Service manual Komatsu PW148-11E1 H16051 & Up | VENBM77000

VENBM77000 PW148-11E1
Table of Contents
Foreword
– Abbreviation List
— List of Abbreviations Used in the Text
— List of Abbreviations Used in the Circuit Diagrams
– Foreword, Safety, Basic Information
— How to Read the Shop Manual
— Composition of the Shop Manual
— Symbols
— Signal Word
— Safety Notice for Operation
— Safety Considerations
— General Precautions
— Preparations for Work
— Precautions During Work
– Hoisting Instructions
— Hoisting
— Wire Ropes
– Coating Materials
– Standard Tightening Torque
— Standard Tightening Torque of Bolts and Nuts
— Tightening Torque of Hose Nuts
— Tightening Torque of Split Flange Bolts
— Tightening Torques for Hoses (Taper Seal Type and Face Seal Type)
— Tightening Torque for 107 Engine Series (bolts and nuts)
— Tightening Torque for 107 Engine Series (Eye Joints)
— Tightening Torque for 107 Engine Series (Tapered Screws)
– Electric Wire Code
— Classification by Thickness
— Classification by Color and Code
– Conversion Tables
— Method of Using the Conversion Table
– Units
Specification
– Specification Dimension Drawings
— Dimensions
– Working Ranges
— Working Range: 1-Piece Boom
— Working Range: 2-Piece Boom
– Weight Table
— 1-Piece Boom
— 2-Piece Boom
– Fuel, Coolant, Lubricant
Structure and Function
– UREA SCR System
— Layout Drawing of UREA SCR System
— Detailed Drawing of ATS Assembly
— Detailed Drawing of DEF Tank
— UREA SCR System Diagram
— Function of UREA SCR System
— Function of DEF System
— DEF Injection Function
— DEF Purge Function
— Function of DEF Thawing and Preventing From Freezing
— Inducement Strategy
— Component Parts of ATS System
— SCR Assembly
— Structure of SCR Assembly
— KDPF
— Structure of KDPF
— DEF Tank
— DEF Pump
— DEF Injector
— DEF Hose
— DEF Tank Heating Valve
– BOOT-UP System
— Layout Drawing of BOOT-UP System
— System Operating Lamp System
— System Operating Lamp System Diagram
— Function of System Operating Lamp System
— Battery Disconnect Switch
— Function of Battery Disconnect Switch
— Function of Battery Disconnect Switch
– Engine System
— Layout Drawing of Engine System
— Engine Control System
— Engine Control System Diagram
— Function of Engine Control System
— Auto-Deceleration System
— Auto-Deceleration system diagram
— Engine Automatic Warm-up System
— Engine Automatic Warm-up System Diagram
— Function of Engine Automatic Warm-up System
— Overheat Prevention System
— Overheat Prevention System Diagram
— Function of Overheat Prevention System
— Turbocharger Protection System
— Turbocharger Protection System Diagram
— Function of Turbocharger Protection System
— Automatic Idle Stop System
— System Diagram of Automatic Idle Stop System
— Function of Automatic Idle Stop System
— Setting Time
— Abrupt Engine Stop Is Detected
— Component Parts of Engine System
— Structure of Turbocharger
— Crankcase Ventilation System
— System Diagram of Crankcase Ventilation System
— Function of Crankcase Ventilation System
— Impactor (Filterless)
— Structure of Impactor (Filterless)
— Operation of Impactor (Filterless)
— Exhaust Throttle Valve
— Structure of Exhaust Throttle Valve
– Cooling system
— Layout Drawing of Cooling System
— Fan Speed Control System of Fan Clutch
— Engine Output Control System of Fan Clutch
— Engine Output Control System Diagram of Fan Clutch
— Function of Engine Output Control System of Fan Clutch
— Component Parts of Cooling System
— Fan Clutch
– Control System
— Machine Monitor System
— System Diagram of Machine Monitor System
— Function of Machine Monitor System
— KomVision System
— Layout Drawing of KomVision System
— Around Cab and Floor
— KomVision System Diagram
— Function of KomVision System
— KOMTRAX System
— KOMTRAX System Diagram
— Function of KOMTRAX System
— Component Parts of Control System
— Machine Monitor
— Monitor Display
— Monitor Items and Display
— Caution Monitor
— Pilot Monitor
— Steering Mode Operation Guidance
— Travel and Road Display Guidance
— Overload Warning Device
— Monitor Switches
— Declaration of Switch Function on Keypad
— Guidance Icon and Function Switch
— Operator Mode Function
— Service Mode Function of Machine Monitor
— Gateway Controller
— Communication Terminal
— KomVision Controller
— Structure of KomVision Controller
— KomVision Camera
— Pump Controller
— Machine Controller
— Engine Controller
— Fuel Control Dial
— Machine Control System Diagram
— 1. Engine and Pump Control Function
— PPC Levers
— LH PPC Lever
— RH PPC Lever
– Power Train System
— Layout Drawing of Power Train System
— Component Parts of Power Train System
— Front Axle
— Rear Axle
— Transmission
— Travel Motor
— Operation of Travel Motor
— Clutch Control Circuit
— Travel System
— Travel Circuit
— Travel Motor Performance
— Travel PPC Pedal
— Swivel Joint
— Braking System
— Structure and Function
— Gear Pump
— Priority Valve
— Power Brake Valve
— Accumulator for Brake Valve
— Digging Brake Valve
— Digging Brake Controller
— Steering System
— Steering System 2WS
— Steering System JSS
— Steering System 4WS
— Steering Column JSS
— Steering Column STD
— Orbitrol Valve STD
— Orbitrol Valve JSS
— Suspension Lock Cylinder (Axle Lock)
— Specifications
— Structure and function
— Circuit
— Axle Oscillation
– Swing System
— Swing Circle
— Swing Machinery & Motor
— Operation of Swing Lock
— Relief Valve Portion
— Operation
— Work Equipment – Swing PPC Valve
– Undercarriage
— Undercarriage 2WS
— Undercarriage 4WS
– Trailer
— Calculation of Maximum Coupling Load
— Automatic Trailer Coupling for Blade
— Functional Check
— Possible Faults in the Coupling
— Wear Limits
— Automatic Trailer Coupling for Outrigger
— Height Adjustment Components
— Possible Faults in the Coupling
— Wear Limits
— Inspection
– Hydraulic System
— Layout Drawing of Hydraulic System
— CLSS
— Structure of CLSS
— Features of CLSS
— Composition of CLSS
— Function of CLSS
— LS Differential Pressure (ΔPLS) and Pump Swash Plate Angle
— Pressure Compensation Control
— Component Parts of Hydraulic System
— Hydraulic Tank
— Main Pump
— LS Valve
— PC Valve
— 1. LS valve
— LS(PC)-EPC Valve
— Pilot Pressure Control (PPC) System
— Control Valve
— Hydraulic Circuit Diagram and Name of Valves
— 1. Unload Valve
— 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 …
— 2. Introduction of LS Pressure
— 3. LS Bypass Plug
— 4. Pressure Compensation Valve
— 5. Area Ratio of Pressure Compensation Valve
— 6. Boom Regeneration Circuit
— 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.
— 7. Arm Regeneration Circuit
— 8. Swing Bleeding Valve
— 9. LS Select Valve
— Solenoid Valve Block
— ATT EPC Assembly
— ON / OFF Solenoid Valves (3 Way Valve)
— ON / OFF Solenoid Valves (4 Way Valve)
— Hi/ Lo Solenoid Valve (4 Way Valve)
— Attachment PPC Valve
— Undercarriage Solenoid Valve Block
— Boom/Outrigger Schematic
— Undercarriage Attachment Schematic
— Proportional Attachment Control
— Proportional Attachment Schematic
— Bucket to 1ATT
— Boom Safety Valve
— Boom Floating
— PPC Pressure Reduction/ Boom Floating Logic
— Tool Control
— Breaker Return Valve
— 1st Attachment Circuit Hydraulic Performance (Main Valve Bypassed)
— Steering Control Solenoid Valve Group
— 2nd Auxiliary Circuit in the Undercarriage
— Hydraulic Quick Coupler
— Hydraulic Quick Coupler Solenoid Valve
— Quick Coupler Error Logic
— Full Hydraulic Quick Coupler
— ECSS
— ECSS Logic
— ECSS Hydraulic Schematic
— ECSS Accumulator Position
— ECSS Valve
— ECSS Hydraulic Diagram
– Work Equipment
— 1. Dimension of Arm
— 2. Dimension of Bucket
— Hydraulic Cylinder
— Boom Cylinder
— Arm Cylinder
— Bucket Cylinder
— Adjust Cylinder
— Outrigger Cylinder
— Dozer Cylinder
– Air Conditioner Unit
— Air Conditioner Component
— Specifications of Air Conditioner
– Sensors
— Ambient Pressure Sensor
— Charge (Boost) Pressure and Temperature Sensor
— Coolant Temperature Sensor
— Ne (Crankshaft) Speed Sensor
— Bkup (Camshaft) Speed Sensor
— Common Rail Pressure Sensor
— Exhaust manifold Pressure Sensor
— TBAP Ambient Pressure and Temperature Sensor
— KDPF Differential Pressure and Outlet Pressure Sensor
— KDOC Inlet Temperature Sensor
— Engine Oil Level Sensor
— Fuel Level Sensor
— WIF (Water-In-Fuel Detection) Sensor
— Coolant Level Sensor
— Hydraulic Oil Temperature Sensor
— Air Cleaner Clogging Sensor
— Overload Caution Sensor
— Swing Proximity Sensor
— Brake Sensors
— Brake Accumulator Low Pressure Sensor (CN-P60)
— Brake Stop Light Sensor (CN-S19)
— Service Brake Pressure Sensor (CN-P64)
— Service Brake Pressure Sensor (CN-P62)
— Park Brake Pressure Sensor (CN-P61)
— PPC Pressure Sensors and Switches
— Main Valve Sensor
— Block Pressure Sensors and Switches
— ATS area
– Lubrication
— Auto-Grease Pump
— Overview
— Display and Control Unit
— LED-Display
— Push Buttons
— Three-Digit LED Display
— Check Central Lubrication System, Fill Up Grease
— Lubrication Diagrams
— Auto-Grease Pump With One-Piece Boom
— Auto-Grease Pump With Two-Piece Boom
— Manual System One-Piece Boom
— Manual System Two-Piece Boom
– Additional Preparations
— Preparation Heatable fuel filter
— Preparation Hydraulic Oil Heater
— Preparation Fuel Pump (Refuelling Pump)
Standard Value Table
– Standard Value Table for Engine Related Parts
– Standard Value Table for Chassis Related Parts
— Flow Control Characteristic of PC Valve (STD)
– PM Clinic Service
— Check Sheet
Testing and Adjusting
– Engine and Cooling System
— Examine Engine Speed
— How to Examine Engine Speed
— Examine Boost Pressure
— How to Examine Boost Pressure on Machine Monitor
— How to Examine Boost Pressure
— Examine Exhaust Gas Color
— How to Examine Exhaust Gas Color with the Handy Smoke Checker
— How to Examine Exhaust Gas Color with Smoke Meter
— Examine and Adjust Valve Clearance
— Check Valve Clearance
— Adjust Valve Clearance
— Examine Compression Pressure
— How to Examine Compression Pressure
— Examine Blowby Pressure
— How to Examine Blowby Pressure
— Examine Engine Oil Pressure
— Examine Fuel Pressure
— How to Examine Fuel Pressure
— Examine Low-Pressure Circuit (Fuel Main Filter Inlet Side)
— Examine Low-Pressure Circuit (Pressure Difference)
— Examine Return Circuit
— Examine Negative Pressure Circuit
— Examine Fuel Discharge, Return and Leakage
— How to Examine Fuel Discharge, Return, and Leakage
— Examine Supply Pump Discharge Volume
— Examine Supply Pump Return Rate
— Examine the Leakage from the Pressure Limiter
— Examine the Return Rate of the Injector
— Bleed Air from Fuel System
— How to Bleed Air from Fuel System
— Examine Fuel Circuit for Leakage
— How to Examine Fuel System for Leakage
— Examine Fuel Circuit for Leakage at Engine Low Idle
— How to Examine Fuel Circuit for Leakage at Engine High Idle
— How to Examine Fuel Circuit for Leakage at Engine Rated Speed
— Handle Cylinder Cut-out Mode Operation
— Handle No-Injection Cranking Operation
— Examine and Adjust Air Conditioner Compressor Belt Tension
— Check air conditioner compressor belt
— How to Adjust Air Conditioner Compressor Belt
— Replace the Fan Belt
— Examine Cooling Fan Speed
— Method for Testing Cooling Fan Speed
— Write Correction for Ash in Soot Accumulation to Engine Controller
— How to Write Correction for Ash in Soot Accumulation to Engine Controller
— Examine SCR Related Functions
— Examine DEF Pump Raised Pressure
— How to Examine DEF Pump Raised Pressure
— Examine Injection Volume from DEF Injector
— How to Examine Injection Volume from DEF Injector
— Examine DEF Line Heater Relay 1
— How to Examine DEF Line Heater Relay 1
— Examine DEF Line Heater Relay 2
— How to Examine DEF Line Heater Relay 2
— Examine DEF Pump Heater Relay
— How to Examine AdBlue/ DEF Pump Heater Relay
— Examine DEF Tank Heater Valve
— How to Examine DEF Tank Heater Valve
— Examine SCR Denitration Efficiency
— How to Examine SCR Denitration Efficiency
– Clean DEF Tank
— How to Clean DEF Tank
— Bleed Air from Coolant Circuit of DEF Tank
– Examine Swing Circle Bearing Clearance
– Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
— Measurement
— Adjustment
– Examine Oil Pressure of Control Circuit
— Measurement
— Procedure for pressure reducing adjustment
– Examine and Adjust Oil Pressure in Pump PC Control Circuit (Valve Inlet)
— Measurement
— Adjustment
– Examine and Adjust Pump LS Differential Pressure
— Measurement
— Adjustment
– How to Examine Solenoid Valve Output Pressure
— Examine Proportional Control PPC Circuit
– Adjust of Work Equipment and Swing PPC Valve
– How to Examine Quick Coupler Control Valve Output Pressure
– Examine Travel Motor Relief Pressure
— How to Examine Travel Motor Relief Pressure
– Examine Propshaft Speed
— How to Examine Rotating Speed of Propshaft
– Examine Transmission Clutch Control Circuit
— Description
– Examine Parts Which Cause Hydraulic Drift of Work Equipment
– Release of Remaining Pressure in Hydraulic Circuit
– Examine Oil Leakage
– Air Bleeding of Various Parts
– Examine Diodes
– Electrical System
— Set and Operate Machine Monitor
— Specification
— Operator Mode
— Service Mode
— Table of Self-Define Monitoring
— Abnormality Record Menu
— Default Menu
— Diagnostic Tests Menu
— Adjustment Menu
— KOMTRAX settings menu
— Method for Starting up KOMTRAX Terminal
– Examine and adjust ECSS (ACCU Pressure)
— Maintenance
– Examine and Adjust Tool Control
— Troubleshooting
– Examine Lubrication Interval Times
– How to Chang the Joystick Steering Control
– How to Adjust Digging Brake System
– Procedure to Adjust Rearview Camera Angle
— Method for adjusting rear view camera angle
– Adjust KomVision Camera Angle
— Tools to Adjust KomVision Camera Angle
— How to Adjust Rearview Camera Angle
– Adjust KomVision Related Function
— Setting of KomVision (main setting)
— Method for setting KomVision (main setting)
— Setting of KomVision (Camera Setting)
— How to Set KomVision (Camera Setting)
— Setting of KomVision (Camera Calibration)
— How to Set KomVision (Camera Calibration)
Troubleshooting
– Related Information to Troubleshooting
— General Troubleshooting Points
— When the Failure Code Cannot be Cleared by “Loaded Diagnostics Operation to Confirm Failure Correction” or “Loaded Diagnostics Operation to Clear Failure Code”
— Sequence of Events in Troubleshooting
— Walk-around check
— How to Disconnect and Connect Connector with a Special Lock
— Connector Table
– T-Branch Box and T-Branch Adapter Table
— T-Boxes and T-Adapters Table
– Fuse Location Table
— Precautions for Replacing KDOC
— Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
– Failure Code Table (Display of Code)
Troubleshooting (Display of Code)
– Failure Code [2G00MA] – Brake Oil Pressure Abnormality
– Failure Code [602ENX] – Return Filter Clogging
– Failure Code [6AZ0MA] – Quick Coupler System Defective Function
– Failure Code [6AZ0ZG] – Quick Coupler Pressure Low
– Failure Code [6B2JMA] – Travel hydraulic abnormality
– Failure Code [879AKA] – A/C Recirculation Air Temperature Sensor Open Circuit
– Failure Code [879AKB] – A/C Inner Sensor Short Circuit
– Failure Code [879BKA] – A/C Outer Sensor Open Circuit
– Failure Code [879BKB] – A/C Outer Sensor Short Circuit
– Failure Code [879CKA] – Ventilating Sensor Open Circuit
– Failure Code [879CKB] – Ventilating Sensor Short Circuit
– Failure Code [879DKZ] – Sunlight Sensor Open Or Short Circuit
– Failure Code [879EMC] – Ventilation Damper Abnormality
– Failure Code [879FMC] – Air Mix Damper Abnormality
– Failure Code [879GKX] – Refrigerant Abnormality
– Failure Code [989L00] – Engine Controller Lock Caution 1
– Failure Code [989M00] – Engine Controller Lock Caution 2
– Failure Code [989N00] – Engine Controller Lock Caution 3
– Failure Code [A1U0N3] – HC Desorb Request 1
– Failure Code [A1U0N4] – HC Desorb Request 2
– Failure Code [A900FR] – Abrupt Engine Stop by Auto Idling Stop 3
– Failure Code [A900N6] – Abrupt Engine Stop by Auto Idling Stop 1
– Failure Code [A900NY] – Abrupt Engine Stop by Auto Idling Stop 2
– Failure Code [AA10NX] – Air Cleaner Clogging
– Failure Code [AB00KE] – Charge Voltage Low
– Failure Code [AQ10MB] – Manual Stationary Regeneration Request 2
– Failure Code [AQ10N3] – Manual Stationary Regeneration Request
– Failure Code [AS00R2] – Warning 2
– Failure Code [AS00R3] – Inducement 1
– Failure Code [AS00R4] – Inducement 2
– Failure Code [AS00R5] – Inducement 3
– Failure Code [AS00R6] – Temporary Recovery Of Inducement
– Failure Code [AS00ZK] – DEF Level Low Error 5
– Failure Code [AS10KM] – DEF Injector Overheat Warning
– Failure Code [AS10NR] – DEF Injector High Temperature Warning
– Failure Code [AS10NT] – DEF Injector Overheat Caution
– Failure Code [B@BAZG] – Engine Oil Pressure Low
– Failure Code [B@BAZK] – Engine Oil Level Low
– Failure Code [B@BCNS] – Engine Coolant Overheat
– Failure Code [B@BCQA] – Engine Coolant Level Low
– Failure Code [B@BCZK] – Engine Coolant Level Low
– Failure Code [B@HANS] – Hydraulic Oil Overheat
– Failure Code [CA115] – Engine Neutral and Backup Speed Sensor Error
– Failure Code [CA122] – Charge Air Press Sensor High Error
– Failure Code [CA123] – Charge Air Press Sensor Low Error
– Failure Code [CA131] – Throttle Sensor High Error
– Failure Code [CA132] – Throttle Sensor Low Error
– Failure Code [CA144] – Coolant Temperature Sensor High Error
– Failure Code [CA145] – Coolant Temperature Sensor Low Error
– Failure Code [CA153] – Charge Air Temperature Sensor High Error
– Failure Code [CA154] – Charge Air Temperature Sensor Low Error
– Failure Code [CA187] – Sensor 2 Supply Voltage Low Error
– Failure Code [CA227] – Sensor 2 Supply Voltage High Error
– Failure Code [CA234] – Engine Overspeed
– Failure Code [CA238] – NE Speed Sensor Supply Voltage Error
– Failure Code [CA239] – NE Speed Sensor Supply Voltage High Error
– Failure Code [CA249] – Ambient Air Temp Sensor High Error
– Failure Code [CA256] – Ambient Air Temp Sensor Low Error
– Failure Code [CA271] – PCV 1 Short Circuit Error
– Failure Code [CA272] – PCV 1 Open Circuit Error
– Failure Code [CA322] – Injector #1 (L#1) Open Circuit Error or Short Circuit Error
– Failure Code [CA324] – Injector #3 (L#3) Open Circuit Error or Short Circuit Error
– Failure Code [CA331] – Injector #2 (L#2) Open Circuit Error or Short Circuit Error
– Failure Code [CA332] – Injector #4 (L#4) Open Circuit Error or Short Circuit Error
– Failure Code [CA343] – Engine Controller Internal Failure
– Failure Code [CA351] – Injectors Drive Circuit Error
– Failure Code [CA352] – Sensor 1 Supply Voltage Low Error
– Failure Code [CA386] – Sensor 1 Supply Voltage High Error
– Failure Code [CA428] – Water In Fuel Sensor High Error
– Failure Code [CA429] – Water In Fuel Sensor Low Error
– Failure Code [CA435] – Engine Oil Pressure SW Error
– Failure Code [CA441] – Battery Voltage Low Error
– Failure Code [CA442] – Battery Voltage High Error
– Failure Code [CA451] – Common Rail Pressure Sensor High Error
– Failure Code [CA452] – Common Rail Pressure Sensor Low Error
– Failure Code [CA488] – Charge Air Temperature High Torque Derate
– Failure Code [CA515] – Charge Air Temperature High Torque Derate
– Failure Code [CA516] – Common Rail Pressure Sensor Supply Voltage Low Error
– Failure Code [CA553] – Common Rail Pressure High Error 1
– Failure Code [CA555] – Crankcase Pressure High Error 1
– Failure Code [CA556] – Crankcase Pressure High Error 3
– Failure Code [CA559] – Common Rail Pressure Low Error 1
– Failure Code [CA689] – Engine NE Speed Sensor Error
– Failure Code [CA691] – Intake Air Temperature Sensor High Error
– Failure Code [CA692] – Intake Air Temperature Sensor Low Error
– Failure Code [CA697] – Engine Controller Internal Temperature Sensor High Error
– Failure Code [CA698] – Engine Controller Internal Temperature Sensor Low Error
– Failure Code [CA731] – Engine Backup Speed Sensor Phase Error
– Failure Code [CA741] – Compressor Inlet Press Sensor High Error
– Failure Code [CA742] – Compressor Inlet Press Sensor Low Error
– Failure Code [CA743] – Compressor Inlet Press Sensor In Range Error
– Failure Code [CA778] – Engine Backup Speed Sensor Error
– Failure Code [CA1117] – Engine Controller Partial Data Lost Error
– Failure Code [CA1664] – KDOC Abnormality
– Failure Code [CA1669] – DEF Level Sensor Voltage High Error
– Failure Code [CA1673] – DEF Level Low Error 3
– Failure Code [CA1677] – DEF Temperature Sensor Low Error
– Failure Code [CA1678] – DEF Temperature Sensor High Error
– Failure Code [CA1682] – DEF Pump Priming Error
– Failure Code [CA1683] – DEF Tank Heating Valve Voltage High Error
– Failure Code [CA1684] – DEF Tank Heating Valve Voltage Low Error
– Failure Code [CA1686] – DEF Quality Sensor Voltage High Error
– Failure Code [CA1695] – Sensor 5 Supply Voltage High Error
– Failure Code [CA1696] – Sensor 5 Supply Voltage Low Error
– Failure Code [CA1712] – DEF Tank Thawing Error
– Failure Code [CA1713] – DEF Tank Heater Valve Open Stuck Error
– Failure Code [CA1714] – DEF Quality Sensor Out Of Calibration Error
– Failure Code [CA1715] – DEF Quality Sensor Internal Circuit Error
– Failure Code [CA1776] – Sensor Supply Relay Voltage High Error
– Failure Code [CA1777] – Sensor Supply Relay Voltage Low Error
– Failure Code [CA1843] – Crankcase Pressure Sensor High Error
– Failure Code [CA1844] – Crankcase Pressure Sensor Low Error
– Failure Code [CA1879] – KDPF Differential Pressure Sensor High Error
– Failure Code [CA1881] – KDPF Differential Pressure Sensor Low Error
– Failure Code [CA1883] – KDPF Differential Pressure Sensor In Range Error
– Failure Code [CA1885] – Turbo Outlet NOx Sensor Circuit Error
– Failure Code [CA1887] – SCR Outlet NOx Sensor Circuit Error
– Failure Code [CA1921] – KDPF Soot Load High Error 1
– Failure Code [CA1922] – KDPF Soot Load High Error 2
– Failure Code [CA1942] – Crankcase Pressure Sensor In Range Error
– Failure Code [CA1993] – KDPF Differential Pressure Low Error
– Failure Code [CA2185] – Throttle Sensor Supply Voltage High Error
– Failure Code [CA2186] – Throttle Sensor Supply Voltage Low Error
– Failure Code [CA2311] – IMV Solenoid Error
– Failure Code [CA2373] – Exhaust Manifold Pressure Sensor High Error
– Failure Code [CA2374] – Exhaust Manifold Pressure Sensor Low Error
– Failure Code [CA2554] – Exhaust Manifold Pressure Sensor In Range Error
– Failure Code [CA2555] – Intake Air Heater Relay Open Circuit Error
– Failure Code [CA2556] – Intake Air Heater Relay Short Circuit Error
– Failure Code [CA2637] – KDOC Face Plugging
– Failure Code [CA2639] – Manual Stationary Regeneration Request
– Failure Code [CA2771] – SCR Outlet NOx Sensor Datalink Timeout Error
– Failure Code [CA2973] – Charge Air Pressure Sensor In Range Error
– Failure Code [CA2976] – DEF Pump Temperature Sensor Signal Error
– Failure Code [CA3133] – KDPF Outlet Pressure Sensor High Error
– Failure Code [CA3134] – KDPF Outlet Pressure Sensor Low Error
– Failure Code [CA3135] – KDPF Outlet Pressure Sensor In Range Error
– Failure Code [CA3142] – SCR Temperature Sensor High Error
– Failure Code [CA3143] – SCR Temperature Sensor Low Error
– Failure Code [CA3144] – SCR Temperature Sensor In Range Error
– Failure Code [CA3146] – SCR Outlet Temperature Sensor High Error
– Failure Code [CA3147] – SCR Outlet Temperature Sensor Low Error
– Failure Code [CA3148] – SCR Outlet Temperature Sensor In Range Error
– Failure Code [CA3151] – SCR Catalyst Efficiency Low Error 2
– Failure Code [CA3165] – SCR Outlet Temperature High Error
– Failure Code [CA3228] – Turbo Outlet NOx Sensor In Range Error
– Failure Code [CA3229] – SCR Temperature High Error
– Failure Code [CA3231] – SCR Temperature High Error Non Regeneration
– Failure Code [CA3232] – Turbo Outlet NOx Sensor Datalink Timeout Error
– Failure Code [CA3235] – SCR Outlet Temperature High Error – Non Regeneration
– Failure Code [CA3239] – DEF Line Heater 2 Voltage High Error
– Failure Code [CA3241] – DEF Line Heater 2 Voltage Low Error
– Failure Code [CA3242] – DEF Tank Heating Error
– Failure Code [CA3251] – KDOC Inlet Temperature High Error
– Failure Code [CA3253] – KDOC Temperature Error – Non Regeneration
– Failure Code [CA3254] – KDOC Outlet Temperature High Error 1
– Failure Code [CA3255] – KDPF Temperature Error – Non Regeneration
– Failure Code [CA3256] – KDPF Outlet Temperature High Error 1
– Failure Code [CA3311] – KDOC Outlet Temperature High Error 2
– Failure Code [CA3312] – KDPF Outlet Temperature High Error 2
– Failure Code [CA3313] – KDOC Inlet Temperature Sensor Low Error
– Failure Code [CA3314] – KDOC Inlet Temperature Sensor High Error
– Failure Code [CA3315] – KDOC Inlet Temperature Sensor In Range Error
– Failure Code [CA3316] – KDOC Outlet Temperature Sensor Low Error
– Failure Code [CA3317] – KDOC Outlet Temperature Sensor High Error
– Failure Code [CA3318] – KDOC Outlet Temperature Sensor In Range Error
– Failure Code [CA3319] – KDPF Outlet Temp Sensor High Error
– Failure Code [CA3321] – KDPF Outlet Temperature Sensor Low Error
– Failure Code [CA3322] – KDPF Outlet Temperature Sensor In Range Error
– Failure Code [CA3419] – MAF Sensor Supply Voltage High Error
– Failure Code [CA3421] – MAF Sensor Supply Voltage Low Error
– Failure Code [CA3497] – DEF Level Low Error 1
– Failure Code [CA3498] – DEF Level Low Error 2
– Failure Code [CA3545] – SCR Outlet NOx Sensor Unstable Error
– Failure Code [CA3547] – DEF Level Low Error 4
– Failure Code [CA3558] – DEF Pump Voltage High Error
– Failure Code [CA3559] – DEF Pump Voltage Low Error
– Failure Code [CA3562] – DEF Line Heater Relay 1 Voltage High Error
– Failure Code [CA3563] – DEF Line Heater Relay 1 Voltage Low Error
– Failure Code [CA3567] – DEF Injector Open Circuit Error or Short Circuit Error
– Failure Code [CA3568] – DEF Malfunction
– Failure Code [CA3571] – DEF Pump Pressure Sensor High Error
– Failure Code [CA3572] – DEF Pump Pressure Sensor Low Error
– Failure Code [CA3574] – DEF Pump Pressure Too Low Error
– Failure Code [CA3575] – DEF Pump Pressure Too High Error
– Failure Code [CA3577] – DEF FCV Voltage High Error
– Failure Code [CA3578] – DEF FCV Voltage Low Error
– Failure Code [CA3583] – SCR Outlet NOx Sensor Heater Warming Up Error
– Failure Code [CA3596] – DEF Pump Pressure Unstable Error
– Failure Code [CA3649] – Turbo Outlet NOx Sensor Heater Warming Up Error
– Failure Code [CA3681] – SCR Outlet NOx Sensor Power Voltage Error
– Failure Code [CA3682] – Turbo Outlet NOx Sensor Power Voltage Error
– Failure Code [CA3713] – DEF Line Heater 1 Voltage High Error
– Failure Code [CA3717] – SCR Outlet NOx Sensor Voltage Mismatch Error
– Failure Code [CA3718] – Turbo Outlet NOx Sensor Voltage Mismatch Error
– Failure Code [CA3725] – Turbo Outlet NOx Sensor Unstable Error
– Failure Code [CA3741] – Rail Press Valve Trip Error
– Failure Code [CA3748] – Turbo Outlet NOx Sensor Stuck In Range Error
– Failure Code [CA3755] – DEF Dosing Performance Degradation Error
– Failure Code [CA3866] – DEF Low Concentration Error 2
– Failure Code [CA3867] – DEF Low Concentration Error 1
– Failure Code [CA3868] – DEF Tank Sensor Datalink Timeout Error
– Failure Code [CA4151] – KDOC and KDPF Temperature Sensor Datalink Timeout Error
– Failure Code [CA4152] – SCR Temperature Sensor Datalink Timeout Error
– Failure Code [CA4155] – DEF Pump Heater Relay Voltage High Error
– Failure Code [CA4156] – DEF Pump Heater Relay Voltage Low Error
– Failure Code [CA4157] – DEF FCV Malfunction
– Failure Code [CA4158] – KDOC and KDPF Temperature Sensor Internal Circuit Error
– Failure Code [CA4159] – SCR Temperature Sensor Internal Circuit Error
– Failure Code [CA4161] – KDOC and KDPF Temperature Sensor ECU Voltage High Error
– Failure Code [CA4162] – KDOC and KDPF Temperature Sensor ECU Voltage Low Error
– Failure Code [CA4163] – KDOC and KDPF Temperature Sensor ECU Over Temperature Error
– Failure Code [CA4164] – SCR Temperature Sensor ECU Voltage High Error
– Failure Code [CA4165] – SCR Temperature Sensor ECU Voltage Low Error
– Failure Code [CA4166] – SCR Temperature Sensor ECU High Temperature Error
– Failure Code [CA4168] – DEF Pump Heater ON Stuck Error
– Failure Code [CA4169] – DEF Pump Heater OFF Stuck Error
– Failure Code [CA4171] – DEF Pump Thawing Error
– Failure Code [CA4249] – DEF Pump Temperature Sensor 1 In Range Error
– Failure Code [CA4251] – DEF Pump Temperature Sensor 2 In Range Error
– Failure Code [CA4259] – KDOC and KDPF Temperature Sensor Power Interrupt Error
– Failure Code [CA4261] – SCR Temperature Sensor Power Interrupt Error
– Failure Code [CA4277] – DEF Quality Sensor Liquid Distinction Impossible Error
– Failure Code [CA4459] – DEF Line Heater Relay 2 Voltage High Error
– Failure Code [CA4461] – DEF Line Heater Relay 2 Voltage Low Error
– Failure Code [CA4731] – DEF Temperature Sensor Transmission Data Error
– Failure Code [CA4732] – DEF Level Sensor Transmission Data Error
– Failure Code [CA4739] – DEF Level Sensor Internal Circuit Error
– Failure Code [CA4768] – Fuel in DEF Tank Error
– Failure Code [CA4769] – DEF Level Measurement Impossible
– Failure Code [CA4842] – DEF High Concentration Error
– Failure Code [CA4952] – System Operating Lamp Short Circuit (Engine Controller)
– Failure Code [CA5115] – DEF Line Heater 1 Voltage Low Error
– Failure Code [CA5179] – Engine Room Temperature Sensor High Error
– Failure Code [CA5181] – Engine Room Temperature Sensor Low Error
– Failure Code [CA5271] – Exhaust Throttle Valve Motor Driver Voltage High Error
– Failure Code [CA5272] – Exhaust Throttle Valve Motor Driver Voltage Low Error
– Failure Code [CA5273] – Exhaust Throttle Valve Motor Driver Open Error
– Failure Code [CA5274] – Exhaust Throttle Valve Position Sensor In Range Error
– Failure Code [CA5275] – Exhaust Throttle Valve Position Sensor High Error
– Failure Code [CA5276] – Exhaust Throttle Valve Position Sensor Low Error
– Failure Code [CA5383] – Ash Accumulation High Error
– Failure Code [CA5631] – Manual Stationary Regeneration Request (Automatic Regeneration Uncompleted)
– Failure Code [CA5632] – Manual Stationary Regeneration Request but Regeneration Disable
– Failure Code [CA5655] – SCR Catalyst Degradation Error
– Failure Code [CA5689] – SCR Outlet NOx Sensor Tamparing Error
– Failure Code [CA5715] – KDPF Delta P Sensor In Range Dither Error
– Failure Code [CA5716] – KDPF Outlet Press Sensor In Range Dither Error
– Failure Code [CA5838] – SCR Outlet NOx Sensor Self-Diag Stuck In-range Error
– Failure Code [CA5864] – DEF Pump Short to Battery
– Failure Code [CA5865] – DEF Pump Short to Ground
– Failure Code [CA5938] – Manual Stationary Regeneration Request
– Failure Code [CA6513] – DEF Pump Thawing Error
– Failure Code [CA6771] – Aftertreatment Tempe Sens Auto Defective Misconfiguration
– Failure Code [D109KA] – ECSS Relay Open Circuit
– Failure Code [D109KB] – ECSS Relay Short Circuit
– Failure Code [D109KY] – ECSS Relay Hot Short Circuit
– Failure Code [D109MA] – ECSS Relay Defective Function
– Failure Code [D110KB] – Battery Relay Output Short Circuit
– Failure Code [D19JKZ] – Personal Code Relay Abnormality
– Failure Code [D19QKB] – Short Circuit in Refuel Pump Relay
– Failure Code [D19QKY] – Hot Short Circuit in Refuel Pump Relay
– Failure Code [D1EMKA] – Parking Brake Relay Open Circuit
– Failure Code [D1EMKB] – Parking Brake Relay Short Circuit
– Failure Code [D1EMKY] – Parking Brake Relay Hot Short Circuit
– Failure Code [D1EMMA] – Parking Brake Relay Defective Function
– Failure Code [D811MC] – KOMTRAX Malfunction
– Failure Code [D862KA] – GPS Antenna Open Circuit
– Failure Code [D8ALKA] – System Operating Lamp Open Circuit (KOMTRAX)
– Failure Code [D8ALKB] – System Operating Lamp Short Circuit (KOMTRAX)
– Failure Code [D8AQKR] – CAN2 Discon (KOMTRAX)
– Failure Code [D8ARKR] – CAN1 Defective Communication (Gateway Controller)
– Failure Code [D8G1KT] – Malfunction (Gateway Controller)
– Failure Code [D8G6KT] – Malfunction (Communication Terminal)
– Failure Code [DA20MC] – Pump Controller Malfunction
– Failure Code [DA22KK] – Pump Solenoid Power Low Error
– Failure Code [DA22KT] – Pump Controller Solenoid Power Controller Internal Failure
– Failure Code [DA25KP] – 5 V Sensor 1 Power Voltage Low Error
– Failure Code [DA26KP] – 5 V Sensor 2 Power Voltage Low Error
– Failure Code [DA27KP] – 24V Sensor Power Abnormality
– Failure Code [DA29KQ] – Model Selection Signal Mismatch
– Failure Code [DA2JKT] – Pump Controller Solenoid Return Circuit Controller Internal Failure
– Failure Code [DA2JKY] – Pump Controller Solenoid Return Circuit Hot Short Circuit
– Failure Code [DA2LKA] – System Operating Lamp Open Circuit (Pump Controller System)
– Failure Code [DA2LKB] – System Operating Lamp Short Circuit
– Failure Code [DA2QKR] – Controller Area Network 2 Defective Communication
– Failure Code [DA2RKR] – Controller Area Network 1 Defective Communication
– Failure Code [DA80KB] – Auto Grease System Monitoring Signal Short Circuit
– Failure Code [DAB0KT] – Internal Flash Memory Error (Pump Controller System)
– Failure Code [DAC3KB] – Cruise Control System Power Supply Short Circuit
– Failure Code [DAC3KY] – Cruise Control System Power Supply Hot Short Circuit
– Failure Code [DAF0KM] – Inconsistency of KomVision Setting
– Failure Code [DAF0MB] – Monitor ROM Abnormality
– Failure Code [DAF0MC] – Monitor Malfunction
– Failure Code [DAF7KB] – Fuel Ref-Meter Power Abnormality
– Failure Code [DAF8KB] – Camera Power Supply Short Circuit
– Failure Code [DAF9KQ] – Model Selection Abnormality
– Failure Code [DAFGMC] – GPS Module Malfunction
– Failure Code [DAFLKA] – System Operating Lamp Open Circuit (Monitor)
– Failure Code [DAFLKB] – System Operating Lamp Short Circuit (Monitor)
– Failure Code [DAFQKR] – CAN 2 Defective Communication (Monitor)
– Failure Code [DAFSMC] – Fuel Ref-Meter Communication Error
– Failure Code [DAZ9KQ] – Model Selection Signal Mismatch (Air Conditioner)
– Failure Code [DAZQKR] – CAN 2 Defective Communication (A/C ECU)
– Failure Code [DB2QKR] – CAN2 Discon (Engine Con)
– Failure Code [DB2RKR] – CAN1 Discon (Engine Con)
– Failure Code [DB30KR] – Joystick Steering Controller Malfunction
– Failure Code [DBP0KM] – KomVision Setting Error
– Failure Code [DBP0KT] – KomVision Controller Abnormality
– Failure Code [DBP5KB] – Camera Power Supply Short Circuit
– Failure Code [DBP5KY] – Camera Power Hot Short Circuit
– Failure Code [DBPQKR] – CAN 2 Defective Communication (KomVision)
– Failure Code [DCS0KT] – Internal Flash Memory Error (Machine Controller System)
– Failure Code [DCS0MC] – Machine Controller Malfunction
– Failure Code [DCS2KK] – Machine Controller Solenoid Power Voltage Low Error
– Failure Code [DCS2KT] – Machine Controller Solenoid Power Controller Internal Failure
– Failure Code [DCS5KP] – 5V Sensor 1 Power Voltage Low Error
– Failure Code [DCS6KP] – 5V Sensor 2 Power Voltage Low Error
– Failure Code [DCS7KP] – 24V Sensor Power Voltage Low Error
– Failure Code [DCS9KQ] – Model Selection Signal Mismatch (Machine Controller)
– Failure Code [DCSJKT] – Machine Controller Solenoid Return Circuit Controller Internal Failure
– Failure Code [DCSJKY] – Machine Controller Solenoid Return Circuit Hot Short Circuit
– Failure Code [DCSLKA] – System Operating Lamp Open Circuit (Machine Controller)
– Failure Code [DCSLKB] – System Operating Lamp Short Circuit (Machine Controller)
– Failure Code [DCSQKR] – CAN 2 Defective Communication (Machine Controller)
– Failure Code [DCSRKR] – CAN 1 Defective Communication (Machine Controller)
– Failure Code [DDAFKA] – Swing Lock SW Open Circuit
– Failure Code [DDAFKB] – Swing Lock SW Short Circuit
– Failure Code [DDAGL4] – Emergency Swing Brake SW Mismatch
– Failure Code [DDB6KA] – Parking Brake SW Open Circuit
– Failure Code [DDB6KB] – Parking Brake SW Short Circuit
– Failure Code [DDC4KA] – ECSS SW Open Circuit
– Failure Code [DDC4KB] – ECSS SW Short Circuit
– Failure Code [DDJ1KA] – Quick Coupler Inductive Sensor 1 Open Circuit
– Failure Code [DDJ2KA] – Quick Coupler Inductive Sensor 2 Open Circuit
– Failure Code [DDK8KA] – SUSLock Forced SW Open Circuit
– Failure Code [DDK8KB] – SUSLock Forced SW Short Circuit
– Failure Code [DDKVKA] – Joystick Steering Activation SW Open Circuit
– Failure Code [DDKVKB] – Joystick Steering Activation SW Short Circuit
– Failure Code [DDNRKA] – W/E Lever Lock SW Open Circuit
– Failure Code [DDNRKY] – W/E Lever Lock SW Short Circuit
– Failure Code [DDNS00] – Lock Lever Auto Lock Release SW ON
– Failure Code [DDP4KX] – Disconnection in Travel PPC Pressure Switch
– Failure Code [DDQ1KA] – SUSLock Mode Selection SW Open Circuit
– Failure Code [DDQ1KB] – SUSLock Mode Selection SW Short Circuit
– Failure Code [DDWCKZ] – Direction Switch Abnormality
– Failure Code [DDWMKZ] – FBR Attachment SW Abnormality
– Failure Code [DFB1KZ] – Service Lever Potentio 1 Open or Short Circuit
– Failure Code [DFB2KZ] – Service Lever Potentio 2 Open or Short Circuit
– Failure Code [DFB3L8] – Service Lever 1 Potentiometer Error
– Failure Code [DFB4L8] – Service Lever 2 Potentiometer Error
– Failure Code [DFB6KZ] – Service Lever Sub Potentio 2 Open or Short Circuit
– Failure Code [DGH2KA] – Hydraulic Oil Temperature Sensor Open Circuit
– Failure Code [DGH2KB] – Hydraulic Oil Temperature Sensor Ground Fault
– Failure Code [DHA4KA] – Air Cleaner Clog Sensor Open Circuit
– Failure Code [DHAAMA] – KDPF Differential Pressure Sensor Frozen
– Failure Code [DHACMA] – KDPF Outlet Pressure Sensor Frozen
– Failure Code [DHH2MA] – Return Line Filter Press Sensor Abnormally
– Failure Code [DHPAMA] – Front Pump Pressure Sensor Defective Function
– Failure Code [DHS3MA] – Arm IN PPC Pressure Sensor Defective Function
– Failure Code [DHS4MA] – Bucket CURL PPC Pressure Sensor Defective Function
– Failure Code [DHS5KX] – Travel PPC Sensor Abnormality
– Failure Code [DHS8MA] – Boom RAISE PPC Pressure Sensor Defective Function
– Failure Code [DHS9MA] – Boom LOWER PPC Pressure Sensor Defective Function
– Failure Code [DHSAMA] – Swing Right PPC Pressure Sensor Defective Function
– Failure Code [DHSBMA] – Swing Left PPC Pressure Sensor Defective Function
– Failure Code [DHSCMA] – Arm OUT PPC Pressure Sensor Defective Function
– Failure Code [DHSDMA] – Bucket DUMP PPC Pressure Sensor Defective Function
– Failure Code [DHT8KA] – S/T Oil Pressure Sensor Open Circuit or Ground Fault
– Failure Code [DHT8KB] – S/T Oil Pressure Sensor Hot Short Circuit
– Failure Code [DHT8ZG] – S/T Oil Pressure Low
– Failure Code [DHTFKA] – Service Brake Press Sensor 2 Open Circuit
– Failure Code [DHTFKY] – Service Brake Press Sensor 2 Short Circuit
– Failure Code [DHTFL8] – Service Brake Press Sensor Defective Function
– Failure Code [DHTGKA] – Steering orbitroll pressure sensor open circuit or short circuit
– Failure Code [DHTGKY] – Steering orbitroll pressure sensor short circuit
– Failure Code [DHU1KA] – Brake Accumulator Press Sensor Open Circuit
– Failure Code [DHU1KY] – Brake Accumulator Press Sensor Short Circuit
– Failure Code [DHUCKA] – Parking Brake Press Sensor Open Circuit
– Failure Code [DHUCKY] – Parking Brake Press Sensor Short Circuit
– Failure Code [DHUGKA] – Service Brake Press Sensor Open Circuit
– Failure Code [DHUGKY] – Service Brake Press Sensor Short Circuit
– Failure Code [DHX1MA] – Overload Sensor Abnormality
– Failure Code [DKULKA] – PPC Lock Relay Open Circuit
– Failure Code [DKULKB] – PPC Lock Relay Short Circuit
– Failure Code [DKULKY] – PPC Lock Relay Hot Short Circuit
– Failure Code [DLM5KA] – Fan Speed Sensor Open Circuit
– Failure Code [DLM5MB] – Fan Control: Mismatch
– Failure Code [DLT4KA] – Speed Sensor Open Circuit
– Failure Code [DNCHL5] – Front alignment sensor signal error
– Failure Code [DNCJL4] – Steering cylinder alignment SW abnormality
– Failure Code [DNCKL5] – Rear small alignment sensor signal error
– Failure Code [DNCLL5] – Rear large alignment sensor signal error
– Failure Code [DLT4KB] – Speed Sensor Short Circuit
– Failure Code [DR10KA] – KomVision Camera Open Circuit
– Failure Code [DR12KA] – Disconnection of Camera 1 NTSC Input
– Failure Code [DR20KA] – Disconnection of Camera 2 NTSC Input
– Failure Code [DR21KX] – Camera 2 Picture Rev. Drive Abnormality
– Failure Code [DR30KA] – Disconnection of Camera 3 NTSC Input
– Failure Code [DR31KX] – Camera 3 Picture Reverse Drive Input Out of Range
– Failure Code [DR40KA] – Disconnection of Camera 4 NTSC Input
– Failure Code [DUMBKA] – Operating Lamp Open Circuit (KomVision)
– Failure Code [DUMBKB] – Operating Lamp Short Circuit (KomVision)
– Failure Code [DV00KA] – Buzzer Output Open Circuit (KomVision)
– Failure Code [DV00KB] – Buzzer Output Short Circuit (KomVision)
– Failure Code [DV20KB] – Travel Alarm Short Circuit
– Failure Code [DW44KA] – Travel F/R Solenoid Open Circuit
– Failure Code [DW44KB] – Travel F/R Solenoid Short Circuit
– Failure Code [DW44KY] – Travel F/R Solenoid Hot Short Circuit
– Failure Code [DW45KA] – Swing Parking Brake Solenoid Open Circuit
– Failure Code [DW45KB] – Swing Parking Brake Solenoid Short Circuit
– Failure Code [DW45KY] – Swing Parking Brake Solenoid Hot Short Circuit
– Failure Code [DW4AKA] – SUSLock Sol Open Circuit
– Failure Code [DW4AKB] – SUSLock Sol Short Circuit
– Failure Code [DW4AKY] – SUSLock Sol Hot Short Circuit
– Failure Code [DW4BKA] – Parking Brake Sol Open Circuit
– Failure Code [DW4BKB] – Parking Brake Sol Short Circuit
– Failure Code [DW4BKY] – Parking Brake Sol Short Circuit
– Failure Code [DW4CKY] – PPC Lock Solenoid Hot Short Circuit
– Failure Code [DW4MKA] – Disconnection in Creep Solenoid
– Failure Code [DW4MKB] – Short Circuit in Creep Solenoid
– Failure Code [DW4MKY] – Hot Short Circuit in Creep Solenoid
– Failure Code [DW4YKA] – High Gear Sol Open Circuit
– Failure Code [DW4YKB] – High Gear Sol Short Circuit
– Failure Code [DW4YKY] – High Gear Sol Hot Short Circuit
– Failure Code [DW4ZKA] – Low Gear Sol Open Circuit
– Failure Code [DW4ZKB] – Low Gear Sol Short Circuit
– Failure Code [DW4ZKY] – Low Gear Sol Hot Short Circuit
– Failure Code [DW88KA] – ECSS Accumulator Sol Open Circuit
– Failure Code [DW88KB] – ECSS Accumulator Sol Short Circuit
– Failure Code [DW88KY] – ECSS Accumulator Sol Hot Short Circuit
– Failure Code [DW91KA] – Travel Neutral Sol Open Circuit
– Failure Code [DW91KB] – Travel Neutral Sol Short Circuit
– Failure Code [DW91KY] – Travel Neutral Sol Hot Short Circuit
– Failure Code [DWA2KA] – Attachment Single or 2-Way Change Solenoid Open Circuit (Breaker Mode Relay)
– Failure Code [DWA2KB] – Attachment Single or 2-Way Change Solenoid Short Circuit (Breaker Mode Relay)
– Failure Code [DWA2KY] – Attachment Single or 2-Way Change Solenoid Hot Short Circuit (Breaker Mode Relay)
– Failure Code [DWB1KA] – Outrigger Selection Sol Relay Open Circuit
– Failure Code [DWB1KB] – Outrigger Selection Sol Relay Short Circuit
– Failure Code [DWB2KA] – Disconnection in 1st Outrigger Solenoid
– Failure Code [DWB2KB] – Outrigger Sol.1 Short Circuit
– Failure Code [DWB2KY] – Outrigger Sol.1 Hot Short Circuit
– Failure Code [DWB3KA] – Outrigger Sol.2 Open Circuit
– Failure Code [DWB3KB] – Outrigger Sol.2 Short Circuit
– Failure Code [DWB3KY] – Outrigger Sol.2 Hot Short Circuit
– Failure Code [DWB4KA] – Outrigger Sol.3 Open Circuit
– Failure Code [DWB4KB] – Outrigger Sol.3 Short Circuit
– Failure Code [DWB4KY] – Outrigger Sol.3 Hot Short Circuit
– Failure Code [DWB5KA] – Outrigger Sol.4 Open Circuit
– Failure Code [DWB5KB] – Outrigger Sol.4 Short Circuit
– Failure Code [DWB5KY] – Outrigger Sol.4 Hot Short Circuit
– Failure Code [DWD2KA] – Disconnection in 2WS Steering solenoid
– Failure Code [DWD2KB] – 2WS Steering solenoid Short circuit
– Failure Code [DWD2KY] – 2WS Steering solenoid Hot Short Circuit
– Failure Code [DWD3KA] – Disconnection in 4WS Steering solenoid
– Failure Code [DWD3KB] – 4WS Steering solenoid Short circuit
– Failure Code [DWD3KY] – 4WS Steering solenoid Hot Short Circuit
– Failure Code [DWD4KA] – Disconnection in 4WS-R Steering solenoid
– Failure Code [DWD4KB] – 4WS-R Steering solenoid Short circuit
– Failure Code [DWD4KY] – 4WS-R Steering solenoid Hot Short Circuit
– Failure Code [DWD5KA] – Disconnection in 4WS-C Steering solenoid
– Failure Code [DWD5KB] – 4WS-C Steering solenoid Short circuit
– Failure Code [DWD5KY] – 4WS-C Steering solenoid Hot Short Circuit
– Failure Code [DWK0KA] – 2-Stage Relief Solenoid Open Circuit
– Failure Code [DWK0KB] – 2-Stage Relief Solenoid Short Circuit
– Failure Code [DWK0KY] – 2-Stage Relief Solenoid Hot Short Circuit
– Failure Code [DWK2KA] – Variable Back Pressure Solenoid Open Circuit
– Failure Code [DWK2KB] – Variable Back Pressure Solenoid Short Circuit
– Failure Code [DWK2KY] – Variable Back Pressure Solenoid Hot Short Circuit
– Failure Code [DWKSKA] – Boom Float Sol Open Circuit
– Failure Code [DWKSKB] – Boom Float Sol Short Circuit
– Failure Code [DWKSKY] – Boom Float Sol Hot Short Circuit
– Failure Code [DWMBKA] – Work Equipment PPC Reduction Solenoid Open Circuit
– Failure Code [DWMBKB] – Work Equipment PPC Reduction Solenoid Short Circuit
– Failure Code [DWMBKY] – Work Equipment PPC Reduction Solenoid Hot Short Circuit
– Failure Code [DWMCKA] – Auxiliary Hydraulic Circuit 1 Solenoid Open Circuit
– Failure Code [DWMCKB] – Auxiliary Hydraulic Circuit 1 Solenoid Short Circuit
– Failure Code [DWMCKY] – Auxiliary Hydraulic Circuit 1 Solenoid Hot Short Circuit
– Failure Code [DWMDKB] – Auxiliary Hydraulic Circuit 2 Solenoid Short Circuit
– Failure Code [DWMDKY] – Auxiliary Hydraulic Circuit 2 Solenoid Hot Short Circuit
– Failure Code [DWN5KA] – Fan Clutch Solenoid Open Circuit
– Failure Code [DWN5KB] – Fan Clutch Solenoid Short Circuit
– Failure Code [DWN5KY] – Fan Clutch Solenoid Hot Short Circuit
– Failure Code [DXA8KA] – Pump PC-EPC Solenoid Open Circuit
– Failure Code [DXA8KB] – Pump PC-EPC Solenoid Short Circuit
– Failure Code [DXE0KA] – LS-EPC Solenoid Open Circuit
– Failure Code [DXE0KB] – LS-EPC Solenoid Short Circuit
– Failure Code [DXE7KA] – Attachment Flow Regulating EPC 2 Solenoid Open Circuit
– Failure Code [DXE7KB] – Attachment Flow Regulating EPC 2 Solenoid Short Circuit
– Failure Code [DXE7KY] – Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit
– Failure Code [DXE8KA] – Attachment Flow Regulating EPC 3 Solenoid Open Circuit
– Failure Code [DXE8KB] – Attachment Flow Regulating EPC 3 Solenoid Short Circuit
– Failure Code [DXE8KY] – Attachment Flow Regulating EPC 3 Solenoid Hot Short Circuit
– Failure Code [DXE9KA] – Attachment Flow Regulating EPC 4 Solenoid Open Circuit
– Failure Code [DXE9KB] – Attachment Flow Regulating EPC 4 Solenoid Short Circuit
– Failure Code [DXE9KY] – Attachment Flow Regulating EPC 4 Solenoid Hot Short Circuit
– Failure Code [DXEAKA] – Attachment Flow Regulating EPC 5 Solenoid Open Circuit
– Failure Code [DXEAKB] – Attachment Flow Regulating EPC 5 Solenoid Short Circuit
– Failure Code [DXEAKY] – Attachment Flow Regulating EPC 5 Solenoid Hot Short Circuit
– Failure Code [DXEKKA] – Attachment Variable Press EPC1 Open Circuit
– Failure Code [DXEKKB] – Attachment Variable Press EPC1 Short Circuit
– Failure Code [DXEKKY] – Attachment Variable Press EPC1 Hot Short Circuit
– Failure Code [DXELKA] – Attachment Variable Press EPC2 Open Circuit
– Failure Code [DXELKB] – Attachment Variable Press EPC2 Short Circuit
– Failure Code [DXELKY] – Attachment Variable Press EPC2 Hot Short Circuit
– Failure Code [DXK3KA] – Travel Pedal Throttle EPC Solenoid Open Circuit
– Failure Code [DXK3KB] – Travel Pedal Throttle EPC Solenoid Short Circuit
– Failure Code [DY20KA] – Wiper Motor Open Circuit
– Failure Code [DY20MA] – Wiper Motor Defective Function
– Failure Code [DY2CKB] – Washer Motor Short Circuit
– Failure Code [DY2DKB] – Wiper Motor (Normal Rotation) Short Circuit
– Failure Code [DY2EKB] – Wiper Motor (Reverse Rotation) Short Circuit
– Failure Code [F311KA] – Centralized Warning Lamp Signal 1 Open Circuit
– Failure Code [F311KB] – Centralized Warning Lamp Signal 1 Short Circuit
– Failure Code [F312KA] – Centralized Warning Lamp Signal 2 Open Circuit
– Failure Code [F312KB] – Centralized Warning Lamp Signal 2 Short Circuit
– Failure Code [F313KA] – Communication Terminal Startup Signal Open Circuit
– Failure Code [F313KB] – Communication Terminal Startup Signal Short Circuit
– Failure Code [F314KA] – Software Update Signal Open Circuit
– Failure Code [F314KB] – Software Update Signal Short Circuit
– Failure Code [F315KA] – Engine Controller WAKE Signal Open Circuit
– Failure Code [F315KB] – Engine Controller WAKE Signal Short Circuit
– Failure Code [F315KY] – Engine Controller WAKE Signal Hot Short Circuit
– Failure Code [F316KA] – 3rd Party Component Startup Signal Open Circuit
– Failure Code [F316KB] – 3rd Party Component Startup Signal Short Circuit
– Failure Code [F316KY] – 3rd Party Component Startup Signal Hot Short Circuit
– Failure Code [F318KB] – Communication Terminal Power Supply 1 Short Circuit
– Failure Code [F318KY] – Communication Terminal Power Supply 1 Hot Short Circuit
– Failure Code [F31AKB] – Ethernet Power Supply Short Circuit
– Failure Code [F31AKY] – Ethernet Power Supply Hot Short Circuit
– Failure Code [F31BKB] – 5V Sensor Power Supply Short Circuit (Gateway Controller)
– Failure Code [F31BKY] – 5V Sensor Power Supply Hot Short Circuit (Gateway Controller)
– Failure Code [F31CKB] – 12V Sensor Power Supply Short Circuit (Gateway Controller)
– Failure Code [F31CKY] – 12V Sensor Power Supply Hot Short Circuit (Gateway Controller)
– Failure Code [F31DKB] – 24V Sensor Power Supply Short Circuit (Gateway Controller)
– Failure Code [F31DKY] – 24V Sensor Power Supply Hot Short Circuit (Gateway Controller)
– Failure Code [F31EKB] – 24V Sensor Power Supply Booster Output Short Circuit (Gateway Controller)
– Failure Code [F31EKY] – 24V Sensor Power Supply Booster Output Hot Short Circuit (Gateway Controller)
– Failure Code [F7FQKR] – CAN2 Discon (ID Key Con)
– Failure Code [F7G0MC] – ID Key Receiving Antenna Malfunction
– Failure Code [FS10ZE] Engine Controller Remote Access Abnormality
– Troubleshooting of Central Lubrication System (CLS)
— Trouble
— Troubleshooting During Grease Pump Operation
— Pump Element
— Check Power Supply
— Changing the Control Unit
— Troubleshooting – Grease System Faults
— Venting of the System
— General Assembly Advice
– Troubleshooting of Engine (S-Mode)
– S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position
– S-2 Engine Cranks but No Exhaust Smoke Comes Out
– S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)
– S-4 Engine Startability is Unsatisfactory
– S-5 Engine Does Not Pick Up Smoothly
– S-6 Engine Stops During Operation
– S-7 Engine Runs Rough or is Not Stable
– S-8 Engine Lacks Power
– S-9 Exhaust Smoke is Black
– S-10 Engine Oil Consumption Is Excessive
– S-11 Oil Becomes Dirty Quickly
– S-12 Fuel Consumption Is Excessive
– S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
– S-14 Oil Pressure Drops
– S-15 Fuel Mixes into Engine Oil
– S-16 Water Mixes into Engine Oil (Milky)
– S-17 Coolant Temperature Rises Too High (Overheating)
– S-18 Unusual Noise is Heard
– S-19 Vibration is Excessive
– S-20 Air Cannot be Bled from Fuel Circuit
– S-21 Active Regeneration is Executed Frequently
– S-22 Active Regeneration Takes Time
– S-23 White Smoke is Exhausted During Active Regeneration
– S-24 DEF Consumption is Excessive
– S-25 There is Unusual Smell (Irritating Odor)
– S-26 Foreign Materials Enter DEF (DEF Increases)
Disassembly and Assembly
– FRONT AXLE
— Note
— Table of contents
— Preface
— General
— Examples of gear-tooth contact pattern for the Gleason gear-tooth system
— Conversion table
— Denomination of standard dimensions
— Tightening torques for screws
— Special tools
— Commercial tools
— 1. Disassembly steering
— 2. Disassembly output
— 2.1 Disassembly planetary carrier
— 2.2 Disassembly brake
— 2.3 Disassembly hub
— 2.4 Disassembly knuckle housing
— 2.5 Disassembly output assy
— 3. Disassembly input
— 4. Disassembly differential
— 4.1 DZ-500 and D-500
— 4.2 DZ-750 and D-750
— 5. Reassembly differential
— 5.1 DZ-500 and D-500
— 5.2 DZ-750 and D-750
— 6. Reassembly input
— 6.1 Install input pinion
—- 6.1.1 Determine thickness of the shim to obtain a correct contact pattern
—- 6.1.2 Setting of rolling torque of the input pinion bearing
— 6.2 Setting instructions for bevel gear set backlash and bearing rolling torque of the differential bearing
—- 6.2.1 Check of backlash pattern of the bevel gear set
— 6.3 Mount shaft seal ring (input flange)
— 7. Reassembly output
— 7.1 Preassembly axle housing
— 7.2 Reassembly knuckle housing
— 7.3 Reassembly hub
— 7.4 Reassembly disk brake
—- 7.4.1 Make leakage test of multi-disk brake
—- 7.4.2 Adjust and check piston stroke
— 7.5 Reassembly planetary carrier
— 7.6 Reassembly output assy
— 7.7 Reassembly pivot bearing
— 8. Reassembly steering
— 8.1 Preassemble steering
— 8.2 Mount steering
— 8.3 Track setting and checking
— 8.4 Steering angle setting
— 8.5 Check leakage of steering
– REAR AXLE
— Note
— Table of contents
— Preface
— General
— Examples of gear-tooth contact pattern for the Gleason gear-tooth system
— Conversion table
— Denomination of standard dimensions
— Tightening torques for screws
— Special tools
— Commercial tools
— 1. Disassembly of output
— 1.1 Disassembly of planetary carrier
— 1.2 Disassembly of brake
— 1.3 Disassembly of hub
— 1.4 Disassembly of output assy
— 2. Disassembly of input
— 2.1 Version with HL transmission
— 2.2 Standard version
— 3. Disassembly differential
— 3.1 DZ-500 und D-500
— 3.2 DZ-750 und D-750
— 4. Reassembly differential
— 4.1 DZ-500 und D-500
— 4.2 DZ-750 und D-750
— 5. Reassembly of input
— 5.1 Version with HL-transmission
—- 5.1.1 Determination of shims for setting the bearing rolling torque (differential bearing) and the backlash (bevel gear set)
— 5.2 Standard version (without HL transmission)
—- 5.2.1 Reinstallation of input pinion
—- 5.2.2 Adjust backlash of crown wheel set and bearing rolling torque of differential bearing
—- 5.2.3 Fitting of shaft seal ring (input flange)
— 6. Reassembly of output
— 6.1 Reassembly of hub carrier
— 6.2 Reassembly of hub (Hub bearing SET-RIGHT)
— 6.3 Reassembly of multi-disk brake
—- 6.3.1 Leakage test of multi-disk brake
—- 6.3.2 Adjustment and check of piston stroke
— 6.4 Reassembly of planetary carrier
— 6.5 Reassembly of output assy
– 4WS AXLE
— MS‑E 3060 II 4 WS
— Copyright
— Table of Contents
— 1 Preface
— 1.1 Validity and field of application
— 1.2 Product designation
— 1.3 Information on the documentation
— 1.4 Document overview
— 2 Safety
— 2.1 Signal words and symbols
— 2.2 General safety instructions
— 2.3 Product-specific safety instructions
—- 2.3.1 Bolted joint
— 3 Information regarding work on the ZF product
— 3.1 General information
— 3.2 Cleaning the ZF product
— 3.3 Dismantling the ZF product
— 3.4 Assembling the ZF product
— 3.5 Cleaning parts
— 3.6 Reusing parts
— 3.7 Replacing parts
— 3.8 Reworking parts
— 4 Description
— 4.1 Brief product description
— 5 Technical Data
— 5.1 Oil grade
— 5.2 Type plate of axle
— 6 Settings
— 7 Tightening Torques
— 8 Workshop Equipment
— 8.1 Special tools
— 8.2 Standard tools and fixtures
— 8.3 Operating supplies and auxiliary materials
— 9 Preparatory Activities
— 9.1 Mounting the axle on assembly truck
— 9.2 Draining oil
— 10 Replacing components
— 10.1 Removing output
— 10.2 Mounting output
— 11 Dismantling
— 11.1 Dismantling the steering and removing the steering cylinder
— 11.2 Removing and dismantling the planetary carrier
— 11.3 Removing ring gear and dismantling brake
— 11.4 Removing and dismantling hub
— 11.5 Removing and dismantling the joint housing
— 11.6 Dismantling and removing axle housing
— 11.7 Dismantling the input
— 11.8 Dismantling differential DZ-500 and D-500
— 12 Testing, Measuring, Adjusting
— 12.1 Checking contact pattern (Gleason‑gearing)
—- 12.1.1 Contact pattern on crown wheel shifted towards the root
—- 12.1.2 Contact pattern on crown wheel shifted towards the tip
—- 12.1.3 Special case “Line” contact pattern
— 13 Assembling
— 13.1 Assembling input
—- 13.1.1 Installing the pinion
—- 13.1.2 Assembling differential D-500
—- 13.1.3 Installing the differential
—- 13.1.4 Installing the shaft sealing ring
— 13.2 Assembling output
—- 13.2.1 Installing universal shaft
—- 13.2.2 Installing Hall sensor
—- 13.2.3 Assembling and installing the joint housing
—- 13.2.4 Assembling and installing hub
—- 13.2.5 Installing multi-disk brake
—- 13.2.6 Checking multi-disc brake for leaks
—- 13.2.7 Checking piston stroke
—- 13.2.8 Assembling and installing the planetary carrier
—- 13.2.9 Installing bushes of self-aligning bearing
— 13.3 Assembling the steering
—- 13.3.1 Assembling the steering cylinder
—- 13.3.2 Installing the steering cylinder
—- 13.3.3 Setting the track
—- 13.3.4 Adjusting steering angle
—- 13.3.5 Checking steering for leaks
— 14 Disposal
— 14.1 General notes on disposal
— 14.2 Product-related notes on disposal
—- 14.2.1 Disposal of the HV components
— 15 Follow-up Activities
— 15.1 Filling oil
— 15.2 Checking the optical sensor on the steering cylinder
— 15.3 Checking the Hall sensor on the axle housing
— 16 Annex
— 16.1 Formulary and conversion tables
—- 16.1.1 Conversion value to be adjusted on the torque wrench
— 16.2 Revision history
— ZF Friedrichshafen AG, www.zf.com
– TRANSMISSION
— Note
— Table of contents
— Preface
— General
— Conversion table
— Denomination of standard dimensions
— Torque limits for screws
— Special tools
— Commercial tools
— 1. Separate HL-Transmission from axle housing
— 2. Disassembly – Brake/Clutch/Planetary carrier
— 2.1 Lubrication pump and shift interlock
—- 2.1.1 Version “Lubrication pump”
— 2.2 Speed sensor
— 2.3 Emergency release (Parking Brake)
— 2.4 Input housing and modulation valve
— 2.5 Brake and clutch
— 2.6 Planetary carrier
— 3. Disassembly – Output
— 3.1 Version “Axle attachment”
— 3.2 Version “Separate Installation”
— 4. Reassembly – Output
— 4.1 Version “Axle attachment”
—- 4.1.1 Determine shim for pinion gap
—- 4.1.2 Determine adjusting ring for rolling torque/pinion bearing
—- 4.1.3 Check rolling torque of pinion bearing
—- 4.1.4 Shaft seal output flange
—- 4.1.5 Check the pinion gap
— 4.2 Version “Separate installation”
—- 4.2.1 Shaft seal output flange
— 5. Reassembly – Brake/Clutch/Planety carrier
— 5.1 Planetary carrier
— 5.2 Brake and clutch
—- 5.2.1 Disc components brake and clutch
—– 5.2.1.1 Version “HL-290”
—– 5.2.1.2 Version “HL-270”
—– 5.2.1.3 Version “HL-250”
—- 5.2.2 Adjust and check the disc clearance/piston stroke of brake and clutch
— 5.3 Install modulation valve and input housing
— 5.4 Emergency release (Parking brake)
—- 5.4.1 Check emergency release for leak tightness
—- 5.4.2 Check the multi-disk brake and multi-disc clutch for leak tightness as well as closing pressure
— 5.5 Speed sensor
— 5.6 Lubrication pump/shift interlock
— 6. Disassembly – Lubrication pump/shift interlock and valve block
— 6.1 Version “with” lubrication pump
— 6.2 Version “with” hydr. shift interlock
— 6.3 Disassembly valve block
— 7. Reassembly Lubrication pump
— 8. Reassembly shift interlock
— 9. Valve block (shifting low gear – high gear)
— 10. Mount HL-Transmission to axle
Maintenance Standard
– Engine and Cooling System
— Maintenance Standard of Engine Mount
— Maintenance Standard of Cooling System
– Power Train
— Maintenance Standard of Swing Circle
— Maintenance Standard of Swing Machinery
— Axles and Prop Shaft
— Orbitrol Valve (STD/JSS)
— Trailer Preparation
— Cabin Mounting
– Hydraulic System
— Maintenance Standard of Hydraulic Tank
— Main Pump
— Maintenance Standard of LS-EPC valve
— Maintenance Standard of PC-EPC Valve
— Control Valve
— Maintenance Standard of Anti-Drop Valve for 1. Boom LH
— Maintenance Standard of Anti-Drop Valve for 1. Boom RH
— Maintenance Standard of Anti-Drop Valve for 2. Boom
— Maintenance Standard of Anti-Drop Valve for Arm/Bucket
— Maintenance Standard of Work Equipment and Swing PPC Valve
— Solenoid Valve Block
– Work Equipment
— Work Equipment Linkage
— Dimension of Arm
– Hydraulic Cylinder
— Boom Cylinder
— Arm Cylinder
— Bucket Cylinder
— Adjust Cylinder
— Outrigger Cylinder
— Dozer Cylinder
— Bellow Tube
Appendix
– Precautions Before Work
– Air Conditioner System
— Precautions for Refrigerant
— Air Conditioner Component
— Specifications of Air Conditioner Unit
— Outline of Refrigeration Cycle
— Compression (Compressor)
— Condensation (Condenser)
— Expansion (Expansion Valve)
— Evaporation (Evaporator)
— Relation between Refrigerant and Cooling Trouble
– Component parts of Air Conditioner System
— Air Conditioner Unit
— Configuration Diagram of Air Conditioner Unit
— Function of Air Conditioner Unit
— Component Parts of Air Conditioner Unit
— Function of Evaporator as Air Conditioner Unit Component
— Heater Core as Air Conditioner Unit Component
— Function of Evaporator Temperature Sensor as Air Conditioner Unit Component
— Function of Servo Motor as Air Conditioner Unit Component
— Structure of Expansion Valve as Air Conditioner Unit Component
— Function of Expansion Valve as Air Conditioner Unit Component
— Operate Expansion Valve as Air Conditioner Unit Component
— Function of Dual Pressure Switch
— Air Conditioner Controller
— Structure of Air Conditioner Controller
— Compressor
— Structure of Compressor
— Specifications of Compressor
— Function of Compressor
— Condenser
— Structure of Condenser
— Specifications of Condenser
— Function of Condenser
— Air Conditioner Related Sensors
— Structure of Sunlight Sensor
— Function of Sunlight Sensor
— Structure of Outside Temperature Sensor
— Function of Outside Air Temperature Sensor
– Explanation of Procedure for Testing and Troubleshooting of Air Conditioner
— Basic Flow Chart to Examine and Troubleshoot
— Examine the Refrigerant Quantity Through the Sight Gauge
– Circuit Diagram and Configuration of Connector Pins of Air Conditioner
– System Diagram of Air Conditioner
— Input and Output Signals of Air Conditioner Controller
— Function of Air Conditioner Controller
– Locations of Air Conditioner Parts and Layout of Connectors
— Fuses Layout in the Fuse Boxes
— Air Conditioner Controller and Connectors Layout
— Air Conditioner Unit and Connectors Layout
— Sunlight Sensor Connectors Layout
— Machine Monitor Connectors Layout
— Dual Pressure Switch Connectors Layout
— Air Conditioner Compressor Connectors Layout
— Outside Air Temperature Sensor Connectors Layout
– Examine Air Leakage (Duct)
— How to Examine Air Leakage (Duct)
– Examine Air Conditioner with Self-Diagnosis Function
– Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
– Examine vent (mode) Changeover
– Examine FRESH/RECIRC Air Changeover
— How to Examine FRESH/RECIRC Air Changeover
– Examine Sunlight Sensor
— How to Examine Sunlight Sensor
– Examine Refrigerant (Dual) Pressure Switch
— How to Examine (Dual) Pressure Switch for Refrigerant
— Test Relays
— How to Examine Relays
– Air Conditioner Troubleshooting Chart 1
– Air Conditioner Troubleshooting Chart 2
– Information Shown in Troubleshooting Table
– Failure Code [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit
– Failure Code [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit
– Failure Code [879BKA] A/C Fresh Air Temperature Sensor Open Circuit
– Failure Code [879BKB] A/C Fresh Air Temperature Sensor Short Circuit
– Failure Code [879CKA] Ventilating Sensor Open Circuit
– Failure Code [879CKB] Ventilating Sensor Short Circuit
– Failure Code [879DKZ] Sunlight Sensor Open Circuit or Short Circuit
– Failure Code [879EMC] Ventilation Damper Malfunction
– Failure Code [879FMC] Air Mix Damper Malfunction
– Failure Code [879GKX] Refrigerant Pressure Input Signal Out of Range
– A-1 Troubleshooting for Power Supply System (Air Conditioner Does not Operate)
– A-2 Troubleshooting for Compressor and Refrigerant System (Air is not Cooled)
– A-3 Troubleshooting for Blower Motor System (no Air comes out or Air Flow is Abnormal)
– A-4 Troubleshooting for FRESH/RECIRC Air Changeover
– Troubleshooting by Gauge Pressure
– Connect Service Tool
— How to Connect Service Tool
– Precautions for Disconnection and Connection of Air Conditioner Piping
— Precautions for Disconnection
— Precautions for Connection
– Handle Compressor Oil
— Management of Compressor Oil (DENSO: ND-OIL8 for R134a)
— Quantity of the Compressor Oil When the Compressor is Replaced
– How to Replace Desiccant
– Joystick Steering
– Overview of Failure Groups and Descriptions
– Error Handling
— 1 Malfunction of Pump Controller
— 1.1 Joystick Activation Signals Have the Same Value
— 2 Malfunction of SASA-Sensor
— 2.1 CRC
— 2.2 CAN Count
— 2.3 CAN Timeout
— 2.4 Sensor Chip
— 2.5 Steering Angle
— 2.6 CAN Input Message
— 2.7 Power
— 2.8 CPU
— 2.9 Memory
— 2.10 Temperature
— 2.11 Angle Not Available (from CAN)
— 2.12 RPM Not Available (from CAN)
— 2.13 CAN Redundant
— 2.14 Sensor
— 2.15 RAM Corruption
— 3 Malfunction of Hall-Sensor
— 3.1 Joystick Signals out of Range
— 3.2 Joystick Redundant Signals Mismatch
— 3.3 Joystick out of Neutral When Activating Steering System
— 3.4 No Signal Available
— 4 Malfunction of PVES (Electrical Activation) Orbitrol
— 4.1 Steering Valve Feedback Value out of Range (Beneath 25% UDC or Above 75% UDC)
— 4.2 Steering Valve Feedback (SP) value and Control Value (US) Mismatch
— 4.3 Error Pin (C2p01) High Signal, Also Indicated on PVES-SP LED:
— 5 Wiring-Failure
— 5.1 Joystick Signals out of Range
— 5.2 Joystick Redundant Signals Mismatch
— 5.3 Joystick Mode Signals have the Same Value
— 5.4 Cut Off valve current output and feedback mismatch
— 5.5 Steering Valve Supply Current Output and Feedback Mismatch
— 5.6 Steering Valve Control Duty Output and Feedback Mismatch
— 5.7 Steering Valve Control
— 5.8 Steering Valve Supply
— 5.9 Steering Valve Failure Signal
— 5.10 Cut Off Valve Outputs
— 5.11 Joystick Mode Switch Reference
— 5.12 Failure LED Output
— 5.13 Joystick Mode Inputs
— 5.14 Joystick Active Inputs
— 5.15 Joystick Signals
— 5.16 Steering Valve Failure Signal Input
— 5.17 Steering Valve Position Feedback Input
— 6 Miscellaneous
— 6.1 CAN time out
— 6.2 Joystick Calibration Failure
— 6.3 SASA Sensor CAN Timeout
— 6.4 CAN Bus Failure
— 6.5 Bus Off
— 6.6 Driver Error
— 6.7 Passive Mode Error
— 6.8 Overflow
— 6.9 Joystick Mode Signals Have the Same Value
— 6.10 Joystick Steering Profile Parameters out of Range
— 7 Failure of SC024-120
— 7.1 HWPCBVoltages.InRange
— 7.2 OS.CrcStatus
— 7.3 OS.ChecksumFailure
— 7.4 SafetyLayer.Failure
— 7.5 Battery Power Outside of Allowable Ranges
— 7.6 Sensor Power Outside of Specified Ranges
— 7.7 NVMem.Status
— 8 Error Descriptions
— 8.1 Inputs 1
— 8.2 Inputs 2
— 8.3 Safety function 1
— 8.4 Outputs 1
— 8.5 Outputs 2
— 8.6 Joystick Controller Internal
— 8.7 Error Counters Page 1
— 8.8 Error Counters Page 2
— 9 Acronyms
Circuit Diagrams
– Hydraulic Circuit Diagram
— Hydraulic Circuit Diagram (1/3)
— Hydraulic Circuit Diagram (2/3)
— Hydraulic Circuit Diagram (3/3)
– Wiring Circuit Diagram
— Index
— 1-0 Power Supply
— 1-1 Grounding
— 1-2 Model Select
— 2-0 Engine
— 2-1 Engine
— 2-2 Engine Power Supply, Air Intake
— 2-3 Engine Start
— 2-4 2nd Engine Stop, Operating Lamp, DEF-Alive
— 2-5 AdBlue/DEF Datalink
— 2-6 AdBlue/DEF Power
— 3-0 Refueling System, Fuel Dial
— 3-1 Brake
— 3-2 EPC
— 3-3 Cruise Control
— 3-4 Travel
— 3-5 SUS-Lock, Speed SNR, Joystick POTI
— 3-6 Sensors Engine & Oil
— 4-0 Quick Coupler, Pressure Sensor
— 4-1 PPC Reduction, Floating, Pressure Sensor
— 4-2 Swing Lock, Pressure Sensor, Joystick SW
— 4-3 Bucket/2ATT Switching
— 4-4 Smart Construction
— 4-5 Smart Construction
— 4-6 Smart Construction
— 5-0 Lower Attachments
— 5-1 Roto-Tilt
— 5-2 Boom/Stabiliser, Auxiliary Circuit, Breaker
— 5-3 4-Wheel Steering
— 6-0 Road Light
— 6-1 Indicator, Side Light, Stop Light
— 6-2 Arm Marker Light + QC Signal Boom
— 6-3 Beacon, Trailer (Opt)
— 6-4 Worklamp
— 6-5 Worklamps Cabin
— 6-6 Camera SW, Service-Con., KOMNET
— 6-7 GATEWAY Controller
— 6-8 KomVision
— 7-0 Air Condition, Heated Mirror
— 7-1 Radio, 12V Socket, Cigar Lighter, Room Lamp
— 7-2 PPC-Lock, Starter Cut, Seat
— 7-3 ID-key
— 7-4 Horn, Travel Alarm
— 7-5 Wiper, Washer
— 8-0 CLS
— 9-0 Joystick Steering
— 10-0 Fan Clutch, Tool Control
— 11-0 ECSS
— 12-0 Digging Brake
— W1-1 Wiring Harness List
— W1-2 Wiring Harness List
— W2-1 Connector List
— W2-2 Connector List
— W2-3 Connector List
— W2-4 Connector List
— W2-5 Connector List
— W2-6 Connector List
— W2-7 Connector List
— W2-8 Connector List
— W3-1 PIN Location List
— W3-2 PIN Location List
— W3-3 PIN Location List
— W3-4 PIN Location List
— W3-5 PIN Location List
— W3-6 PIN Location List
— W3-7 PIN Location List
— W3-8 PIN Location List
— W3-9 PIN Location List
— W3-10 PIN Location List
— W3-11 PIN Location List
— W3-12 PIN Location List
— W3-13 PIN Location List
— W3-14 PIN Location List
— W3-15 PIN Location List
— W3-16 PIN Location List
— W3-17 PIN Location List
— W3-18 PIN Location List
— W3-19 PIN Location List
— W3-20 PIN Location List
— W3-21 PIN Location List
— W3-22 PIN Location List
— W3-23 PIN Location List
— W3-24 PIN Location List
— W3-25 PIN Location List
— W3-26 PIN Location List
— W3-27 PIN Location List
— W3-28 PIN Location List
— W3-29 PIN Location List
— W3-30 PIN Location List
— W3-31 PIN Location List
— W3-32 PIN Location List
— W3-33 PIN Location List
— W3-34 PIN Location List
— W3-35 PIN Location List
— W3-36 PIN Location List
— W3-37 PIN Location List
— W3-38 PIN Location List
— W3-39 PIN Location List
— W3-40 PIN Location List
— W3-41 PIN Location List
— W3-42 PIN Location List
— W3-43 PIN Location List
— W3-44 PIN Location List
— W3-45 PIN Location List
— W3-46 PIN Location List
— W3-47 PIN Location List
— W3-48 PIN Location List
— W3-49 PIN Location List
— W3-50 PIN Location List
— W3-51 PIN Location List
— W3-52 PIN Location List
— W4-1 Parts List
— W4-2 Parts List
— W4-3 Parts List
— W4-4 Parts List
— W4-5 Parts List
– Connector Diagram
— Connector Diagram 1/13
— Revolving Frame Harness 1
— Connector Diagram 2/13
— Revolving Frame Harness 2
— Connector Diagram 3/13
— Operator‘s Cab Wiring Harness (Part 1/2)
— Connector Diagram 4/13
— Operators Cab Wiring Harness (Part 2/2)
— Connector Diagram 5/13
— Connector Table Switch Group
— Connector Diagram 6/13
— Connector Table Steering
— Connector Diagram 7/13
— Connector Table Various Wiring Harness
— Connector Diagram 8/13
— Connector Table Optionally Wiring Harness (Part 1/4)
— Connector Diagram 9/13
— Connector Table Optionally Wiring Harness (Part 2/4)
— Connector Diagram (10/13)
— Connector Table Optionally Wiring Harness (Part 3/4)
— Connector Diagram (11/13)
— Connector Table Optionally Wiring Harness (Part 4/4)
— Connector Diagram (12/13)
— Connector Diagram (13/13)
— Brake Valve A., Electric