
DEF tank 96
DEF Pump 98
DEF injector 99
DEF Hose 100
DEF Tank Heating Valve 101
BOOT-UP system 102
Layout Drawing of BOOT-UP System 102
System Operating Lamp System 103
System Operating Lamp System Diagram 103
Function of System Operating Lamp System 103
Battery Disconnect Switch . 104
Function of Battery Disconnect Switch . 104
Function of Battery Disconnect Switch . 105
Engine System . 106
Layout Drawing of Engine System . 106
Engine Control System . 107
Engine Control System Diagram . 107
Function of Engine Control System . 108
Auto-Deceleration System 111
Auto-Deceleration system diagram 111
Engine Automatic Warm-up System . 113
Engine Automatic Warm-up System Diagram . 113
Function of Engine Automatic Warm-up System . 114
Overheat Prevention System 115
Overheat Prevention System Diagram 115
Function of Overheat Prevention System 116
Turbocharger Protection System 117
Turbocharger Protection System Diagram 117
Function of Turbocharger Protection System 118
Automatic Idle Stop System 119
System Diagram of Automatic Idle Stop System 119
Function of Automatic Idle Stop System 119
Setting Time 121
Abrupt Engine Stop Is Detected 122
Component Parts of Engine System 123
Structure of Turbocharger . 123
Crankcase Ventilation System 125
System Diagram of Crankcase Ventilation System 125
Function of Crankcase Ventilation System 125
Impactor (Filterless) . 126
Structure of Impactor (Filterless) 126
Operation of Impactor (Filterless) 126
Exhaust Throttle Valve 127
Structure of Exhaust Throttle Valve . 127
Cooling system 128
Layout Drawing of Cooling System 128
Fan Speed Control System of Fan Clutch 129
Engine Output Control System of Fan Clutch 131
Engine Output Control System Diagram of Fan Clutch 131
Function of Engine Output Control System of Fan Clutch 131
Component Parts of Cooling System . 133
Fan Clutch 133
Control System 134
Machine Monitor System 134
System Diagram of Machine Monitor System 134
Function of Machine Monitor System 135
KomVision System 136
Layout Drawing of KomVision System 136
Around Cab and Floor 137
KomVision System Diagram 138
Function of KomVision System 139
KOMTRAX System 140
KOMTRAX System Diagram 140
Function of KOMTRAX System 140
Component Parts of Control System . 141
Machine Monitor . 141
Monitor Display . 144
Monitor Items and Display . 146
Caution Monitor . 148
Pilot Monitor . 152
Overload Warning Device . 155
Monitor Switches 156
Declaration of Switch Function on Keypad 157
Guidance Icon and Function Switch . 159
Operator Mode Function 162
Service Mode Function of Machine Monitor 164
Gateway Controller 165
Communication Terminal 169
KomVision Controller 170
Structure of KomVision Controller . 170
KomVision Camera 174
Pump Controller . 176
Machine Controller 180
Engine Controller . 184
Fuel Control Dial . 189
Machine Control System Diagram 190
1. Engine and Pump Control Function . 191
PPC Levers 216
LH PPC Lever 216
RH PPC Lever 217
Power Train System 218
Layout Drawing of Power Train System 218
Component Parts of Power Train System . 220
Front Axle 220
Rear Axle . 222
Transmission 224
Travel Motor 227
Operation of Travel Motor . 229
Clutch Control Circuit 231
Travel System . 233
Travel Circuit 233
Travel Motor Performance 234
Travel PPC pedal 236
Swivel Joint 238
Braking System 240
Structure and Function 241
Gear Pump . 242
Priority Valve 244
Power Brake Valve . 246
Accumulator for Brake Valve . 247
Digging Brake Valve . 249
Digging Brake Controller 250
Steering System . 251
Steering System JSS . 252
Steering Column JSS . 254
Steering Column STD . 256
Orbitrol Valve STD 257
Orbitrol Valve JSS 258
Suspension Lock Cylinder (Axle Lock) 260
Circuit . 261
Axle Oscillation 261
Swing System 262
Swing Circle 262
Swing Machinery & Motor . 263
Swing Motor . 265
Operation of Swing Lock . 268
Relief Valve Portion 269
Work Equipment – Swing PPC Valve 270
Undercarriage . 274
Trailer . 276
Calculation of Maximum Coupling Load 276
Automatic Trailer Coupling for Blade 277
Functional Check 277
Possible Faults in the Coupling . 278
Wear Limits . 279
Automatic Trailer Coupling for Outrigger 281
Functional check 281
Height Adjustment Components 282
Possible Faults in the Coupling . 283
Wear Limits . 284
Inspection 286
Hydraulic System 288
Layout Drawing of Hydraulic System 288
CLSS 290
Structure of CLSS . 290
Features of CLSS 290
Composition of CLSS . 290
Function of CLSS 291
LS Differential Pressure (ΔPLS) and Pump Swash Plate Angle 291
Pressure Compensation Control . 292
Component Parts of Hydraulic System . 293
Hydraulic Tank 293
Main Pump . 294
LS Valve 299
PC Valve 300
LS(PC)-EPC Valve 313
Pilot Pressure Control (PPC) System . 316
Control Valve . 318
Hydraulic Circuit Diagram and Name of Valves 333
1. Unload Valve . 335
When the control valve is at neutral, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. At this time, pump discharge pressure PP is set at 3.38 MPa {34.5 kg/cm²} by spring (3) inside the valve. (LS . 335
2. Introduction of LS Pressure 338
3. LS Bypass Plug . 339
4. Pressure Compensation Valve 340
5. Area Ratio of Pressure Compensation Valve 341
6. Boom Regeneration Circuit 343
When the boom is lowered and falls due to its own weight because the bottom pressure A in the cylinder (1) is higher than the head pressure B, this circuit brings the return flow on the bottom side to the head side to increase the cylinder speed . 343
7. Arm Regeneration Circuit . 345
8. Swing Bleeding Valve . 347
9. LS Select Valve 348
Solenoid Valve Block 349
ATT EPC Assembly 351
ON / OFF Solenoid Valves (3 Way Valve) 352
ON / OFF Solenoid Valves (4 Way Valve) 354
Hi/ Lo Solenoid Valve (4 Way Valve) . 356
Attachment PPC Valve 357
Undercarriage Solenoid Valve Block 360
Boom/Outrigger Schematic 361
Undercarriage Attachment Schematic 362
Proportional Attachment Control . 363
Proportional Attachment Schematic . 364
Bucket to 1ATT 365
Boom Safety Valve . 367
Boom Floating . 369
PPC pressure reduction/ Boom floating logic . 369
Tool Control 375
Breaker Return Valve 376
1st Attachment Circuit Hydraulic Performance (Main Valve Bypassed) 380
2nd Auxiliary Circuit in the Undercarriage 381
Hydraulic Quick Coupler . 383
Hydraulic Quick Coupler Solenoid Valve 384
Quick Coupler Error Logic . 385
Full Hydraulic Quick Coupler 386
ECSS 388
ECSS Logic 388
ECSS Hydraulic Schematic 390
ECSS Accumulator Position . 391
ECSS Valve 392
ECSS Hydraulic Diagram 393
Work Equipment 394
Dimension of Arm 396
Hydraulic Cylinder 398
Boom Cylinder . 398
Arm Cylinder 398
Bucket Cylinder . 398
Adjust Cylinder . 399
Outrigger Cylinder 400
Dozer Cylinder 402
Air Conditioner Unit 404
Air Conditioner Component . 404
Specifications of Air Conditioner . 405
Sensors . 406
Ambient Pressure Sensor . 408
Charge (Boost) Pressure and Temperature Sensor 409
Coolant Temperature Sensor 410
Ne (Crankshaft) Speed Sensor 410
Bkup (Camshaft) Speed Sensor 411
Common Rail Pressure Sensor . 411
Exhaust manifold Pressure Sensor 412
TBAP Ambient Pressure and Temperature Sensor 413
KDPF Differential Pressure and Outlet Pressure Sensor . 414
KDOC Inlet Temperature Sensor . 415
Engine Oil Level Sensor . 416
Fuel Level Sensor . 417
WIF (Water-In-Fuel Detection) Sensor 418
Coolant Level Sensor 419
Hydraulic Oil Temperature Sensor 420
Air Cleaner Clogging Sensor . 420
Overload Caution Sensor . 421
Swing Proximity Sensor 422
Brake Sensors . 422
Brake Accumulator Low Pressure Sensor (CN-P60) 423
Brake Stop Light Sensor (CN-S19) 423
Service Brake Pressure Sensor (CN-P64) 423
Service Brake Pressure Sensor (CN-P62) 423
Park Brake Pressure Sensor (CN-P61) . 424
PPC Pressure Sensors and Switches . 424
Main Valve Sensor . 425
Block Pressure Sensors and Switches . 425
ATS area 426
Lubrication . 427
Auto-Grease Pump 427
Overview 428
Display and Control Unit 428
LED-Display . 429
Push Buttons 429
Three-Digit LED Display . 430
Check Central Lubrication System, Fill Up Grease 431
Lubrication Diagrams 432
Auto-Grease Pump With One-Piece Boom 432
Auto-Grease Pump With Two-Piece Boom 433
Manual System One-Piece Boom 434
Manual System Two-Piece Boom 435
Additional Preparations . 436
Preparation Heatable fuel filter 436
Preparation Hydraulic Oil Heater 436
Preparation Fuel Pump (Refuelling Pump) . 436
Standard Value Table for Engine Related Parts . 438
Standard Value Table for Chassis Related Parts 446
Flow Control Characteristic of PC Valve (STD) . 459
PM Clinic Service . 460
Check Sheet . 461
Standard Value Table 437
Testing and Adjusting . 467
Engine and Cooling System . 470
Examine Engine Speed 470
How to Examine Engine Speed . 470
Examine Boost Pressure 473
How to Examine Boost Pressure on Machine Monitor 473
How to Examine Boost Pressure . 474
Examine Exhaust Gas Color . 475
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 475
How to Examine Exhaust Gas Color with Smoke Meter . 476
Examine and Adjust Valve Clearance 478
Check Valve Clearance . 478
Adjust Valve Clearance 480
Examine Compression Pressure 480
How to Examine Compression Pressure . 481
Examine Blowby Pressure . 486
How to Examine Blowby Pressure 486
Examine Engine Oil Pressure . 488
Examine Fuel Pressure . 489
How to Examine Fuel Pressure 491
Examine Low-Pressure Circuit (Fuel Main Filter Inlet Side) 491
Examine Low-Pressure Circuit (Pressure Difference) 492
Examine Return Circuit 493
Examine Negative Pressure Circuit . 494
Examine Fuel Discharge, Return and Leakage 495
How to Examine Fuel Discharge, Return, and Leakage 497
Examine Supply Pump Discharge Volume 497
Examine Supply Pump Return Rate . 498
Examine the Leakage from the Pressure Limiter . 499
Examine the Return Rate of the Injector . 500
Bleed Air from Fuel System 501
How to Bleed Air from Fuel System . 501
Examine Fuel Circuit for Leakage 502
How to Examine Fuel System for Leakage 502
Examine Fuel Circuit for Leakage at Engine Low Idle . 503
How to Examine Fuel Circuit for Leakage at Engine High Idle . 503
How to Examine Fuel Circuit for Leakage at Engine Rated Speed . 504
Handle Cylinder Cut-out Mode Operation 505
Handle No-Injection Cranking Operation 505
Examine and Adjust Air Conditioner Compressor Belt Tension 506
Check air conditioner compressor belt . 506
How to Adjust Air Conditioner Compressor Belt . 506
Replace the Fan Belt 508
Examine cooling fan speed . 509
Method for testing cooling fan speed 509
Write Correction for Ash in Soot Accumulation to Engine Controller 510
How to Write Correction for Ash in Soot Accumulation to Engine Controller . 510
Examine SCR Related Functions . 511
Examine DEF Pump Raised Pressure 514
How to Examine DEF Pump Raised Pressure . 515
Examine Injection Volume from DEF Injector 518
How to Examine Injection Volume from DEF Injector . 519
Examine DEF Line Heater Relay 1 . 523
How to Examine DEF Line Heater Relay 1 523
Examine DEF Line Heater Relay 2 . 526
How to Examine DEF Line Heater Relay 2 527
Examine DEF Pump Heater Relay . 529
How to Examine AdBlue/ DEF Pump Heater Relay 530
Examine DEF Tank Heater Valve . 532
How to Examine DEF Tank Heater Valve 533
Examine SCR Denitration Efficiency 535
How to Examine SCR Denitration Efficiency . 536
Clean DEF Tank 539
How to Clean DEF Tank . 539
Bleed Air from Coolant Circuit of DEF Tank 543
Examine Swing Circle Bearing Clearance 545
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 546
Measurement . 546
Adjustment 547
Examine Oil Pressure of Control Circuit . 550
Measurement . 550
Procedure for pressure reducing adjustment 551
Examine and Adjust Oil Pressure in Pump PC Control Circuit (Valve Inlet) 552
Measurement . 552
Adjustment 554
Examine and Adjust Pump LS Differential Pressure 556
Measurement . 556
Adjustment 559
How to Examine Solenoid Valve Output Pressure . 560
Examine Proportional Control PPC Circuit 562
Adjust of Work Equipment and Swing PPC Valve 563
How to Examine Quick Coupler Control Valve Output Pressure 564
Specification . 565
Examine Travel Motor Relief Pressure 566
How to Examine Travel Motor Relief Pressure . 566
Examine Propshaft Speed . 567
How to Examine Rotating Speed of Propshaft 567
Examine Transmission Clutch Control Circuit . 568
Description . 568
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 570
Release of Remaining Pressure in Hydraulic Circuit 572
Examine Oil Leakage . 573
Air bleeding of various parts . 576
Examine Diodes 579
Electrical system . 581
Set and Operate Machine Monitor . 581
Specification . 582
Operator Mode . 585
Service Mode 590
Table of Self-Define Monitoring . 607
Abnormality Record Menu . 616
Default Menu 630
Diagnostic Tests Menu . 645
Adjustment Menu . 657
KOMTRAX settings menu . 665
Method for Starting up KOMTRAX Terminal . 669
Examine and adjust ECSS (ACCU Pressure) . 675
Maintenance . 675
Examine and Adjust Tool Control . 680
Troubleshooting . 686
Examine Lubrication Interval Times 690
How to Chang the Joystick Steering Control 691
How to Adjust Digging Brake System 692
Procedure to Adjust Rearview Camera Angle . 694
Method for adjusting rear view camera angle . 694
Adjust KomVision camera angle . 696
Tools to Adjust KomVision Camera Angle 696
How to Adjust Rearview Camera Angle . 698
Adjust KomVision Related Function . 699
Setting of KomVision (main setting) . 699
Method for setting KomVision (main setting) . 699
Setting of KomVision (Camera Setting) . 703
How to Set KomVision (Camera Setting) . 703
Setting of KomVision (Camera Calibration) . 703
How to Set KomVision (Camera Calibration) . 704
Troubleshooting . 717
Related Information to Troubleshooting 718
General Troubleshooting Points 718
When the Failure Code Cannot be Cleared by “Loaded Diagnostics Operation to Confirm Failure Correction” or “Loaded Diagnostics Operation to Clear Failure Code” . 721
Sequence of Events in Troubleshooting . 731
Walk-around check . 735
How to Disconnect and Connect Connector with a Special Lock . 737
Connector table . 748
T-Branch Box and T-Branch Adapter Table . 791
T-Boxes and T-Adapters Table 796
Fuse Location Table . 800
Precautions for Replacing KDOC 802
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 803
Failure Code Table (Display of Code) 804
Troubleshooting by Failure Code . 819
Failure Code [2G00MA] – Brake Oil Pressure Abnormality 829
Failure Code [602ENX] – Return Filter Clogging 830
Failure Code [6AZ0MA] – Quick Coupler System Defective Function . 831
Failure Code [6AZ0ZG] – Quick Coupler Pressure Low 832
Failure Code [6B2JMA] – Travel hydraulic abnormality 834
Failure Code [879AKA] – A/C Recirculation Air Temperature Sensor Open Circuit . 835
Failure Code [879AKB] – A/C Inner Sensor Short Circuit 836
Failure Code [879BKA] – A/C Outer Sensor Open Circuit . 838
Failure Code [879BKB] – A/C Outer Sensor Short Circuit 840
Failure Code [879CKA] – Ventilating Sensor Open Circuit . 842
Failure Code [879CKB] – Ventilating Sensor Short Circuit 843
Failure Code [879DKZ] – Sunlight Sensor Open Or Short Circuit . 844
Failure Code [879EMC] – Ventilation Damper Abnormality 846
Failure Code [879FMC] – Air Mix Damper Abnormality 847
Failure Code [879GKX] – Refrigerant Abnormality . 848
Failure Code [989L00] – Engine Controller Lock Caution 1 850
Failure Code [989M00] – Engine Controller Lock Caution 2 851
Failure Code [989N00] – Engine Controller Lock Caution 3 852
Failure Code [A1U0N3] – HC Desorb Request 1 . 853
Failure Code [A1U0N4] – HC Desorb Request 2 . 854
Failure Code [A900FR] – Abrupt Engine Stop by Auto Idling Stop 3 855
Failure Code [A900N6] – Abrupt Engine Stop by Auto Idling Stop 1 856
Failure Code [A900NY] – Abrupt Engine Stop by Auto Idling Stop 2 857
Failure Code [AA10NX] – Air Cleaner Clogging 858
Failure Code [AB00KE] – Charge Voltage Low 860
Failure Code [AQ10MB] – Manual Stationary Regeneration Request 2 862
Failure Code [AQ10N3] – Manual Stationary Regeneration Request 863
Failure Code [AS00R2] – Warning 2 . 864
Failure Code [AS00R3] – Inducement 1 865
Failure Code [AS00R4] – Inducement 2 866
Failure Code [AS00R5] – Inducement 3 867
Failure Code [AS00R6] – Temporary Recovery Of Inducement 868
Failure Code [AS00ZK] – DEF Level Low Error 5 . 869
Failure Code [AS10KM] – DEF Injector Overheat Warning . 870
Failure Code [AS10NR] – DEF Injector High Temperature Warning . 871
Failure Code [AS10NT] – DEF Injector Overheat Caution . 872
Failure Code [B@BAZG] – Engine Oil Pressure Low . 873
Failure Code [B@BAZK] – Engine Oil Level Low 874
Failure Code [B@BCNS] – Engine Coolant Overheat . 875
Failure Code [B@BCQA] – Engine Coolant Level Low 876
Failure Code [B@BCZK] – Engine Coolant Level Low 878
Failure Code [B@HANS] – Hydraulic Oil Overheat 880
Failure Code [CA115] – Engine Neutral and Backup Speed Sensor Error . 882
Failure Code [CA122] – Charge Air Press Sensor High Error . 884
Failure Code [CA123] – Charge Air Press Sensor Low Error 886
Failure Code [CA131] – Throttle Sensor High Error . 888
Failure Code [CA132] – Throttle Sensor Low Error 890
Failure Code [CA144] – Coolant Temperature Sensor High Error 892
Failure Code [CA145] – Coolant Temperature Sensor Low Error . 894
Failure Code [CA153] – Charge Air Temperature Sensor High Error . 896
Failure Code [CA154] – Charge Air Temperature Sensor Low Error 898
Failure Code [CA187] – Sensor 2 Supply Voltage Low Error 900
Failure Code [CA227] – Sensor 2 Supply Voltage High Error . 902
Failure Code [CA234] – Engine Overspeed . 904
Failure Code [CA238] – NE Speed Sensor Supply Voltage Error . 905
Failure Code [CA239] – NE Speed Sensor Supply Voltage High Error 906
Failure Code [CA249] – Ambient Air Temp Sensor High Error . 908
Failure Code [CA256] – Ambient Air Temp Sensor Low Error 910
Failure Code [CA271] – PCV 1 Short Circuit Error 912
Failure Code [CA272] – PCV 1 Open Circuit Error . 914
Failure Code [CA322] – Injector #1 (L#1) Open Circuit Error or Short Circuit Error 916
Failure Code [CA324] – Injector #3 (L#3) Open Circuit Error or Short Circuit Error 918
Failure Code [CA331] – Injector #2 (L#2) Open Circuit Error or Short Circuit Error 920
Failure Code [CA332] – Injector #4 (L#4) Open Circuit Error or Short Circuit Error 922
Failure Code [CA343] – Engine Controller Internal Failure . 924
Failure Code [CA351] – Injectors Drive Circuit Error 924
Failure Code [CA352] – Sensor 1 Supply Voltage Low Error 926
Failure Code [CA386] – Sensor 1 Supply Voltage High Error . 928
Failure Code [CA428] – Water In Fuel Sensor High Error 930
Failure Code [CA429] – Water In Fuel Sensor Low Error . 932
Failure Code [CA435] – Engine Oil Pressure SW Error . 934
Failure Code [CA441] – Battery Voltage Low Error 936
Failure Code [CA442] – Battery Voltage High Error . 938
Failure Code [CA451] – Common Rail Pressure Sensor High Error . 940
Failure Code [CA452] – Common Rail Pressure Sensor Low Error 942
Failure Code [CA488] – Charge Air Temperature High Torque Derate 943
Failure Code [CA515] – Charge Air Temperature High Torque Derate 944
Failure Code [CA516] – Common Rail Pressure Sensor Supply Voltage Low Error . 946
Failure Code [CA553] – Common Rail Pressure High Error 1 947
Failure Code [CA555] – Crankcase Pressure High Error 1 948
Failure Code [CA556] – Crankcase Pressure High Error 3 949
Failure Code [CA559] – Common Rail Pressure Low Error 1 . 950
Failure Code [CA689] – Engine NE Speed Sensor Error . 952
Failure Code [CA691] – Intake Air Temperature Sensor High Error . 954
Failure Code [CA692] – Intake Air Temperature Sensor Low Error 956
Failure Code [CA697] – Engine Controller Internal Temperature Sensor High Error . 958
Failure Code [CA698] – Engine Controller Internal Temperature Sensor Low Error 959
Failure Code [CA731] – Engine Backup Speed Sensor Phase Error . 960
Failure Code [CA741] – Compressor Inlet Press Sensor High Error . 962
Failure Code [CA742] – Compressor Inlet Press Sensor Low Error 964
Failure Code [CA743] – Compressor Inlet Press Sensor In Range Error . 966
Failure Code [CA778] – Engine Backup Speed Sensor Error . 967
Failure Code [CA1117] – Engine Controller Partial Data Lost Error . 972
Failure Code [CA1664] – KDOC Abnormality 974
Failure Code [CA1669] – DEF Level Sensor Voltage High Error . 976
Failure Code [CA1673] – DEF Level Low Error 3 . 977
Failure Code [CA1677] – DEF Temperature Sensor Low Error 978
Failure Code [CA1678] – DEF Temperature Sensor High Error . 979
Failure Code [CA1682] – DEF Pump Priming Error 980
Failure Code [CA1683] – DEF Tank Heating Valve Voltage High Error . 982
Failure Code [CA1684] – DEF Tank Heating Valve Voltage Low Error 984
Failure Code [CA1686] – DEF Quality Sensor Voltage High Error . 986
Failure Code [CA1695] – Sensor 5 Supply Voltage High Error 987
Failure Code [CA1696] – Sensor 5 Supply Voltage Low Error . 988
Failure Code [CA1712] – DEF Tank Thawing Error 990
Failure Code [CA1713] – DEF Tank Heater Valve Open Stuck Error 992
Failure Code [CA1714] – DEF Quality Sensor Out Of Calibration Error . 994
Failure Code [CA1715] – DEF Quality Sensor Internal Circuit Error . 995
Failure Code [CA1776] – Sensor Supply Relay Voltage High Error 996
Failure Code [CA1777] – Sensor Supply Relay Voltage Low Error . 998
Failure Code [CA1843] – Crankcase Pressure Sensor High Error 1000
Failure Code [CA1844] – Crankcase Pressure Sensor Low Error .1002
Failure Code [CA1879] – KDPF Differential Pressure Sensor High Error 1004
Failure Code [CA1881] – KDPF Differential Pressure Sensor Low Error .1006
Failure Code [CA1883] – KDPF Differential Pressure Sensor In Range Error 1008
Failure Code [CA1885] – Turbo Outlet NOx Sensor Circuit Error .1012
Failure Code [CA1887] – SCR Outlet NOx Sensor Circuit Error .1014
Failure Code [CA1921] – KDPF Soot Load High Error 1 .1016
Failure Code [CA1922] – KDPF Soot Load High Error 2 .1018
Failure Code [CA1942] – Crankcase Pressure Sensor In Range Error 1021
Failure Code [CA1993] – KDPF Differential Pressure Low Error 1022
Failure Code [CA2185] – Throttle Sensor Supply Voltage High Error .1024
Failure Code [CA2186] – Throttle Sensor Supply Voltage Low Error 1026
Failure Code [CA2311] – IMV Solenoid Error 1027
Failure Code [CA2373] – Exhaust Manifold Pressure Sensor High Error .1028
Failure Code [CA2374] – Exhaust Manifold Pressure Sensor Low Error 1030
Failure Code [CA2554] – Exhaust Manifold Pressure Sensor In Range Error .1032
Failure Code [CA2555] – Intake Air Heater Relay Open Circuit Error 1034
Failure Code [CA2556] – Intake Air Heater Relay Short Circuit Error .1036
Failure Code [CA2637] – KDOC Face Plugging 1038
Failure Code [CA2639] – Manual Stationary Regeneration Request 1040
Failure Code [CA2771] – SCR Outlet NOx Sensor Datalink Timeout Error 1042
Failure Code [CA2973] – Charge Air Pressure Sensor In Range Error .1045
Failure Code [CA2976] – DEF Pump Temperature Sensor Signal Error 1046
Failure Code [CA3133] – KDPF Outlet Pressure Sensor High Error 1048
Failure Code [CA3134] – KDPF Outlet Pressure Sensor Low Error .1050
Failure Code [CA3135] – KDPF Outlet Pressure Sensor In Range Error 1052
Failure Code [CA3142] – SCR Temperature Sensor High Error .1056
Failure Code [CA3143] – SCR Temperature Sensor Low Error 1057
Failure Code [CA3144] – SCR Temperature Sensor In Range Error .1058
Failure Code [CA3146] – SCR Outlet Temperature Sensor High Error 1060
Failure Code [CA3147] – SCR Outlet Temperature Sensor Low Error .1061
Failure Code [CA3148] – SCR Outlet Temperature Sensor In Range Error 1062
Failure Code [CA3151] – SCR Catalyst Efficiency Low Error 2 .1064
Failure Code [CA3165] – SCR Outlet Temperature High Error .1070
Failure Code [CA3228] – Turbo Outlet NOx Sensor In Range Error 1072
Failure Code [CA3229] – SCR Temperature High Error 1074
Failure Code [CA3231] – SCR Temperature High Error Non Regeneration .1076
Failure Code [CA3232] – Turbo Outlet NOx Sensor Datalink Timeout Error 1078
Failure Code [CA3235] – SCR Outlet Temperature High Error – Non Regeneration 1082
Failure Code [CA3239] – DEF Line Heater 2 Voltage High Error 1084
Failure Code [CA3241] – DEF Line Heater 2 Voltage Low Error .1086
Failure Code [CA3242] – DEF Tank Heating Error 1088
Failure Code [CA3251] – KDOC Inlet Temperature High Error .1090
Failure Code [CA3253] – KDOC Temperature Error – Non Regeneration .1092
Failure Code [CA3254] – KDOC Outlet Temperature High Error 1 1094
Failure Code [CA3255] – KDPF Temperature Error – Non Regeneration .1096
Failure Code [CA3256] – KDPF Outlet Temperature High Error 1 1098
Failure Code [CA3311] – KDOC Outlet Temperature High Error 2 1100
Failure Code [CA3312] – KDPF Outlet Temperature High Error 2 1102
Failure Code [CA3313] – KDOC Inlet Temperature Sensor Low Error .1104
Failure Code [CA3314] – KDOC Inlet Temperature Sensor High Error 1105
Failure Code [CA3315] – KDOC Inlet Temperature Sensor In Range Error 1106
Failure Code [CA3316] – KDOC Outlet Temperature Sensor Low Error 1108
Failure Code [CA3317] – KDOC Outlet Temperature Sensor High Error .1109
Failure Code [CA3318] – KDOC Outlet Temperature Sensor In Range Error .1110
Failure Code [CA3319] – KDPF Outlet Temp Sensor High Error 1112
Failure Code [CA3321] – KDPF Outlet Temperature Sensor Low Error 1113
Failure Code [CA3322] – KDPF Outlet Temperature Sensor In Range Error .1114
Failure Code [CA3419] – MAF Sensor Supply Voltage High Error 1116
Failure Code [CA3421] – MAF Sensor Supply Voltage Low Error .1118
Failure Code [CA3497] – DEF Level Low Error 1 .1120
Failure Code [CA3498] – DEF Level Low Error 2 .1121
Failure Code [CA3545] – SCR Outlet NOx Sensor Unstable Error 1122
Failure Code [CA3547] – DEF Level Low Error 4 .1124
Failure Code [CA3558] – DEF Pump Voltage High Error .1126
Failure Code [CA3559] – DEF Pump Voltage Low Error 1128
Failure Code [CA3562] – DEF Line Heater Relay 1 Voltage High Error 1130
Failure Code [CA3563] – DEF Line Heater Relay 1 Voltage Low Error .1132
Failure Code [CA3567] – DEF Injector Open Circuit Error Or Short Circuit Error 1134
Failure Code [CA3568] – DEF Malfunction .1137
Failure Code [CA3571] – DEF Pump Pressure Sensor High Error .1142
Failure Code [CA3572] – DEF Pump Pressure Sensor Low Error 1144
Failure Code [CA3574] – DEF Pump Pressure Too Low Error .1146
Failure Code [CA3575] – DEF Pump Pressure Too High Error 1148
Failure Code [CA3577] – DEF FCV Voltage High Error 1150
Failure Code [CA3578] – DEF FCV Voltage Low Error .1152
Failure Code [CA3583] – SCR Outlet NOx Sensor Heater Warming Up Error .1154
Failure Code [CA3596] – DEF Pump Pressure Unstable Error 1156
Failure Code [CA3649] – Turbo Outlet NOx Sensor Heater Warming Up Error .1160
Failure Code [CA3681] – SCR Outlet NOx Sensor Power Voltage Error .1162
Failure Code [CA3682] – Turbo Outlet NOx Sensor Power Voltage Error .1167
Failure Code [CA3713] – DEF Line Heater 1 Voltage High Error 1172
Failure Code [CA3717] – SCR Outlet NOx Sensor Voltage Mismatch Error 1174
Failure Code [CA3718] – Turbo Outlet NOx Sensor Voltage Mismatch Error 1175
Failure Code [CA3725] – Turbo Outlet NOx Sensor Unstable Error 1176
Failure Code [CA3741] – Rail Press Valve Trip Error .1178
Failure Code [CA3748] – Turbo Outlet NOx Sensor Stuck In Range Error 1180
Failure Code [CA3755] – DEF Dosing Performance Degradation Error 1182
Failure Code [CA3866] – DEF Low Concentration Error 2 .1184
Failure Code [CA3867] – DEF Low Concentration Error 1 .1188
Failure Code [CA3868] – DEF Tank Sensor Datalink Timeout Error 1190
Failure Code [CA4151] – KDOC and KDPF Temperature Sensor Datalink Timeout Error .1193
Failure Code [CA4152] – SCR Temperature Sensor Datalink Timeout Error .1196
Failure Code [CA4155] – DEF Pump Heater Relay Voltage High Error 1200
Failure Code [CA4156] – DEF Pump Heater Relay Voltage Low Error .1202
Failure Code [CA4157] – DEF FCV Malfunction .1204
Failure Code [CA4158] – KDOC and KDPF Temperature Sensor Internal Circuit Error .1206
Failure Code [CA4159] – SCR Temperature Sensor Internal Circuit Error .1207
Failure Code [CA4161] – KDOC and KDPF Temperature Sensor ECU Voltage High Error .1208
Failure Code [CA4162] – KDOC and KDPF Temperature Sensor ECU Voltage Low Error 1210
Failure Code [CA4163] – KDOC and KDPF Temperature Sensor ECU Over Temperature Error .1212
Failure Code [CA4164] – SCR Temperature Sensor ECU Voltage High Error .1214
Failure Code [CA4165] – SCR Temperature Sensor ECU Voltage Low Error 1216
Failure Code [CA4166] – SCR Temperature Sensor ECU High Temperature Error .1218
Failure Code [CA4168] – DEF Pump Heater ON Stuck Error 1220
Failure Code [CA4169] – DEF Pump Heater OFF Stuck Error .1222
Failure Code [CA4171] – DEF Pump Thawing Error 1224
Failure Code [CA4249] – DEF Pump Temperature Sensor 1 In Range Error 1226
Failure Code [CA4251] – DEF Pump Temperature Sensor 2 In Range Error 1228
Failure Code [CA4259] – KDOC and KDPF Temperature Sensor Power Interrupt Error 1230
Failure Code [CA4261] – SCR Temperature Sensor Power Interrupt Error 1232
Failure Code [CA4277] – DEF Quality Sensor Liquid Distinction Impossible Error 1236
Failure Code [CA4459] – DEF Line Heater Relay 2 Voltage High Error 1238
Failure Code [CA4461] – DEF Line Heater Relay 2 Voltage Low Error .1240
Failure Code [CA4731] – DEF Temperature Sensor Transmission Data Error 1242
Failure Code [CA4732] – DEF Level Sensor Transmission Data Error 1243
Failure Code [CA4739] – DEF Level Sensor Internal Circuit Error .1244
Failure Code [CA4768] – Fuel in DEF Tank Error 1246
Failure Code [CA4769] – DEF Level Measurement Impossible 1248
Failure Code [CA4842] – DEF High Concentration Error 1250
Failure Code [CA4952] – System Operating Lamp Short Circuit (Engine Controller) .1252
Failure Code [CA5115] – DEF Line Heater 1 Voltage Low Error .1254
Failure Code [CA5179] – Engine Room Temperature Sensor High Error .1258
Failure Code [CA5181] – Engine Room Temperature Sensor Low Error 1260
Failure Code [CA5271] – Exhaust Throttle Valve Motor Driver Voltage High Error 1262
Failure Code [CA5272] – Exhaust Throttle Valve Motor Driver Voltage Low Error .1264
Failure Code [CA5273] – Exhaust Throttle Valve Motor Driver Open Error 1266
Failure Code [CA5274] – Exhaust Throttle Valve Position Sensor In Range Error .1268
Failure Code [CA5275] – Exhaust Throttle Valve Position Sensor High Error .1270
Failure Code [CA5276] – Exhaust Throttle Valve Position Sensor Low Error 1272
Failure Code [CA5383] – Ash Accumulation High Error .1274
Failure Code [CA5631] – Manual Stationary Regeneration Request (Automatic Regeneration Uncompleted) .1275
Failure Code [CA5632] – Manual Stationary Regeneration Request but Regeneration Disable .1276
Failure Code [CA5655] – SCR Catalyst Degradation Error 1277
Failure Code [CA5689] – SCR Outlet NOx Sensor Tamparing Error .1282
Failure Code [CA5715] – KDPF Delta P Sensor In Range Dither Error .1284
Failure Code [CA5716] – KDPF Outlet Press Sensor In Range Dither Error 1288
Failure Code [CA5838] – SCR Outlet NOx Sensor Self-Diag Stuck In-range Error 1292
Failure Code [CA5864] – DEF Pump Short to Battery .1294
Failure Code [CA5865] – DEF Pump Short to Ground 1296
Failure Code [CA5938] – Manual Stationary Regeneration Request 1298
Failure Code [CA6513] – DEF Pump Thawing Error 1299
Failure Code [CA6771] – Aftertreatment Tempe Sens Auto Defective Misconfiguration .1300
Failure Code [D109KA] – ECSS Relay Open Circuit .1304
Failure Code [D109KB] – ECSS Relay Short Circuit 1306
Failure Code [D109KY] – ECSS Relay Hot Short Circuit 1308
Failure Code [D109MA] – ECSS Relay Defective Function .1310
Failure Code [D110KB] – Battery Relay Output Short Circuit 1312
Failure Code [D19JKZ] – Personal Code Relay Abnormality .1314
Failure Code [D19QKB] – Short Circuit in Refuel Pump Relay 1316
Failure Code [D19QKY] – Hot Short Circuit in Refuel Pump Relay 1318
Failure Code [D1EMKA] – Parking Brake Relay Open Circuit 1320
Failure Code [D1EMKB] – Parking Brake Relay Short Circuit .1322
Failure Code [D1EMKY] – Parking Brake Relay Hot Short Circuit .1324
Failure Code [D1EMMA] – Parking Brake Relay Defective Function 1326
Failure Code [D811MC] – KOMTRAX Malfunction .1328
Failure Code [D862KA] – GPS Antenna Open Circuit 1329
Failure Code [D8ALKA] – System Operating Lamp Open Circuit (KOMTRAX) 1330
Failure Code [D8ALKB] – System Operating Lamp Short Circuit (KOMTRAX) .1332
Failure Code [D8AQKR] – CAN2 Discon (KOMTRAX) .1334
Failure Code [D8ARKR] – CAN1 Defective Communication (Gateway Controller) .1338
Failure Code [D8G1KT] – Malfunction (Gateway Controller) 1342
Failure Code [D8G6KT] – Malfunction (Communication Terminal) 1342
Failure Code [DA20MC] – Pump Controller Malfunction .1343
Failure Code [DA22KK] – Pump Solenoid Power Low Error .1344
Failure Code [DA22KT] – Pump Controller Solenoid Power Controller Internal Failure 1346
Failure Code [DA25KP] – 5 V Sensor 1 Power Voltage Low Error 1348
Failure Code [DA26KP] – 5 V Sensor 2 Power Voltage Low Error 1350
Failure Code [DA27KP] – 24V Sensor Power Abnormality 1352
Failure Code [DA29KQ] – Model Selection Signal Mismatch .1354
Failure Code [DA2JKT] – Pump Controller Solenoid Return Circuit Controller Internal Failure .1356
Failure Code [DA2JKY] – Pump Controller Solenoid Return Circuit Hot Short Circuit .1357
Failure Code [DA2LKA] – System Operating Lamp Open Circuit (Pump Controller System) .1358
Failure Code [DA2LKB] – System Operating Lamp Short Circuit .1360
Failure Code [DA2QKR] – Controller Area Network 2 Defective Communication .1362
Failure Code [DA2RKR] – Controller Area Network 1 Defective Communication .1366
Failure Code [DA80KB] – Auto Grease System Monitoring Signal Short Circuit 1370
Failure Code [DAB0KT] – Internal Flash Memory Error (Pump Controller System) 1372
Failure Code [DAC3KB] – Cruise Control System Power Supply Short Circuit 1374
Failure Code [DAC3KY] – Cruise Control System Power Supply Hot Short Circuit 1376
Failure Code [DAF0KM] – Inconsistency of KomVision Setting 1378
Failure Code [DAF0MB] – Monitor ROM Abnormality .1378
Failure Code [DAF0MC] – Monitor Malfunction .1379
Failure Code [DAF7KB] – Fuel Ref-Meter Power Abnormality 1380
Failure Code [DAF8KB] – Camera Power Supply Short Circuit .1381
Failure Code [DAF9KQ] – Model Selection Abnormality .1383
Failure Code [DAFGMC] – GPS Module Malfunction 1384
Failure Code [DAFLKA] – System Operating Lamp Open Circuit (Monitor) 1385
Failure Code [DAFLKB] – System Operating Lamp Short Circuit (Monitor) .1388
Failure Code [DAFQKR] – CAN 2 Defective Communication (Monitor) .1390
Failure Code [DAFSMC] – Fuel Ref-Meter Communication Error 1394
Failure Code [DAZ9KQ] – Model Selection Signal Mismatch (Air Conditioner) .1395
Failure Code [DAZQKR] – CAN 2 Defective Communication (A/C ECU) .1396
Failure Code [DB2QKR] – CAN2 Discon (Engine Con) 1399
Failure Code [DB2RKR] – CAN1 Discon (Engine Con) 1404
Failure Code [DB30KR] – Joystick Steering Controller Malfunction 1409
Failure Code [DBP0KM] – KomVision Setting Error .1410
Failure Code [DBP0KT] – KomVision Controller Abnormality 1411
Failure Code [DBP5KB] – Camera Power Supply Short Circuit .1412
Failure Code [DBP5KY] – Camera Power Hot Short Circuit 1414
Failure Code [DBPQKR] – CAN 2 Defective Communication (KomVision) .1416
Failure Code [DCS0KT] – Internal Flash Memory Error (Machine Controller System) .1420
Failure Code [DCS0MC] – Machine Controller Malfunction 1421
Failure Code [DCS2KK] – Machine Controller Solenoid Power Voltage Low Error .1422
Failure Code [DCS2KT] – Machine Controller Solenoid Power Controller Internal Failure .1424
Failure Code [DCS5KP] – 5V Sensor 1 Power Voltage Low Error .1426
Failure Code [DCS6KP] – 5V Sensor 2 Power Voltage Low Error .1428
Failure Code [DCS7KP] – 24V Sensor Power Voltage Low Error 1430
Failure Code [DCS9KQ] – Model Selection Signal Mismatch (Machine Controller) 1432
Failure Code [DCSJKT] – Machine Controller Solenoid Return Circuit Controller Internal Failure 1434
Failure Code [DCSJKY] – Machine Controller Solenoid Return Circuit Hot Short Circuit 1435
Failure Code [DCSLKA] – System Operating Lamp Open Circuit (Machine Controller) .1436
Failure Code [DCSLKB] – System Operating Lamp Short Circuit (Machine Controller) 1438
Failure Code [DCSQKR] – CAN 2 Defective Communication (Machine Controller) 1440
Failure Code [DCSRKR] – CAN 1 Defective Communication (Machine Controller) 1442
Failure Code [DDB6KA] – Parking Brake SW Open Circuit .1444
Failure Code [DDB6KB] – Parking Brake SW Short Circuit 1446
Failure Code [DDC4KA] – ECSS SW Open Circuit 1448
Failure Code [DDC4KB] – ECSS SW Short Circuit .1450
Failure Code [DDJ1KA] – Quick Coupler Inductive Sensor 1 Open Circuit .1452
Failure Code [DDJ2KA] – Quick Coupler Inductive Sensor 2 Open Circuit .1454
Failure Code [DDK8KA] – SUSLock Forced SW Open Circuit 1456
Failure Code [DDK8KB] – SUSLock Forced SW Short Circuit .1458
Failure Code [DDKVKA] – Joystick Steering Activation Sw Open Circuit 1460
Failure Code [DDKVKB] – Joystick Steering Activation SW Short Circuit .1461
Failure Code [DDNRKA] – W/E Lever Lock SW Open Circuit 1462
Failure Code [DDNRKY] – W/E Lever Lock SW Short Circuit .1464
Failure Code [DDNS00] – Lock Lever Auto Lock Release SW ON 1466
Failure Code [DDP4KX] – Disconnection in Travel PPC Pressure Switch .1468
Failure Code [DDQ1KA] – SUSLock Mode Selection SW Open Circuit 1470
Failure Code [DDQ1KB] – SUSLock Mode Selection SW Short Circuit .1472
Failure Code [DDWCKZ] – Direction Switch Abnormality 1474
Failure Code [DDWMKZ] – FBR Attachment SW Abnormality .1476
Failure Code [DFB1KZ] – Service Lever Potentio 1 Open or Short Circuit 1478
Failure Code [DFB2KZ] – Service Lever Potentio 2 Open or Short Circuit 1480
Failure Code [DFB3L8] – Service Lever 1 Potentiometer Error .1482
Failure Code [DFB4L8] – Service Lever 2 Potentiometer Error .1483
Failure Code [DFB6KZ] – Service Lever Sub Potentio 2 Open or Short Circuit 1486
Failure Code [DGH2KA] – Hydraulic Oil Temperature Sensor Open Circuit .1488
Failure Code [DGH2KB] – Hydraulic Oil Temperature Sensor Ground Fault .1490
Failure Code [DHA4KA] – Air Cleaner Clog Sensor Open Circuit 1492
Failure Code [DHAAMA] – KDPF Differential Pressure Sensor Frozen 1494
Failure Code [DHACMA] – KDPF Outlet Pressure Sensor Frozen 1495
Failure Code [DHH2MA] – Return Line Filter Press Sensor Abnormally 1496
Failure Code [DHPAMA] – Front Pump Pressure Sensor Defective Function .1498
Failure Code [DHS3MA] – Arm IN PPC Pressure Sensor Defective Function .1500
Failure Code [DHS4MA] – Bucket CURL PPC Pressure Sensor Defective Function 1502
Failure Code [DHS5KX] – Travel PPC Sensor Abnormality .1504
Failure Code [DHS8MA] – Boom RAISE PPC Pressure Sensor Defective Function .1506
Failure Code [DHS9MA] – Boom LOWER PPC Pressure Sensor Defective Function .1508
Failure Code [DHSAMA] – Swing Right PPC Pressure Sensor Defective Function 1510
Failure Code [DHSBMA] – Swing Left PPC Pressure Sensor Defective Function .1512
Failure Code [DHSCMA] – Arm OUT PPC Pressure Sensor Defective Function 1514
Failure Code [DHSDMA] – Bucket DUMP PPC Pressure Sensor Defective Function 1516
Failure Code [DHT8KA] – S/T Oil Pressure Sensor Open Circuit or Ground Fault 1518
Failure Code [DHT8KB] – S/T Oil Pressure Sensor Hot Short Circuit .1520
Failure Code [DHT8ZG] – S/T Oil Pressure Low 1522
Failure Code [DHTFKA] – Service Brake Press Sensor 2 Open Circuit .1524
Failure Code [DHTFKY] – Service Brake Press Sensor 2 Short Circuit 1526
Failure Code [DHTFL8] – Service Brake Press Sensor Defective Function .1528
Failure Code [DHU1KA] – Brake Accumulator Press Sensor Open Circuit .1530
Failure Code [DHU1KY] – Brake Accumulator Press Sensor Short Circuit 1532
Failure Code [DHUCKA] – Parking Brake Press Sensor Open Circuit .1534
Failure Code [DHUCKY] – Parking Brake Press Sensor Short Circuit 1536
Failure Code [DHUGKA] – Service Brake Press Sensor Open Circuit .1538
Failure Code [DHUGKY] – Service Brake Press Sensor Short Circuit 1540
Failure Code [DHX1MA] – Overload Sensor Abnormality .1542
Failure Code [DKULKA] – PPC Lock Relay Open Circuit .1544
Failure Code [DKULKB] – PPC Lock Relay Short Circuit 1546
Failure Code [DKULKY] – PPC Lock Relay Hot Short Circuit 1548
Failure Code [DLM5KA] – Fan Speed Sensor Open Circuit .1550
Failure Code [DLM5MB] – Fan Control: Mismatch .1552
Failure Code [DLT4KA] – Speed Sensor Open Circuit .1554
Failure Code [DLT4KB] – Speed Sensor Short Circuit 1556
Failure Code [DR10KA] – KomVision Camera Open Circuit .1558
Failure Code [DR12KA] – Disconnection of Camera 1 NTSC Input 1560
Failure Code [DR20KA] – Disconnection of Camera 2 NTSC Input 1562
Failure Code [DR21KX] – Camera 2 Picture Rev. Drive Abnormality .1564
Failure Code [DR30KA] – Disconnection of Camera 3 NTSC Input 1566
Failure Code [DR31KX] – Camera 3 Picture Reverse Drive Input Out of Range .1568
Failure Code [DR40KA] – Disconnection of Camera 4 NTSC Input 1570
Failure Code [DUMBKA] – Operating Lamp Open Circuit (KomVision) .1572
Failure Code [DUMBKB] – Operating Lamp Short Circuit (KomVision) 1574
Failure Code [DV00KA] – Buzzer Output Open Circuit (KomVision) 1576
Failure Code [DV00KB] – Buzzer Output Short Circuit (KomVision) .1577
Failure Code [DV20KB] – Travel Alarm Short Circuit 1578
Failure Code [DW44KA] – Travel F/R Solenoid Open Circuit 1580
Failure Code [DW44KB] – Travel F/R Solenoid Short Circuit .1582
Failure Code [DW44KY] – Travel F/R Solenoid Hot Short Circuit .1584
Failure Code [DW45KA] – Swing Parking Brake Solenoid Open Circuit .1586
Failure Code [DW45KB] – Swing Parking Brake Solenoid Short Circuit 1588
Failure Code [DW45KY] – Swing Parking Brake Solenoid Hot Short Circuit 1590
Failure Code [DW4AKA] – SUSLock Sol Open Circuit 1592
Failure Code [DW4AKB] – SUSLock Sol Short Circuit .1594
Failure Code [DW4AKY] – SUSLock Sol Hot Short Circuit .1596
Failure Code [DW4BKA] – Parking Brake Sol Open Circuit 1598
Failure Code [DW4BKB] – Parking Brake Sol Short Circuit .1600
Failure Code [DW4BKY] – Parking Brake Sol Short Circuit .1602
Failure Code [DW4CKY] – PPC Lock Solenoid Hot Short Circuit .1604
Failure Code [DW4MKA] – Disconnection in Creep Solenoid .1606
Failure Code [DW4MKB] – Short Circuit in Creep Solenoid .1607
Failure Code [DW4MKY] – Hot Short Circuit in Creep Solenoid .1608
Failure Code [DW4YKA] – High Gear Sol Open Circuit 1610
Failure Code [DW4YKB] – High Gear Sol Short Circuit .1612
Failure Code [DW4YKY] – High Gear Sol Hot Short Circuit .1614
Failure Code [DW4ZKA] – Low Gear Sol Open Circuit .1616
Failure Code [DW4ZKB] – Low Gear Sol Short Circuit 1618
Failure Code [DW4ZKY] – Low Gear Sol Hot Short Circuit 1620
Failure Code [DW91KA] – Travel Neutral Sol Open Circuit .1622
Failure Code [DW91KB] – Travel Neutral Sol Short Circuit 1624
Failure Code [DW91KY] – Travel Neutral Sol Hot Short Circuit 1626
Failure Code [DWA2KA] – Attachment Single or 2-Way Change Solenoid Open Circuit (Breaker Mode Relay) 1628
Failure Code [DWA2KB] – Attachment Single or 2-Way Change Solenoid Short Circuit (Breaker Mode Relay) .1630
Failure Code [DWA2KY] – Attachment Single or 2-Way Change Solenoid Hot Short Circuit (Breaker Mode Relay) .1632
Failure Code [DWB1KA] – Outrigger Selection Sol Relay Open Circuit 1634
Failure Code [DWB1KB] – Outrigger Selection Sol Relay Short Circuit .1636
Failure Code [DWB2KA] – Disconnection in 1st Outrigger Solenoid .1638
Failure Code [DWB2KB] – Outrigger Sol.1 Short Circuit .1640
Failure Code [DWB2KY] – Outrigger Sol.1 Hot Short Circuit .1642
Failure Code [DWB3KA] – Outrigger Sol.2 Open Circuit 1644
Failure Code [DWB3KB] – Outrigger Sol.2 Short Circuit .1646
Failure Code [DWB3KY] – Outrigger Sol.2 Hot Short Circuit .1648
Failure Code [DWB4KA] – Outrigger Sol.3 Open Circuit 1650
Failure Code [DWB4KB] – Outrigger Sol.3 Short Circuit .1652
Failure Code [DWB4KY] – Outrigger Sol.3 Hot Short Circuit .1654
Failure Code [DWB5KA] – Outrigger Sol.4 Open Circuit 1656
Failure Code [DWB5KB] – Outrigger Sol.4 Short Circuit .1658
Failure Code [DWB5KY] – Outrigger Sol.4 Hot Short Circuit .1660
Failure Code [DWK0KA] – 2-Stage Relief Solenoid Open Circuit 1662
Failure Code [DWK0KB] – 2-Stage Relief Solenoid Short Circuit .1664
Failure Code [DWK0KY] – 2-Stage Relief Solenoid Hot Short Circuit .1666
Failure Code [DWK2KA] – Variable Back Pressure Solenoid Open Circuit 1668
Failure Code [DWK2KB] – Variable Back Pressure Solenoid Short Circuit .1670
Failure Code [DWK2KY] – Variable Back Pressure Solenoid Hot Short Circuit .1672
Failure Code [DWKSKA] – Boom Float Sol Open Circuit .1674
Failure Code [DWKSKB] – Boom Float Sol Short Circuit 1676
Failure Code [DWKSKY] – Boom Float Sol Hot Short Circuit 1678
Failure Code [DWMBKA] – Work Equipment PPC Reduction Solenoid Open Circuit 1680
Failure Code [DWMBKB] – Work Equipment PPC Reduction Solenoid Short Circuit .1682
Failure Code [DWMBKY] – Work Equipment PPC Reduction Solenoid Hot Short Circuit .1684
Failure Code [DWMCKA] – Auxiliary Hydraulic Circuit 1 Solenoid Open Circuit .1686
Failure Code [DWMCKB] – Auxiliary Hydraulic Circuit 1 Solenoid Short Circuit 1688
Failure Code [DWMCKY] – Auxiliary Hydraulic Circuit 1 Solenoid Hot Short Circuit 1690
Failure Code [DWMDKB] – Auxiliary Hydraulic Circuit 2 Solenoid Short Circuit 1692
Failure Code [DWMDKY] – Auxiliary Hydraulic Circuit 2 Solenoid Hot Short Circuit 1694
Failure Code [DWN5KA] – Fan Clutch Solenoid Open Circuit 1696
Failure Code [DWN5KB] – Fan Clutch Solenoid Short Circuit .1698
Failure Code [DWN5KY] – Fan Clutch Solenoid Hot Short Circuit .1700
Failure Code [DXA8KA] – Pump PC-EPC Solenoid Open Circuit .1702
Failure Code [DXA8KB] – Pump PC-EPC Solenoid Short Circuit 1704
Failure Code [DXE0KA] – LS-EPC Solenoid Open Circuit 1706
Failure Code [DXE0KB] – LS-EPC Solenoid Short Circuit .1708
Failure Code [DXE7KA] – Attachment Flow Regulating EPC 2 Solenoid Open Circuit 1710
Failure Code [DXE7KB] – Attachment Flow Regulating EPC 2 Solenoid Short Circuit .1712
Failure Code [DXE7KY] – Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit .1714
Failure Code [DXE8KA] – Attachment Flow Regulating EPC 3 Solenoid Open Circuit 1716
Failure Code [DXE8KB] – Attachment Flow Regulating EPC 3 Solenoid Short Circuit .1718
Failure Code [DXE8KY] – Attachment Flow Regulating EPC 3 Solenoid Hot Short Circuit .1720
Failure Code [DXE9KA] – Attachment Flow Regulating EPC 4 Solenoid Open Circuit 1722
Failure Code [DXE9KB] – Attachment Flow Regulating EPC 4 Solenoid Short Circuit .1724
Failure Code [DXE9KY] – Attachment Flow Regulating EPC 4 Solenoid Hot Short Circuit .1726
Failure Code [DXEAKA] – Attachment Flow Regulating EPC 5 Solenoid Open Circuit 1728
Failure Code [DXEAKB] – Attachment Flow Regulating EPC 5 Solenoid Short Circuit .1730
Failure Code [DXEAKY] – Attachment Flow Regulating EPC 5 Solenoid Hot Short Circuit .1732
Failure Code [DXEKKA] – Attachment Variable Press EPC1 Open Circuit .1734
Failure Code [DXEKKB] – Attachment Variable Press EPC1 Short Circuit 1736
Failure Code [DXEKKY] – Attachment Variable Press EPC1 Hot Short Circuit 1738
Failure Code [DXELKA] – Attachment Variable Press EPC2 Open Circuit .1740
Failure Code [DXELKB] – Attachment Variable Press EPC2 Short Circuit 1742
Failure Code [DXELKY] – Attachment Variable Press EPC2 Hot Short Circuit 1744
Failure Code [DXK3KA] – Travel Pedal Throttle EPC Solenoid Open Circuit .1746
Failure Code [DXK3KB] – Travel Pedal Throttle EPC Solenoid Short Circuit 1747
Failure Code [DY20KA] – Wiper Motor Open Circuit 1748
Failure Code [DY20MA] – Wiper Motor Defective Function 1750
Failure Code [DY2CKB] – Washer Motor Short Circuit 1752
Failure Code [DY2DKB] – Wiper Motor (Normal Rotation) Short Circuit .1754
Failure Code [DY2EKB] – Wiper Motor (Reverse Rotation) Short Circuit 1756
Failure Code [F311KA] – Centralized Warning Lamp Signal 1 Open Circuit 1758
Failure Code [F311KB] – Centralized Warning Lamp Signal 1 Short Circuit .1760
Failure Code [F312KA] – Centralized Warning Lamp Signal 2 Open Circuit 1762
Failure Code [F312KB] – Centralized Warning Lamp Signal 2 Short Circuit .1764
Failure Code [F313KA] – Communication Terminal Startup Signal Open Circuit 1766
Failure Code [F313KB] – Communication Terminal Startup Signal Short Circuit .1768
Failure Code [F314KA] – Software Update Signal Open Circuit .1770
Failure Code [F314KB] – Software Update Signal Short Circuit 1772
Failure Code [F315KA] – Engine Controller WAKE Signal Open Circuit 1774
Failure Code [F315KB] – Engine Controller WAKE Signal Short Circuit .1776
Failure Code [F315KY] – Engine Controller WAKE Signal Hot Short Circuit .1778
Failure Code [F316KA] – 3rd Party Component Startup Signal Open Circuit .1780
Failure Code [F316KB] – 3rd Party Component Startup Signal Short Circuit 1782
Failure Code [F316KY] – 3rd Party Component Startup Signal Hot Short Circuit 1784
Failure Code [F318KB] – Communication Terminal Power Supply 1 Short Circuit .1786
Failure Code [F318KY] – Communication Terminal Power Supply 1 Hot Short Circuit .1788
Failure Code [F31AKB] – Ethernet Power Supply Short Circuit .1790
Failure Code [F31AKY] – Ethernet Power Supply Hot Short Circuit .1792
Failure Code [F31BKB] – 5V Sensor Power Supply Short Circuit (Gateway Controller) .1794
Failure Code [F31BKY] – 5V Sensor Power Supply Hot Short Circuit (Gateway Controller) .1796
Failure Code [F31CKB] – 12V Sensor Power Supply Short Circuit (Gateway Controller) 1798
Failure Code [F31CKY] – 12V Sensor Power Supply Hot Short Circuit (Gateway Controller) 1800
Failure Code [F31DKB] – 24V Sensor Power Supply Short Circuit (Gateway Controller) 1802
Failure Code [F31DKY] – 24V Sensor Power Supply Hot Short Circuit (Gateway Controller) 1804
Failure Code [F31EKB] – 24V Sensor Power Supply Booster Output Short Circuit (Gateway Controller) .1806
Failure Code [F31EKY] – 24V Sensor Power Supply Booster Output Hot Short Circuit (Gateway Controller) .1808
Failure Code [F7FQKR] – CAN2 Discon (ID Key Con) 1810
Failure Code [F7G0MC] – ID Key Receiving Antenna Malfunction 1814
Troubleshooting of Central Lubrication System (CLS) .1815
Trouble .1815
Troubleshooting During Grease Pump Operation 1817
Pump Element 1818
Check Power Supply 1819
Changing the Control Unit .1819
Troubleshooting – Grease System Faults 1820
Venting of the System .1821
General Assembly Advice .1822
Troubleshooting of Engine (S-Mode) 1823
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1824
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1825
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1826
S-4 Engine Startability is Unsatisfactory .1827
S-5 Engine Does Not Pick Up Smoothly 1829
S-6 Engine Stops During Operation .1831
S-7 Engine Runs Rough or is Not Stable 1832
S-8 Engine Lacks Power 1833
S-9 Exhaust Smoke is Black 1835
S-10 Engine Oil Consumption Is Excessive 1836
S-11 Oil Becomes Dirty Quickly 1837
S-12 Fuel Consumption Is Excessive 1838
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1839
S-14 Oil Pressure Drops .1840
S-15 Fuel Mixes into Engine Oil .1841
S-16 Water Mixes into Engine Oil (Milky) 1842
S-17 Coolant Temperature Rises Too High (Overheating) .1843
S-18 Unusual Noise is Heard .1844
S-19 Vibration is Excessive .1845
S-20 Air Cannot be Bled from Fuel Circuit .1846
S-21 Active Regeneration is Executed Frequently .1847
S-22 Active Regeneration Takes Time .1848
S-23 White Smoke is Exhausted During Active Regeneration 1849
S-24 DEF Consumption is Excessive .1850
S-25 There is Unusual Smell (Irritating Odor) .1851
S-26 Foreign Materials Enter DEF (DEF Increases) 1852
Disassembly and Assembly 0
Front Axle 1853
Note 1854
Table of contents .1855
Preface .1857
General 1858
Examples of gear-tooth contact pattern for the Gleason gear-tooth system 1860
Conversion table 1864
Denomination of standard dimensions . 0
Tightening torques for screws .1866
Special tools .1867
Commercial tools 1879
1. Disassembly steering .1884
2. Disassembly output .1887
2.1 Disassembly planetary carrier .1887
2.2 Disassembly brake .1888
2.3 Disassembly hub .1890
2.4 Disassembly knuckle housing .1891
2.5 Disassembly output assy .1893
3. Disassembly input 1894
4. Disassembly differential .1898
4.1 DZ-500 and D-500 1898
4.2 DZ-750 and D-750 1901
5. Reassembly differential 1903
5.1 DZ-500 and D-500 1903
5.2 DZ-750 and D-750 1907
6. Reassembly input .1911
6.1 Install input pinion 1911
6.1.1 Determine thickness of the shim to obtain a correct contact pattern .1911
6.1.2 Setting of rolling torque of the input pinion bearing .1913
6.2 Setting instructions for bevel gear set backlash and bearing rolling torque of the differential bearing .1915
6.2.1 Check of backlash pattern of the bevel gear set .1917
6.3 Mount shaft seal ring (input flange) 1919
7. Reassembly output 1920
7.1 Preassembly axle housing 1920
7.2 Reassembly knuckle housing 1921
7.3 Reassembly hub 1925
7.4 Reassembly disk brake .1927
7.4.1 Make leakage test of multi-disk brake .1930
7.4.2 Adjust and check piston stroke 1931
7.5 Reassembly planetary carrier 1933
7.6 Reassembly output assy 1934
7.7 Reassembly pivot bearing 1935
8. Reassembly steering 1936
8.1 Preassemble steering 1936
8.2 Mount steering 1939
8.3 Track setting and checking 1941
8.4 Steering angle setting 1942
8.5 Check leakage of steering .1943
Rear Axle .1944
Note 1945
Table of contents .1946
Preface .1948
General .1949
Examples of gear-tooth contact pattern for the Gleason gear-tooth system 1951
Conversion table 1955
Denomination of standard dimensions .1956
Tightening torques for screws .1957
Special tools .1958
Commercial tools 1965
1. Disassembly of output 1970
1.1 Disassembly of planetary carrier 1970
1.2 Disassembly of brake 1971
1.3 Disassembly of hub 1973
1.4 Disassembly of output assy 1975
2. Disassembly of input .1976
2.1 Version with HL transmission 1976
2.2 Standard version 1978
3. Disassembly differential .1981
3.1 DZ-500 und D-500 1981
3.2 DZ-750 und D-750 1984
4. Reassembly differential .1986
4.1 DZ-500 und D-500 1986
4.2 DZ-750 und D-750 1990
5. Reassembly of input 1994
5.1 Version with HL-transmission 1994
5.1.1 Determination of shims for setting the bearing rolling torque (differential bearing) and the backlash (bevel gear set) 1994
5.2 Standard version (without HL transmission) 1999
5.2.1 Reinstallation of input pinion 1999
5.2.2 Adjust backlash of crown wheel set and bearing rolling torque of differential bearing .2002
5.2.3 Fitting of shaft seal ring (input flange) .2006
6. Reassembly of output .2007
6.1 Reassembly of hub carrier .2007
6.2 Reassembly of hub (Hub bearing SET-RIGHT) .2007
6.3 Reassembly of multi-disk brake 2010
6.3.1 Leakage test of multi-disk brake 2013
6.3.2 Adjustment and check of piston stroke .2014
6.4 Reassembly of planetary carrier .2015
6.5 Reassembly of output assy .2016
Transmission 2017
Note 2018
Table of contents .2019
Preface .2021
General 2022
Conversion table 2024
Denomination of standard dimensions .2025
Torque limits for screws 2026
Special tools .2027
Commercial tools 2036
1. Separate HL-Transmission from axle housing .2041
2. Disassembly – Brake/Clutch/Planetary carrier .2042
2.1 Lubrication pump and shift interlock 2042
2.1.1 Version “Lubrication pump” 2042
2.2 Speed sensor 2043
2.3 Emergency release (Parking Brake) .2043
2.4 Input housing and modulation valve 2044
2.5 Brake and clutch 2045
2.6 Planetary carrier .2051
3. Disassembly – Output .2054
3.1 Version “Axle attachment” .2054
3.2 Version “Separate Installation” .2058
4. Reassembly – Output 2061
4.1 Version “Axle attachment” .2061
4.1.1 Determine shim for pinion gap .2063
4.1.2 Determine adjusting ring for rolling torque/pinion bearing 2067
4.1.3 Check rolling torque of pinion bearing 2068
4.1.4 Shaft seal output flange 2069
4.1.5 Check the pinion gap 2070
4.2 Version “Separate installation” .2071
4.2.1 Shaft seal output flange 2074
5. Reassembly – Brake/Clutch/Planety carrier 2077
5.1 Planetary carrier .2077
5.2 Brake and clutch 2081
5.2.1 Disc components brake and clutch 2083
5.2.1.1 Version “HL-290” 2083
5.2.1.2 Version “HL-270” 0
5.2.1.3 Version “HL-250” 2083
5.2.2 Adjust and check the disc clearance/piston stroke of brake and clutch .2085
5.3 Install modulation valve and input housing 2092
5.4 Emergency release (Parking brake) .2094
5.4.1 Check emergency release for leak tightness 2095
5.4.2 Check the multi-disk brake and multi-disc clutch for leak tightness as well as closing pressure .2096
5.5 Speed sensor 2097
5.6 Lubrication pump/shift interlock 2097
6. Disassembly – Lubrication pump/shift interlock and valve block .2099
6.1 Version “with” lubrication pump .2099
6.2 Version “with” hydr. shift interlock 2102
6.3 Disassembly valve block .2105
7. Reassembly Lubrication pump 2107
8. Reassembly shift interlock .2113
9. Valve block (shifting low gear – high gear) 2121
10. Mount HL-Transmission to axle .2122
Maintenance Standard 2123
Engine and Cooling System .2124
Maintenance Standard of Engine Mount 2124
Maintenance Standard of Cooling System 2125
Power Train .2127
Maintenance Standard of Swing Circle 2127
Maintenance Standard of Swing Machinery .2128
Axles and Prop Shaft 2129
Orbitrol Valve (STD/JSS) 2130
Trailer Preparation .2132
Cabin Mounting 2134
Hydraulic System 2137
Maintenance Standard of Hydraulic Tank 2137
Main Pump .2138
Maintenance Standard of LS-EPC valve 2139
Maintenance Standard of PC-EPC Valve 2140
Control Valve .2141
Maintenance Standard of Anti-Drop Valve for 1. Boom LH 2142
Maintenance Standard of Anti-Drop Valve for 1. Boom RH 2144
Maintenance Standard of Anti-Drop Valve for 2. Boom .2146
Maintenance Standard of Anti-Drop Valve for Arm/Bucket 2148
Maintenance Standard of Work Equipment and Swing PPC Valve 2150
Solenoid Valve Block 2156
Work Equipment 2158
Work Equipment Linkage 2158
Dimension of Arm 2160
Hydraulic Cylinder 2162
Boom Cylinder .2162
Arm Cylinder 2162
Bucket Cylinder .2162
Adjust Cylinder .2163
Outrigger Cylinder 2164
Dozer Cylinder 2166
Bellow Tube .2168
Appendix 2169
Precautions Before Work .2172
Air Conditioner System 2173
Precautions for Refrigerant .2173
Air Conditioner Component .2174
Specifications of Air Conditioner Unit 2176
Outline of Refrigeration Cycle 2178
Compression (Compressor) 2178
Condensation (Condenser) 2178
Expansion (Expansion Valve) .2178
Evaporation (Evaporator) 2179
Relation between Refrigerant and Cooling Trouble 2179
Component parts of Air Conditioner System .2180
Air Conditioner Unit 2180
Configuration Diagram of Air Conditioner Unit .2180
Function of Air Conditioner Unit 2181
Component Parts of Air Conditioner Unit .2183
Function of Evaporator as Air Conditioner Unit Component 2184
Heater Core as Air Conditioner Unit Component .2184
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .2184
Function of Servo Motor as Air Conditioner Unit Component .2184
Structure of Expansion Valve as Air Conditioner Unit Component 2185
Function of Expansion Valve as Air Conditioner Unit Component .2185
Operate Expansion Valve as Air Conditioner Unit Component .2186
Function of Dual Pressure Switch 2186
Air Conditioner Controller 2187
Structure of Air Conditioner Controller .2187
Compressor 2188
Structure of Compressor .2188
Specifications of Compressor 2188
Function of Compressor 2188
Condenser .2189
Structure of Condenser 2189
Specifications of Condenser .2189
Function of Condenser .2189
Air Conditioner Related Sensors .2191
Structure of Sunlight Sensor 2191
Function of Sunlight Sensor .2191
Structure of Outside Temperature Sensor .2191
Function of Outside Air Temperature Sensor 2192
Explanation of Procedure for Testing and Troubleshooting of Air Conditioner .2193
Basic Flow Chart to Examine and Troubleshoot 2193
Examine the Refrigerant Quantity Through the Sight Gauge 2194
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2195
System Diagram of Air Conditioner .2197
Input and Output Signals of Air Conditioner Controller 2198
Function of Air Conditioner Controller 2199
Locations of Air Conditioner Parts and Layout of Connectors .2200
Fuses Layout in the Fuse Boxes 2201
Air Conditioner Controller and Connectors Layout 2201
Air Conditioner Unit and Connectors Layout 2202
Sunlight Sensor Connectors Layout .2202
Machine Monitor Connectors Layout .2202
Dual Pressure Switch Connectors Layout 2202
Air Conditioner Compressor Connectors Layout 2203
Outside Air Temperature Sensor Connectors Layout 2203
Examine Air Leakage (Duct) 2204
How to Examine Air Leakage (Duct) .2204
Examine Air Conditioner with Self-Diagnosis Function 2206
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .2207
Examine vent (mode) Changeover 2208
Examine FRESH/RECIRC Air Changeover .2210
How to Examine FRESH/RECIRC Air Changeover 2210
Examine Sunlight Sensor .2211
How to Examine Sunlight Sensor 2211
Examine Refrigerant (Dual) Pressure Switch 2212
How to Examine (Dual) Pressure Switch for Refrigerant .2212
Test Relays .2213
How to Examine Relays .2213
Air Conditioner Troubleshooting Chart 1 .2214
Air Conditioner Troubleshooting Chart 2 .2215
Information Shown in Troubleshooting Table 2218
Failure Code [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit .2219
Failure Code [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 2220
Failure Code [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .2221
Failure Code [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 2223
Failure Code [879CKA] Ventilating Sensor Open Circuit .2225
Failure Code [879CKB] Ventilating Sensor Short Circuit 2226
Failure Code [879DKZ] Sunlight Sensor Open Circuit or Short Circuit .2227
Failure Code [879EMC] Ventilation Damper Malfunction 2229
Failure Code [879FMC] Air Mix Damper Malfunction 2230
Failure Code [879GKX] Refrigerant Pressure Input Signal Out of Range 2231
A-1 Troubleshooting for Power Supply System (Air Conditioner Does not Operate) 2233
A-2 Troubleshooting for Compressor and Refrigerant System (Air is not Cooled) .2236
A-3 Troubleshooting for Blower Motor System (no Air comes out or Air Flow is Abnormal) 2239
A-4 Troubleshooting for FRESH/RECIRC Air Changeover .2241
Troubleshooting by Gauge Pressure .2243
Connect Service Tool 2245
How to Connect Service Tool .2246
Precautions for Disconnection and Connection of Air Conditioner Piping 2247
Precautions for Disconnection .2247
Precautions for Connection 2248
Handle Compressor Oil .2249
Management of Compressor Oil (DENSO: ND-OIL8 for R134a) .2249
Quantity of the Compressor Oil When the Compressor is Replaced 2250
How to Replace Desiccant 2251
Joystick Steering .2253
Overview of Failure Groups and Descriptions .2253
Error Handling 2255
1 Malfunction of Pump Controller 2255
1.1 Joystick Activation Signals Have the Same Value .2255
2 Malfunction of SASA-Sensor 2255
2.1 CRC .2255
2.2 CAN Count .2255
2.3 CAN Timeout .2255
2.4 Sensor Chip .2255
2.5 Steering Angle 2255
2.6 CAN Input Message .2255
2.7 Power .2255
2.8 CPU .2255
2.9 Memory 2255
2.10 Temperature 2255
2.11 Angle Not Available (from CAN) .2255
2.12 RPM Not Available (from CAN) .2255
2.13 CAN Redundant 2255
2.14 Sensor .2255
2.15 RAM Corruption .2255
3 Malfunction of Hall-Sensor 2256
3.1 Joystick Signals out of Range .2256
3.2 Joystick Redundant Signals Mismatch .2256
3.3 Joystick out of Neutral When Activating Steering System .2256
3.4 No Signal Available .2256
4 Malfunction of PVES (Electrical Activation) Orbitrol 2256
4.1 Steering Valve Feedback Value out of Range (Beneath 25% UDC or Above 75% UDC) .2256
4.2 Steering Valve Feedback (SP) value and Control Value (US) Mismatch 2256
4.3 Error Pin (C2p01) High Signal, Also Indicated on PVES-SP LED: .2257
5 Wiring-Failure 2257
5.1 Joystick Signals out of Range .2257
5.2 Joystick Redundant Signals Mismatch .2257
5.3 Joystick Mode Signals have the Same Value .2257
5.4 Cut Off valve current output and feedback mismatch 2257
5.5 Steering Valve Supply Current Output and Feedback Mismatch 2257
5.6 Steering Valve Control Duty Output and Feedback Mismatch 2257
5.7 Steering Valve Control 2257
5.8 Steering Valve Supply .2257
5.9 Steering Valve Failure Signal .2257
5.10 Cut Off Valve Outputs 2257
5.11 Joystick Mode Switch Reference .2257
5.12 Failure LED Output .2257
5.13 Joystick Mode Inputs .2258
5.14 Joystick Active Inputs .2258
5.15 Joystick Signals .2258
5.16 Steering Valve Failure Signal Input 2258
5.17 Steering Valve Position Feedback Input .2258
6 Miscellaneous .2258
6.1 CAN time out 2258
6.2 Joystick Calibration Failure 2258
6.3 SASA Sensor CAN Timeout .2258
6.4 CAN Bus Failure .2258
6.5 Bus Off .2258
6.6 Driver Error 2258
6.7 Passive Mode Error 2258
6.8 Overflow 2258
6.9 Joystick Mode Signals Have the Same Value .2258
6.10 Joystick Steering Profile Parameters out of Range 2258
7 Failure of SC024-120 2258
7.1 HWPCBVoltages.InRange .2258
7.2 OS.CrcStatus 2258
7.3 OS.ChecksumFailure 2258
7.4 SafetyLayer.Failure .2258
7.5 Battery Power Outside of Allowable Ranges .2258
7.6 Sensor Power Outside of Specified Ranges 2258
7.7 NVMem.Status 2259
8 Error Descriptions 2261
8.1 Inputs 1 2261
8.2 Inputs 2 2264
8.3 Safety function 1 .2265
8.4 Outputs 1 .2266
8.5 Outputs 2 .2270
8.6 Joystick Controller Internal 2272
8.7 Error Counters Page 1 .2273
8.8 Error Counters Page 2 .2282
9 Acronyms 2288
Circuit Diagrams 2289
Hydraulic Circuit Diagram .2293
Hydraulic Circuit Diagram (1/3) .2293
Hydraulic Circuit Diagram (2/3) .2295
Hydraulic Circuit Diagram (3/3) .2297
Wiring Circuit Diagram 2299
Contents 2299
1-0 Power Supply 2301
1-1 Grounding .2302
1-2 Model Select 2303
2-0 Engine 2304
2-1 Engine 2305
2-2 Engine Power Supply, Air Intake .2306
2-3 Engine Start 2307
2-4 2nd Engine Stop, Operating Lamp .2308
2-5 DEF Datalink 2309
2-6 ADDBlue/DPF power .2310
3-0 Refueling System, Fuel Dial .2311
3-1 Brake .2312
3-2 EPC .2313
3-3 Cruise Control 2314
3-4 Travel 2315
3-5 SUS-Lock, Speed Snr, Joystick POTI 2316
3-6 Sensors Engine & Oil 2317
4-0 Quick Coupler, Pressure Sensor 2318
4-1 PPC Reduction, Floating, Pressure Sensor 2319
4-2 Swing Lock, Pressure Sensor, Joystick SW 2320
4-3 Bucket/2ATT Switching .2321
5-0 Lower Attachments .2322
5-1 Roto-Tilt .2323
5-2 Boom/Stabiliser, Auxilary Circuit, Breaker 2324
6-0 Road Light 2325
6-1 Indicator, Side Light, Stop Light .2326
6-2 Arm Marker Light & QC Signal Boom .2327
6-3 Beacon, Trailer (Opt) .2328
6-4 Worklamp Revo Front .2329
6-5 Worklamp Revo Rear 2330
6-6 Worklamp on Cabin .2331
6-7 Camera SW, Service-Con., KOMNET .2332
6-8 GATEWAY Controller 2333
6-9 KomVision .2334
7-0 Air Condition, Heated Mirror 2335
7-1 Radio, 12V Socket, Cigar Lighter, Room Lamp .2336
7-2 PPC-Lock, Starter Cut, Seat .2337
7-3 ID-key 2338
7-4 Horn, Travel Alarm 2339
7-5 Wiper, Washer .2340
8-0 CLS .2341
9-0 Joystick Steering .2342
10-0 Fan Clutch, Tool Control .2343
11-0 ECSS .2344
12-0 Digging Brake 2345
Wiring Harness List .2346
Connector List W2-1 .2347
Connector List W2-2 .2348
Connector List W2-3 .2349
Connector List W2-4 .2350
Connector List W2-5 .2351
Connector List W2-6 .2352
Connector List W2-7 .2353
Connector List W2-8 .2354
Pin Location List W3-1 2355
Pin Location List W3-2 2356
Pin Location List W3-3 2357
Pin Location List W3-4 2358
Pin Location List W3-5 2359
Pin Location List W3-6 2360
Pin Location List W3-7 2361
Pin Location List W3-8 2362
Pin Location List W3-9 2363
Pin Location List W3-10 .2364
Pin Location List W3-11 .2365
Pin Location List W3-12 .2366
Pin Location List W3-13 .2367
Pin Location List W3-14 .2368
Pin Location List W3-15 .2369
Pin Location List W3-16 .2370
Pin Location List W3-17 .2371
Pin Location List W3-18 .2372
Pin Location List W3-19 .2373
Pin Location List W3-20 .2374
Pin Location List W3-21 .2375
Pin Location List W3-22 .2376
Pin Location List W3-23 .2377
Pin Location List W3-24 .2378
Pin Location List W3-25 .2379
Pin Location List W3-26 .2380
Pin Location List W3-27 .2381
Pin Location List W3-28 .2382
Pin Location List W3-29 .2383
Pin Location List W3-30 .2384
Pin Location List W3-31 .2385
Pin Location List W3-32 .2386
Pin Location List W3-33 .2387
Pin Location List W3-34 .2388
Pin Location List W3-35 .2389
Pin Location List W3-36 .2390
Pin Location List W3-37 .2391
Pin Location List W3-38 .2392
Pin Location List W3-39 .2393
Pin Location List W3-40 .2394
Pin Location List W3-41 .2395
Pin Location List W3-42 .2396
Pin Location List W3-43 .2397
Pin Location List W3-44 .2398
Pin Location List W3-45 .2399
Pin Location List W3-46 .2400
Pin Location List W3-47 .2401
Pin Location List W3-48 .2402
Parts List W4-1 .2403
Parts List W4-2 .2404
Parts List W4-3 .2405
Parts List W4-4 .2406
Parts List W4-5 .2407
Connector Diagram .2409
Connector Diagram 1/12 2409
Revolving Frame Harness 1 .2409
Connector Diagram 2/12 2410
Revolving Frame Harness 2 .2410
Connector Diagram 3/12 2411
Operator‘s Cab Wiring Harness (Part 1/2) 2411
Connector Diagram 4/12 2412
Operators Cab Wiring Harness (Part 2/2) .2412
Connector Diagram (5/12) 2413
Connector Table Switch Group 2413
Connector Diagram (6/12) 2414
Connector Table Steering 2414
Connector Diagram (7/12) 2415
Connector Table Various Wiring Harness 2415
Connector Diagram (8/12) 2416
Connector Table Optionally Wiring Harness (Part 1/3) 2416
Connector Diagram (9/12) 2417
Connector Table Optionally Wiring Harness (Part 2/3) 2417
Connector Diagram (10/12) .2418
Connector Table Optionally Wiring Harness (Part 3/3) 2418
Connector Diagram (11/12) .2419
Connector Diagram (12/12) .2420
Brake Valve A., Electric 2420

DESCRIPTION:

Komatsu PW168-11E1 Hydraulic Excavator Shop Manual VENBM75000 – PDF DOWNLOAD

• MACHINE MODEL PW168-11E1
• SERIAL NUMBER H68051 AND UP

G.B 31/12/24