Komatsu PW160-11 Wheeled Excavator Shop Manual VENBM69002 PDF

Description

Komatsu PW160-11 Wheeled Excavator Shop Manual VENBM69002 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PW160-11 Wheeled Excavator Shop Manual VENBM69002 – PDF DOWNLOAD

Language : English
Pages : 2216
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PW160-11 Wheeled Excavator Shop Manual VENBM69002 – PDF DOWNLOAD

• MACHINE MODEL   SERIAL NUMBER
• PW160-11                  H65051 AND UP

VENBM69002 PW160-11 1
FOREWORD . 5
Safety . 5
Important safety notice 5
General precautions 5
Preparations for work 5
Precautions during work 6
General 7
General 7
Structure and function . 7
Testing, adjusting and troubleshooting . 7
Disassembly and assembly . 7
Maintenance standard . 7
How to read the shop manual 8
Volumes 8
Distribution and updating 8
Filing method 8
Revised edition mark . 8
Revisions 8
Symbols 8
Hoisting instructions 9
Hoisting . 9
Wire Ropes . 9
Coating materials 10
Standard tightening torque . 12
Standard tightening torque of bolts and nuts . 12
Tightening torque of hose nuts . 13
Tightening torque of split flange bolts 13
Tightening torques for hoses (taper seal type and face seal type) 13
Tightening torque for 102,107 and 114 engine series (bolts and nuts) . 14
Tightening torque for 102,107 and 114 engine series (eye joints) . 14
Tightening torque for 102,107 and 114 engine series (tapered screws) . 14
Electric wire code . 15
Classification by thickness 15
Classification by color and code . 15
Conversion tables 16
Method of using the conversion table . 16
Units 22
GENERAL 23
Specification dimension drawings . 24
Dimensions . 24
Working ranges . 26
Working range: 1-piece boom 26
Working range: 2-piece boom 27
Weight table . 31
1-piece boom . 32
2-piece boom . 33
Fuel, coolant and lubricants . 34
STRUCTURE AND FUNCTION . 35
Abbreviation list 38
List of abbreviations used in the text . 38
List of abbreviations used in the circuit diagrams . 42
UREA SCR system 43
Layout drawing of UREA SCR system 43
Detailed drawing of SCR assembly . 46
Detailed drawing of AdBlue/DEF tank 47
UREA SCR system diagram 48
Function of UREA SCR system 49
Function of AdBlue/DEF system 50
AdBlue/DEF injection function 50
AdBlue/DEF purge function 51
Function of AdBlue/DEF thawing and preventing from freezing 51
Inducement strategy 52
Inducement strategy when the AdBlue/DEF level in the tank becomes low (for north America) 53
Inducement strategy when abnormality is found in the UREA SCR system devices (for north America) . 54
Inducement strategy when abnormality is found in the KDOC system by the IREA SCR system (for north America) 56
Function of temporary restoration from inducement (for north America) 58
Inducement strategy for abnormality recurrence within 40 hours (for north America) . 59
Inducement strategy when the AdBlue/DEF level in the tank becomes low (for European Union) . 60
Inducement strategy when abnormality is found in the AdBlue/DEF quality or in the UREA SCR system devices (for European Union) . 62
Inducement strategy when abnormality is found in the KDOC system by the IREA SCR system (for Europan Union) 64
Inducement strategy when abnormality is found in the EGR system by the IREA SCR system devices (foR European Union) 66
Function of temporary restoration from inducement (for European Union) . 67
Inducement strategy for abnormality recurrence within 40 hours (for European Union . 68
Component parts of UREA SCR system . 69
AdBlue/DEF MIXING TUBE . 69
SCR assembly . 70
Structure of UREA SCR assembly . 70
AdBlue/DEF tank 72
Structure of AdBlue/DEF tank . 72
AdBlue/DEF tank sensor . 73
Function of AdBlue tank sensor . 73
AdBlue/DEF pump 74
AdBlue/DEF injector 75
AdBlue/DEF hose 76
AdBlue/DEF tank heating valve 77
BOOT-UP system . 78
Layout drawing of BOOT-UP system . 78
System operating lamp system . 79
System operating lamp system diagram . 79
Function of system operating lamp system . 79
Battery disconnect switch 80
Function of battery disconnect switch 80
Engine system 82
Layout drawing of engine system 82
Function of engine system 83
Engine control system 83
Engine control system diagram 83
Function of engine control system 84
Auto-deceleration system . 87
Auto-deceleration system diagram . 87
Engine automatic warm-up system 89
Engine automatic warm-up system diagram 89
Function of engine automatic warm-up system 90
Overheat prevention system . 91
Overheat prevention system diagram . 91
Function of overheat prevention system . 92
Turbocharger protection system . 93
Turbocharger protection system diagram . 93
Function of turbocharger protection system . 94
Automatic idle stop system . 95
Automatic idle stop system diagram . 95
Function of automatic idle stop system . 95
Abrupt engine stop is detected . 98
Component parts of engine system . 99
Structure of VGT . 99
EGR system . 102
Layout drawing of EGR system . 102
Function of EGR system . 102
Circuit diagram of EGR system 103
Operation of EGR system 103
EGR valve 104
Structure of EGR valve . 104
General view and sectional view 104
Operation of EGR valve . 105
EGR cooler . 106
Structure of EGR cooler 106
General view and sectional view 106
Detailed drawing of flat tube 107
Operation of EGR cooler 107
KCCV system 108
Layout drawing of KCCV system 108
KCCV ventilator 110
Structure of KCCV ventilator . 110
Function of KCCV ventilator 110
Operation of KCCV ventilator . 111
CDR valve 111
KDOC . 112
Structure of KDOC 112
Function of KDOC . 113
Types of regeneration functions 113
Cooling system . 116
Layout drawing of cooling system . 116
Specifications of cooling system . 117
Fan speed control system of fan clutch . 118
Engine output control system of fan clutch . 120
Engine output control system diagram of fan clutch . 120
Function of engine output control system of fan clutch . 121
Component parts of cooling system 122
Fan clutch . 122
Power train 124
Swing circle . 126
Specifications . 126
Swing machinery & motor 127
Specification 128
Operation of swing lock 129
Relief valve portion . 130
Operation 130
Undercarriage 132
Transmission . 134
Specifications . 134
Function . 136
Trailer 137
Calculation of maximum coupling Load . 137
Automatic trailer coupling for blade . 138
Functional check . 138
Possible faults in the coupling 139
Wear limits 140
Automatic trailer coupling for outrigger . 142
Functional check . 142
Height adjustment components . 143
Functional check . 143
Possible faults in the coupling 144
Wear limits 146
Inspection . 148
2nd Auxiliary circuit in the undercarriage . 150
Function . 150
Specifications . 151
Schematic of auxiliary circuit . 151
Hydraulic quick coupler 152
Schematic 152
Operation 153
Hydraulic quick coupler solenoid valve . 153
Specification 153
Quick coupler error logic 154
Full hydraulic quick coupler . 155
Travel motor . 158
Function . 159
Operation of travel motor 160
Clutch control circuit . 162
Function . 163
Axle . 164
Outline 164
Suspension lock cylinder . 168
Specifications . 168
Structure and function . 168
Circuit 169
Axle oscillation . 169
Braking system . 170
Structure and function . 171
Gear pump 172
Specifications . 172
Function . 172
Priority valve . 174
Specification 174
Function . 174
Power brake valve 176
Specifications . 177
Function . 177
Accumulator for brake valve 178
Specifications . 178
Structure and function . 178
Steering system 179
Structure and function . 179
Joystick steering system . 180
Structure and function . 181
Steering column JSS 182
Specifications . 183
Steering column STD 185
Steering column JSS 186
Orbitrol valve STD . 187
Specifications . 187
Structure and function . 187
Orbitrol valve JSS . 188
Specifications . 188
Structure and function . 188
Hydraulic equipment layout drawings 189
Hydraulic circuit diagram 191
Hydraulic tank . 192
Specifications . 192
Hydraulic pump . 193
Function . 195
Structure 195
Operation 196
LS valve . 198
PC valve . 199
Function . 200
Operation 201
1. LS valve 201
2. PC valve 205
LS(PC)-EPC valve . 212
Function . 213
Operation 213
Pilot pressure control (PPC) system 216
Function . 217
Operation 217
Control main valve . 218
Outline 218
CLSS . 233
Outline of CLSS 233
Features . 233
Structure 233
Basic Principle 234
Operation for each function and valve 236
Hydraulic circuit diagram and name of valves . 236
1. Unload valve 238
Function . 238
Operation 238
Operation 239
Operation 240
2. Introduction of LS pressure . 241
Work equipment valve . 241
Function . 241
Operation 241
3. LS bypass plug 242
Outline 242
Operation 242
4. Pressure compensation valve . 243
Function . 243
Operation 244
5. Area ratio of pressure compensation valve . 245
Function . 245
6. Boom regeneration circuit . 246
Function . 246
Operation 246
Function . 247
Operation 247
7. Arm regeneration circuit 248
Function . 248
Operation 248
Function . 249
Operation 249
8. Swing bleeding valve 250
Function . 250
Operation (In fine control operation) 251
9. LS select valve . 252
Function . 252
Operation 252
Centre swivel joint 253
Travel PPC pedal . 254
Work equipment – Swing PPC valve . 256
Operation 258
Solenoid valve block with integrated ATT – EPC . 260
ATT EPC Assembly . 262
ON / OFF Solenoid valves (3 way valve) . 263
Operation 263
ON / OFF Solenoid valves (4 way valve) . 265
Operation 265
Hi/ Lo Solenoid valve (4 way valve) 267
Attachment PPC valve . 268
Function . 269
Operation 269
Undercarriage solenoid valve block . 271
Boom/Outrigger schematic . 272
Undercarriage attachment schematic . 273
Proportional attachment control 274
Proportional attachment schematic 275
Bucket to 1ATT . 276
Function . 276
Bucket to 1 ATT valve 277
Boom safety valve 278
Operation 279
Boom floating 280
PPC pressure reduction/ Boom floating logic 280
Hydraulic cylinder . 286
Boom cylinder 286
Arm cylinder . 286
Bucket cylinder 286
Adjust cylinder 287
Outrigger cylinder . 288
Dozer cylinder . 290
Function . 291
Work equipment . 292
Work equipment . 293
1. Dimension of arm 294
2. Dimension of bucket . 296
Tool control . 298
Tool control schematic (detail from hydraulic diagram) . 299
ECSS . 300
ECSS Logic . 300
ECSS Hydraulic Schematic . 302
ECSS Accumulator position 303
ECSS Valve . 304
ECSS Hydraulic diagram . 305
Breaker return valve . 306
Function . 306
Air conditioner 310
Air conditioner component 310
Specifications of air conditioner 313
Electrical wiring diagram 314
Electrical system 315
Engine control . 315
1. Operation of System . 315
2. Component . 316
Engine controller 317
Structure of engine controller . 317
General view . 317
Input and output signals of engine controller 317
Pump controller 322
Machine controller . 326
Machine control system diagram . 329
1. Engine and pump control function 330
Function . 331
Function . 335
Function . 337
Function . 339
Operation 340
Function . 341
Function . 345
Function . 347
Function . 350
Specifications . 351
Function . 351
Function . 352
Operation 352
Machine monitor system . 356
Function of machine monitor 358
Monitor display 362
Monitor items and display 364
Caution monitor 366
Pilot monitor 370
Monitor switches . 374
Declaration of switch function on keypad . 375
Guidance icon and function switch 377
Operator mode function . 380
Service mode function of machine monitor . 382
KOMTRAX system . 384
KOMTRAX terminal . 385
Structure of KOMTRAX terminal 385
Function of KOMTRAX terminal . 385
KomVision system . 387
Layout drawing of KomVision system . 387
Chassis part . 387
Around cab and floor . 388
KomVision system diagram . 388
Function of KomVision system . 389
KomVision controller . 390
Structure of KomVision controller 390
Structure of KomVision camera 394
Overload warning device 395
Outline 395
Function . 395
Structure 395
Sensor . 396
Ambient pressure sensor 398
Charge (boost) pressure and temperature sensor . 399
Coolant temperature sensor . 400
Ne (crankshaft) speed sensor . 400
Bkup (camshaft) speed sensor . 401
Common rail pressure sensor 401
Exhaust manifold pressure sensor . 402
EGR orifice temperature sensor . 402
Variable flow turbocharger motor (with built-in position sensor) . 403
EGR valve (with built-in position sensor) 404
EGR valve lift sensor 405
KVGT speed sensor 406
KVGT position sensor . 407
Mass air flow and temperature sensor . 408
KDOC inlet temperature sensor 409
KDOC outlet temperature sensor . 409
Crankcase pressure sensor 410
Engine oil level sensor 411
Fuel level sensor 412
WIF (Water-In-Fuel detection) sensor . 413
Coolant level sensor . 414
Hydraulic oil temperature sensor . 415
Air cleaner clogging sensor 415
Overload Caution sensor 416
Swing proximity sensor . 417
Brake sensors 417
Brake accumulator low pressure sensor (CN-P60) . 418
Brake stop light sensor (CN-S19) . 418
Service brake pressure sensor (CN-S40) . 418
Service brake pressure sensor (CN-P62) . 418
Park brake pressure sensor (CN-P61) 419
PPC pressure sensors . 419
DPF-SCR Area . 420
Main valve sensor 421
PPC levers . 422
LH PPC lever . 422
RH PPC lever . 423
1st attachment circuit hydraulic performance (main valve bypassed) . 424
Travel system 425
Travel circuit . 425
Travel Motor Performance . 426
Auto-grease pump . 428
Overview . 429
Display and control unit . 429
LED-display 430
Push buttons . 430
Three-digit LED display 431
Check central lubrication system, fill up grease . 432
Lubrication diagrams . 433
Auto-grease pump with one-piece boom . 433
Auto-grease pump with two-piece boom . 434
Manual system one-piece boom . 435
Manual system two-piece boom . 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
Engine and cooling system 470
Test engine speed 470
Method for testing engine speed 470
Replacing the fan belt . 520
Measurement of clearance in swing circle bearing . 521
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel 522
Measurement 522
Adjustment . 523
Inspection and adjustment of control circuit oil pressure 525
Measurement 525
Procedure for pressure reducing adjustment . 526
Inspection and adjustment of pump PC (valve inlet) control oil pressure 527
Measurement 527
Adjustment . 529
Inspection and adjustment of pump LS differential pressure . 530
Measurement 530
Adjustment . 532
Measurement of solenoid valve output pressure 533
Checking Proportional Control PPC Circuit 535
Adjustment of work equipment and swing PPC valve . 536
Measuring and adjusting quick coupler control valve output pressure 537
Testing travel motor relief pressure . 538
Measuring travel motor relief pressure . 538
Testing propshaft speed 539
Measuring rotating speed of propshaft 539
Testing transmission clutch control circuit 540
Description 540
Inspection of locations of hydraulic drift of work equipment . 542
Release of remaining pressure in hydraulic circuit . 544
Measurement of oil leakage . 545
Air bleeding of various parts 548
Inspection procedures for diode 551
Electrical system 552
Special function of monitor panel 552
Service mode . 561
Method for checking pre-defined monitoring information . 564
Table of self-define monitoring 578
Abnormality record menu 589
Method for confirming maintenance record . 594
Method For Operating Maintenance Mode Setting 595
Method for operating phone number entry setting 599
Diagnostic tests menu 612
Adjustment menu 621
KOMTRAX settings menu 629
Method for starting up KOMTRAX terminal 633
Inspection and adjustment of ECSS (ACCU pressure) 638
Maintenance 638
Inspection and adjustment of Tool control 641
Troubleshooting 647
Changing the lubrication interval times 650
Adjust rearview camera angle . 652
Method for adjusting rear view camera angle 652
Adjust KomVision camera angle 654
Tools for adjusting KomVision camera angle . 654
Method for adjusting KomVision camera angle 655
Angle adjustment method for front R.H. camera, rear R.H. camera, and rear L.H. camera 655
Angle adjustment method for rear camera 656
Adjust KomVision related items . 658
Setting of KomVision (main setting) 659
Method for setting KomVision (main setting) 659
Setting of KomVision (camera setting) 661
Method for setting KomVision (camera setting) 661
Setting of KomVision (camera calibration) 661
Method for setting of KomVision (camera calibration) . 662
TESTING AND ADJUSTING 467
TROUBLESHOOTING 673
Abbreviation list 674
List of abbreviations used in the text . 674
List of abbreviations used in the circuit diagrams . 678
Related information on troubleshooting . 679
General troubleshooting points . 679
When the failure code cannot be cleared by “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code” 682
Sequence of events in troubleshooting 692
Walk-around check 696
Method for disconnecting and connecting connector with special lock 698
Connector table 709
T-Branch box and T-Branch adapter table 753
T-boxes and T-adapters table . 758
Fuse location table 762
Precautions for replacing kdoc . 764
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 765
Failure code table (Display of code) . 766
Troubleshooting by failure code (Display of code) 788
Failure code [2G00MA] – Brake oil pressure abnormality . 788
Failure code [602ENX] – Return filter clogging . 789
Failure code [6AZ0ZG] – Quick coupler pressure low . 790
Failure code [6B2JMA] – Travel hydraulic abnormality . 792
Failure code [879AKA] – A/C recirculation air temperature sensor open circuit 793
Failure code [879AKB] – A/C inner sensor short circuit . 794
Failure code [879BKA] – A/C outer sensor open circuit 796
Failure code [879BKB] – A/C outer sensor short circuit . 798
Failure code [879CKA] – Ventilating sensor open circuit 800
Failure code [879CKB] – Ventilating sensor short circuit . 801
Failure code [879DKZ] – Sunlight sensor open or short circuit 802
Failure code [879EMC] – Ventilation damper abnormality . 804
Failure code [879FMC] – Air mix damper abnormality . 805
Failure code [879GKX] – Refrigerant abnormality 806
Failure code [989L00] – Engine controller lock caution 1 . 808
Failure code [989M00] – Engine controller lock caution 2 . 809
Failure code [989N00] – Engine controller lock caution 3 . 810
Failure code [A1U0N3] – HC desorb request 1 811
Failure code [A1U0N4] – HC desorb request 2 812
Failure code [AA10NX] – Air cleaner clogging . 814
Failure code [AB00KE] – Charge voltage low . 816
Failure code [AQ10MB] – Manual stationary regeneration request 2 . 818
Failure code [AQ10N3] – Manual stationary regeneration request . 819
Failure code [AS00R2] – Warning 2 820
Failure code [AS00R3] – Inducement 1 . 821
Failure code [AS00R4] – Inducement 2 . 822
Failure code [AS00R5] – Inducement 3 . 823
Failure code [AS00R6] – Temporary recovery of inducement . 824
Failure code [AS00ZK] – AdBlue/DEF level low error 5 . 825
Failure code [AS10KM] – AdBlue/DEF Injector overheat warning . 826
Failure code [AS10NR] – AdBlue/DEF injector high temperature warning . 827
Failure code [AS10NT] – AdBlue/DEF injector overheat caution . 828
Failure code [B@BAZG] – Engine oil pressure low 829
Failure code [B@BAZK] – Engine oil level low . 830
Failure code [B@BCNS] – Engine coolant overheat 831
Failure code [B@BCZK] – Engine coolant level low . 832
Failure code [B@HANS] – Hydraulic oil overheat . 834
Failure code [CA115] – Engine neutral and backup speed sensor error 836
Failure code [CA122] – Charge air press sensor high error 838
Failure code [CA123] – Charge air press sensor low error . 840
Failure code [CA131] – Throttle sensor high error 842
Failure code [CA132] – Throttle sensor low error . 844
Failure code [CA144] – Coolant temperature sensor high error . 846
Failure code [CA145] – Coolant temperature sensor low error 848
Failure code [CA153] – Charge air temperature sensor high error 850
Failure code [CA154] – Charge air temperature sensor low error . 852
Failure code [CA187] – Sensor 2 supply voltage low error . 854
Failure code [CA221] – Ambient press sensor high error . 856
Failure code [CA222] – Ambient press sensor low error 858
Failure code [CA227] – Sensor 2 supply voltage high error 860
Failure code [CA234] – Engine overspeed 862
Failure code [CA238] – NE speed sensor supply voltage error 863
Failure code [CA239] – NE speed sensor supply voltage high error . 864
Failure code [CA249] – Ambient air temp sensor high error 866
Failure code [CA256] – Ambient air temp sensor low error . 868
Failure code [CA271] – PCV 1 short circuit error . 870
Failure code [CA272] – PCV 1 open circuit error 872
Failure code [CA295] – Ambient pressure sensor in range error 873
Failure code [CA322] – Injector #1 (L#1) open circuit error or short circuit error . 874
Failure code [CA324] – Injector #3 (L#3) open circuit error or short circuit error . 876
Failure code [CA331] – Injector #2 (L#2) open circuit error or short circuit error . 878
Failure code [CA332] – Injector #4 (L#4) open circuit error or short circuit error . 880
Failure code [CA343] – Engine controller internal failure 882
Failure code [CA351] – Injectors drive circuit error . 882
Failure code [CA352] – sensor 1 supply voltage low error . 884
Failure code [CA356] – MAF sensor high error . 886
Failure code [CA357] – MAF sensor low error 888
Failure code [CA386] – sensor 1 supply voltage high error 889
Failure code [CA428] – Water in fuel sensor high error . 890
Failure code [CA429] – Water in fuel sensor low error 892
Failure code [CA435] – Engine oil pressure SW error 894
Failure code [CA441] – Battery voltage low error . 896
Failure code [CA442] – Battery voltage high error 898
Failure code [CA451] – Common rail pressure sensor high error 900
Failure code [CA452] – Common rail pressure sensor low error . 902
Failure code [CA488] – Charge air temperature high torque derate . 903
Failure code [CA515] – Charge air temperature high torque derate . 904
Failure code [CA516] – Common rail pressure sensor supply voltage low error 906
Failure code [CA553] – Common rail pressure high error 1 . 907
Failure code [CA555] – Crankcase pressure high error 1 . 908
Failure code [CA556] – Crankcase pressure high error 3 . 909
Failure code [CA559] – Common rail pressure low error 1 910
Failure code [CA595] – Turbocharger speed high error 2 . 912
Failure code [CA687] – Turbocharger speed low error 914
Failure code [CA689] – Engine NE speed sensor error 916
Failure code [CA691] – Intake air temperature sensor high error 918
Failure code [CA692] – Intake air temperature sensor low error . 920
Failure code [CA697] – Engine controller internal temperature sensor high error 922
Failure code [CA698] – Engine controller internal temperature sensor low error . 923
Failure code [CA731] – Engine backup speed sensor phase error 924
Failure code [CA778] – Engine backup speed sensor error 926
Failure code [CA1117] – Engine controller partial data lost error 930
Failure code [CA1664] – KDOC abnormality . 932
Failure code [CA1669] – AdBlue/DEF level sensor voltage high error . 933
Failure code [CA1673] – AdBlue/DEF level low error 3 . 934
Failure code [CA1677] – AdBlue/DEF temperature sensor low error 935
Failure code [CA1678] – AdBlue/DEF temperature sensor high error . 936
Failure code [CA1682] – AdBlue/DEF pump priming error 938
Failure code [CA1683] – AdBlue/DEF tank heating valve voltage high error . 940
Failure code [CA1684] – AdBlue/DEF tank heating valve voltage low error 942
Failure code [CA1686] – AdBlue/DEF quality sensor voltage high error . 944
Failure code [CA1691] – Defective regeneration . 945
Failure code [CA1695] – Sensor 5 supply voltage high error . 946
Failure code [CA1696] – Sensor 5 supply voltage low error 948
Failure code [CA1712] – AdBlue/DEF tank thawing error 950
Failure code [CA1713] – AdBlue/DEF tank heater valve open stuck error 952
Failure code [CA1714] – AdBlue/DEF quality sensor out of calibration error . 954
Failure code [CA1715] – AdBlue/DEF quality sensor internal circuit error . 955
Failure code [CA1776] – Sensor supply relay voltage high error . 956
Failure code [CA1777] – Sensor supply relay voltage low error 958
Failure code [CA1843] – Crankcase pressure sensor high error . 960
Failure code [CA1844] – Crankcase pressure sensor low error 962
Failure code [CA1885] – Turbo outlet NOx sensor circuit error 964
Failure code [CA1887] – SCR outlet NOx sensor circuit error 966
Failure code [CA1896] – EGR valve stuck error 968
Failure code [CA1898] – KVGT control data error 969
Failure code [CA1938] – KVGT power voltage error . 970
Failure code [CA1942] – Crankcase pressure sensor in range error . 971
Failure code [CA1961] – EGR motor driver IC over temp error 972
Failure code [CA1962] – VGT actuator internal temperature high error . 972
Failure code [CA2185] – Throttle sensor supply voltage high error 973
Failure code [CA2186] – Throttle sensor supply voltage low error . 974
Failure code [CA2198] – KVGT control data error 975
Failure code [CA2272] – EGR valve position sensor low error 976
Failure code [CA2288] – Turbocharger speed high error 1 978
Failure code [CA2311] – IMV solenoid error . 979
Failure code [CA2349] – EGR valve solenoid open circuit error 980
Failure code [CA2353] – EGR valve solenoid short circuit error . 982
Failure code [CA2357] – EGR valve servo error 983
Failure code [CA2373] – Exhaust manifold pressure sensor high error 984
Failure code [CA2374] – Exhaust manifold pressure sensor low error . 986
Failure code [CA2375] – EGR orifice temperature sensor high error 988
Failure code [CA2376] – EGR orifice temperature sensor low error . 990
Failure code [CA2387] – KVGT servo error . 992
Failure code [CA2554] – Exhaust manifold pressure sensor in range error 993
Failure code [CA2634] – KVGT actuator drive circuit error 998
Failure code [CA2635] – KVGT Communication ID error 999
Failure code [CA2636] – KVGT communication error (ECM detection) .1000
Failure code [CA2637] – KDOC face plugging .1002
Failure code [CA2771] – SCR outlet NOx sensor datalink timeout error .1003
Failure code [CA2961] – EGR orifice temperature high error 1 .1006
Failure code [CA2973] – Charge air pressure sensor in range error 1007
Failure code [CA2976] – AdBlue/DEF pump temperature sensor signal error 1008
Failure code [CA3142] – SCR temperature sensor high error 1010
Failure code [CA3143] – SCR temperature sensor low error .1011
Failure code [CA3144] – SCR temperature sensor in rage error .1012
Failure code [CA3146] – SCR outlet temperature sensor high error .1014
Failure code [CA3147] – SCR outlet temperature sensor low error 1015
Failure code [CA3148] – SCR outlet temperature sensor in range error .1016
Failure code [CA3151] – SCR catalyst efficiency low error 2 1018
Failure code [CA3165] – SCR outlet temperature high error 1024
Failure code [CA3228] – Turbo outlet NOx sensor in range error .1026
Failure code [CA3229] – SCR temperature high error .1030
Failure code [CA3231] – SCR temperature high error non regeneration 1032
Failure code [CA3232] – Turbo outlet NOx sensor datalink timeout error .1034
Failure code [CA3235] – SCR outlet temperature high error – non regeneration .1038
Failure code [CA3239] – AdBlue/DEF line heater 2 voltage high error 1040
Failure code [CA3241] – AdBlue/DEF line heater 2 voltage low error .1042
Failure code [CA3242] – AdBlue/DEF tank heating error 1044
Failure code [CA3251] – KDOC inlet temperature high error 1046
Failure code [CA3313] – KDOC inlet temperature sensor low error 1048
Failure code [CA3314] – KDOC inlet temperature sensor high error .1049
Failure code [CA3315] – KDOC inlet temperature sensor in range error .1050
Failure code [CA3419] – MAF sensor supply voltage high error .1052
Failure code [CA3421] – MAF sensor supply voltage low error 1054
Failure code [CA3497] – AdBlue/DEF level low error 1 .1056
Failure code [CA3498] – AdBlue/DEF level low error 2 .1057
Failure code [CA3545] – SCR outlet NOx sensor unstable error .1058
Failure code [CA3547] – AdBlue/DEF level low error 4 .1060
Failure code [CA3558] – AdBlue/DEF pump voltage high error .1062
Failure code [CA3559] – AdBlue/DEF pump voltage low error 1064
Failure code [CA3562] – AdBlue/DEF LineHeater relay 1 voltage high error .1066
Failure code [CA3563] – AdBlue/DEF LineHeater relay 1 voltage low error 1068
Failure code [CA3567] – AdBlue/DEF injector open circuit error or short circuit error 1070
Failure code [CA3568] – AdBlue/DEF malfunction .1073
Failure code [CA3571] – AdBlue/DEF pump pressure sensor high error .1076
Failure code [CA3572] – AdBlue/DEF pump pressure sensor low error 1078
Failure code [CA3574] – AdBlue/DEF pump pressure too low error .1080
Failure code [CA3575] – AdBlue/DEF pump pressure too high error 1082
Failure code [CA3577] – AdBlue/DEF FCV voltage high error 1084
Failure code [CA3578] – AdBlue/DEF FCV voltage low error .1086
Failure code [CA3582] – SCR catalyst efficiency low error 1 1088
Failure code [CA3583] – SCR outlet NOx sensor heater warming up error 1 1092
Failure code [CA3596] – AdBlue/DEF pump pressure unstable error 1094
Failure code [CA3649] – Turbo outlet NOx sensor heater warming up error 1098
Failure code [CA3681] – SCR outlet NOx sensor power voltage error 1100
Failure code [CA3682] – Turbo outlet NOx sensor power voltage error 1105
Failure code [CA3713] – AdBlue/DEF line heater 1 voltage high error 1110
Failure code [CA3717] – SCR outlet NOx sensor voltage mismatch error .1112
Failure code [CA3718] – Turbo outlet NOx sensor voltage mismatch error .1113
Failure code [CA3724] – EGR/KVGT motor driver power low error 1114
Failure code [CA3725] – Turbo outlet NOx sensor unstable error .1115
Failure code [CA3741] – Rail press valve trip error 1117
Failure code [CA3748] – Turbo outlet NOx sensor stuck in range error .1118
Failure code [CA3755] – AdBlue/DEF dosing performance degradation error 1121
Failure code [CA3866] – AdBlue/DEF low concentration error 2 .1123
Failure code [CA3868] – AdBlue/DEF tank sensor datalink timeout error 1126
Failure code [CA4152] – SCR temperature sensor datalink timeout error 1129
Failure code [CA4155] – AdBlue/DEF pump heater relay voltage high error 1132
Failure code [CA4156] – AdBlue/DEF pump heater relay voltage low error .1134
Failure code [CA4157] – AdBlue/DEF FCV malfunction .1136
Failure code [CA4159] – SCR temperature sensor internal circuit error 1138
Failure code [CA4164] – SCR temperature sensor ECU voltage high error 1140
Failure code [CA4165] – SCR temperature sensor ECU voltage low error .1142
Failure code [CA4166] – SCR temperature sensor ECU high temperature error 1144
Failure code [CA4168] – AdBlue/DEF pump heater ON stuck error 1146
Failure code [CA4169] – AdBlue/DEF pump heater OFF stuck error .1148
Failure code [CA4171] – AdBlue/DEF pump thawing error 1150
Failure code [CA4249] – AdBlue/DEF pump temperature sensor 1 in range error 1152
Failure code [CA4251] – AdBlue/DEF pump temperature sensor 2 in range error 1154
Failure code [CA4261] – SCR temperature sensor power interrupt error .1156
Failure code [CA4277] – AdBlue/DEF quality sensor liquid distinction impossible error 1160
Failure code [CA4459] – AdBlue/DEF LineHeater relay 2 voltage high error .1162
Failure code [CA4461] – AdBlue/DEF LineHeater relay 2 voltage low error 1164
Failure code [CA4533] – KDOC outlet temperature sensor high error 1166
Failure code [CA4534] – KDOC outlet temperature sensor low error .1167
Failure code [CA4731] – AdBlue/DEF temperature sensor transmission data error 1168
Failure code [CA4732] – AdBlue/DEF level sensor transmission data error 1169
Failure code [CA4739] – AdBlue/DEF level sensor internal circuit error .1170
Failure code [CA4768] – Fuel in AdBlue/DEF tank error 1171
Failure code [CA4769] – AdBlue/DEF level measurement impossible 1174
Failure code [CA4842] – AdBlue/DEF high concentration error 1176
Failure code [CA4952] – System operating lamp short circuit (engine controller) 1178
Failure code [CA5115] – AdBlue/DEF line heater 1 voltage low error .1180
Failure code [CA5179] – Engine room temperature sensor high error 1182
Failure code [CA5181] – Engine room temperature sensor low error .1184
Failure code [CA5387] – KDOC outlet temperature high error 2 .1186
Failure code [CA5388] – KDOC temperature error – non regeneration 1188
Failure code [CA5389] – KDOC outlet temperature high error 1 .1190
Failure code [CA5391] – KDOC and KDPF temperature sensor datalink timeout error 1192
Failure code [CA5392] – KDOC and KDPF temperature sensor internal circuit error 1196
Failure code [CA5393] – KDOC and KDPF temperature sensor ECU voltage High error 1198
Failure code [CA5394] – KDOC and KDPF temperature sensor ECU voltage low error .1200
Failure code [CA5395] – KDOC and KDPF temperature sensor power interrupt error .1202
Failure code [CA5396] – KDOC and KDPF temperature sensor ECU over temperature error 1204
Failure code [CA5631] – Manual stationary regeneration request (automatic regeneration uncompleted) 1206
Failure code [CA5632] – Manual stationary regeneration request but regeneration disable 1207
Failure code [CA5938] – Manual stationary regeneration request (ineffective regeneration detect) .1208
Failure code [D110KB] – Battery relay output short circuit .1210
Failure code [D19JKZ] – Personal code relay abnormality 1212
Failure code [D19QKB] – Short circuit in refuel pump relay .1214
Failure code [D19QKY] – Hot short circuit in refuel pump relay .1216
Failure code [D1EMKA] – Parking brake relay open circuit .1218
Failure code [D1EMKB] – Parking brake relay short circuit 1220
Failure code [D1EMKY] – Parking brake relay hot short circuit 1222
Failure code [D811MC] – KOMTRAX malfunction 1224
Failure code [D862KA] – GPS antenna open circuit .1225
Failure code [D8ALKA] – System operating lamp open circuit (KOMTRAX) .1226
Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX) 1228
Failure code [D8AQKR] – CAN2 discon (KOMTRAX) 1230
Failure code [DA20MC] – Pump controller malfunction 1234
Failure code [DA22KK] – Pump solenoid power low error 1236
Failure code [DA25KP] – 5 V Sensor 1 power voltage low error .1238
Failure code [DA26KP] – 5 V Sensor 2 power voltage low error .1240
Failure code [DA29KQ] – Model selection signal mismatch 1242
Failure code [DA2LKA] – System operating lamp open circuit (pump controller system) 1244
Failure code [DA2LKB] – System operating lamp short circuit 1246
Failure code [DA2QKR] – Controller area network 2 defective communication 1248
Failure code [DA2RKR] – Controller area network 1 defective communication 1252
Failure code [DA80KB] – Auto grease system monitoring signal short circuit .1256
Failure code [DAB0KT] – Internal flash memory error (pump controller system) .1258
Failure code [DAC3KB] – Cruise control system power supply short circuit .1259
Failure code [DAC3KB] – Cruise control system power supply hot short circuit .1261
Failure code [DAF0KM] – Inconsistency of KomVision setting .1263
Failure code [DAF0MB] – Monitor ROM abnormality 1263
Failure code [DAF0MC] – Monitor malfunction 1264
Failure code [DAF8KB] – Camera power supply short circuit 1266
Failure code [DAF9KQ] – Model selection abnormality 1268
Failure code [DAFGMC] – GPS module malfunction .1269
Failure code [DAFGKA] – System operating lamp open circuit (monitor) .1270
Failure code [DAFGKB] – System operating lamp short circuit (monitor) 1272
Failure code [DAFQKR] – CAN 2 defective communication (monitor) 1274
Failure code [DAZ9KQ] – Model selection signal mismatch (Air conditioner) 1278
Failure code [DAZQKR] – CAN 2 defective communication (A/C ECU) 1279
Failure code [DB2QKR] – CAN2 discon (engine con) .1282
Failure code [DB2RKR] – CAN1 discon (engine con) .1287
Failure code [DB30KR] – Joystick steering controller malfunction .1292
Failure code [DBP0KM] – KomVision setting error 1293
Failure code [DBP0KT] – KomVision controller abnormality .1293
Failure code [DBP5KB] – Camera power supply short circuit 1294
Failure code [DBP5KY] – Camera power hot short circuit .1296
Failure code [DBPQKR] – CAN 2 defective communication (KomVision) 1298
Failure code [DCS0KT] – Internal flash memory error (Machine controller system) 1302
Failure code [DCS0MC] – Machine controller malfunction .1303
Failure code [DCS2KK] – Machine controller solenoid power voltage low error 1304
Failure code [DCS5KP] – 5 V sensor power supply output 1 voltage low or high .1306
Failure code [DCS7KP] – 24V sensor power voltage low error .1308
Failure code [DCS9KQ] – Model selection signal mismatch (machine controller) .1310
Failure code [DCSLKA] – System operating lamp open circuit (machine controller) 1312
Failure code [DCSLKB] – System operating lamp short circuit (machine controller) .1314
Failure code [DCSQKR] – CAN2 defective communication (machine controller) 1316
Failure code [DCSRKR] – CAN 1 Defective Communication (machine controller) .1318
Failure code [DDK8KA] – SUSLock forced SW open circuit .1319
Failure code [DDK8KB] – SUSLock forced SW short circuit 1320
Failure code [DDKVKA] – Joystick steering activation SW open circuit .1322
Failure code [DDKVKB] – Joystick steering activation SW short circuit 1323
Failure code [DDNRKA] – W/E lever lock SW open circuit .1324
Failure code [DDNRKY] – W/E lever lock SW short circuit 1326
Failure code [DDNS00] – Lock lever auto lock release SW ON .1328
Failure code [DDP4KX] – Disconnection in travel PPC pressure switch 1330
Failure code [DDP6L5] – Service brake press SW abnormality .1332
Failure code [DDQ1KA] – SUSLock mode selection SW open circuit .1334
Failure code [DDQ1KB] – SUSLock mode selection SW short circuit 1336
Failure code [DDWCKZ] – Direction switch abnormality .1338
Failure code [DDWMKZ] – FBR attachment SW abnormality 1340
Failure code [DFB1KZ] – Service lever potentio 1 open or short circuit .1342
Failure code [DFB2KZ] – Service lever potentio 2 open or short circuit .1344
Failure code [DFB3L8] – Service lever 1 potentiometer error 1346
Failure code [DFB4L8] – Service lever 2 potentiometer error 1347
Failure code [DFB6KZ] – Service lever sub potentio 2 open or short circuit .1350
Failure code [DGH2KA] – Hydraulic oil temperature sensor open circuit 1352
Failure code [DGH2KB] – Hydraulic oil temperature sensor ground fault 1354
Failure code [DHA4KA] – Air cleaner clog sensor open circuit .1356
Failure code [DHH2MA] – Return line filter press sensor abnormally .1358
Failure code [DHPAMA] – Front pump pressure sensor defective function 1360
Failure code [DHS3MA] – Arm IN PPC pressure sensor defective function 1362
Failure code [DHS4MA] – Bucket CURL PPC pressure sensor defective function .1364
Failure code [DHS5KX] – Travel PPC sensor abnormality 1366
Failure code [DHS8MA] – Boom RAISE PPC pressure sensor defective function 1368
Failure code [DHS9MA] – Boom LOWER PPC pressure sensor defective function 1370
Failure code [DHSAMA] – Swing right PPC pressure sensor defective function .1372
Failure code [DHSBMA] – Swing left PPC pressure sensor defective function 1374
Failure code [DHSCMA] – Arm OUT PPC pressure sensor defective function .1376
Failure code [DHSDMA] – Bucket DUMP PPC pressure sensor defective function .1378
Failure code [DHU1KA] – Brake accumulator press sensor open circuit 1380
Failure code [DHU1KY] – Brake accumulator press sensor short circuit .1382
Failure code [DHUCKA] – Parking brake press sensor open circuit 1384
Failure code [DHUCKY] – Parking brake press sensor short circuit .1386
Failure code [DHUGKA] – Service brake press sensor open circuit 1388
Failure code [DHUGKY] – Service brake press sensor short circuit .1390
Failure code [DHX1MA] – Overload sensor abnormality 1392
Failure code [DKULKA] – PPC lock relay open circuit 1394
Failure code [DKULKB] – PPC lock relay short circuit .1396
Failure code [DKULKY] – PPC lock relay hot short circuit .1398
Failure code [DLM5KA] – Fan speed sensor open circuit 1400
Failure code [DLM5MB] – Fan control: mismatch 1402
Failure code [DLT4KA] – Speed sensor open circuit 1404
Failure code [DLT4KB] – Speed sensor short circuit .1406
Failure code [DR10KA] – KomVision camera open circuit 1408
Failure code [DR12KA] – Disconnection of camera 1 NTSC input .1410
Failure code [DR20KA] – Disconnection of camera 2 NTSC input .1412
Failure code [DR30KA] – Disconnection of camera 3 NTSC input .1414
Failure code [DR31KX] – Camera 3 picture reverse drive input out of range 1416
Failure code [DR40KA] – Disconnection of camera 4 NTSC input .1418
Failure code [DUMBKA] – Operating lamp open circuit (KomVision) 1420
Failure code [DUMBKB] – Operating lamp short circuit (KomVision) .1422
Failure code [DV20KB] – Travel alarm short circuit .1424
Failure code [DW44KA] – Travel F/R solenoid open circuit .1426
Failure code [DW44KB] – Travel F/R solenoid short circuit 1428
Failure code [DW44KY] – Travel F/R solenoid hot short circuit 1430
Failure code [DW45KA] – Swing parking brake solenoid open circuit 1432
Failure code [DW45KB] – Swing parking brake solenoid short circuit .1434
Failure code [DW45KY] – Swing parking brake solenoid hot short circuit .1436
Failure code [DW4AKA] – Disconnection in suspension lock solenoid 1438
Failure code [DW4AKB] – Short circuit in suspension lock solenoid 1440
Failure code [DW4AKY] – SUSLock sol hot short circuit 1442
Failure code [DW4CKY] – PPC lock solenoid hot short circuit 1444
Failure code [DW4MKA] – Disconnection in creep solenoid 1446
Failure code [DW4MKB] – Short circuit in creep solenoid 1447
Failure code [DW4MKY] – Hot short circuit in creep solenoid 1448
Failure code [DW4YKA] – Disconnection in high gear solenoid 1450
Failure code [DW4YKB] – Short circuit in high gear solenoid 1452
Failure code [DW4YKY] – High gear hot short circuit 1454
Failure code [DW4ZKA] – Disconnection in low gear solenoid .1456
Failure code [DW4ZKB] – Short circuit in low gear solenoid .1458
Failure code [DW4ZKY] – Low gear hot short circuit .1460
Failure code [DW91KA] – Travel neutral sol open circuit 1462
Failure code [DW91KB] – Travel neutral sol short circuit .1464
Failure code [DW91KY] – Travel neutral sol hot short circuit .1466
Failure code [DWA2KA] – Attachment single or 2-way change solenoid open circuit (breaker mode relay) .1468
Failure code [DWA2KB] – Attachment single or 2-way change solenoid short circuit (breaker mode relay) 1470
Failure code [DWA2KY] – Attachment single or 2-way change solenoid hot short circuit (breaker mode relay) 1472
Failure code [DWB1KA] – Outrigger selection sol relay open circuit .1474
Failure code [DWB1KB] – Outrigger selection sol relay short circuit 1476
Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid 1478
Failure code [DWB2KB] – Outrigger sol.1 short circuit 1480
Failure code [DWB2KY] – Outrigger sol.1 hot short circuit 1482
Failure code [DWB3KA] – Outrigger sol.2 open circuit .1484
Failure code [DWB3KB] – Outrigger sol.2 short circuit 1486
Failure code [DWB3KY] – Outrigger sol.2 hot short circuit 1488
Failure code [DWB4KA] – Outrigger sol.3 open circuit .1490
Failure code [DWB4KB] – Outrigger sol.3 short circuit 1492
Failure code [DWB4KY] – Outrigger sol.3 hot short circuit 1494
Failure code [DWB5KA] – Outrigger sol.4 open circuit .1496
Failure code [DWB5KB] – Outrigger sol.4 short circuit 1498
Failure code [DWB5KY] – Outrigger sol.4 hot short circuit 1500
Failure code [DWK0KA] – 2-stage relief solenoid open circuit .1502
Failure code [DWK0KB] – 2-stage relief solenoid short circuit 1504
Failure code [DWK0KY] – 2-stage relief solenoid hot short circuit 1506
Failure code [DWK2KA] – 2-stage back pressure solenoid open circuit 1508
Failure code [DWK2KB] – 2-stage back pressure solenoid short circuit .1510
Failure code [DWK2KY] – 2-stage back pressure solenoid hot short circuit .1512
Failure code [DWKSKA] – Boom float sol open circuit 1514
Failure code [DWKSKB] – Boom float sol short circuit .1516
Failure code [DWKSKY] – Boom float sol hot short circuit .1518
Failure code [DWMAKA] – Two piece boom suspension sol open circuit .1520
Failure code [DWMAKB] – Two piece boom suspension sol short circuit 1522
Failure code [DWMAKY] – Two piece boom suspension sol hot short circuit 1524
Failure code [DWMBKA] – Work equipment PPC reduction solenoid open circuit .1526
Failure code [DWMBKB] – Work equipment PPC reduction solenoid short circuit 1528
Failure code [DWMBKY] – Work equipment PPC reduction solenoid hot short circuit 1530
Failure code [DWMCKA] – Auxiliary hydraulic circuit 1 solenoid open circuit 1532
Failure code [DWMCKB] – Auxiliary hydraulic circuit 1 solenoid short circuit .1533
Failure code [DWMCKY] – Auxiliary hydraulic circuit 1 solenoid hot short circuit .1534
Failure code [DWMDKB] – Auxiliary hydraulic circuit 2 solenoid short circuit .1536
Failure code [DWMDKY] – Auxiliary hydraulic circuit 2 solenoid hot short circuit .1538
Failure code [DWN5KA] – Fan clutch solenoid open circuit .1540
Failure code [DWN5KB] – Fan clutch solenoid short circuit 1542
Failure code [DWN5KY] – Fan clutch solenoid hot short circuit 1544
Failure code [DXA8KA] – Pump PC-EPC solenoid open circuit 1546
Failure code [DXA8KB] – Pump PC-EPC solenoid short circuit .1548
Failure code [DXE0KA] – LS-EPC solenoid open circuit .1550
Failure code [DXE0KB] – LS-EPC solenoid short circuit 1552
Failure code [DXE7KA] – Attachment flow regulating EPC 2 solenoid open circuit .1554
Failure code [DXE7KB] – Attachment flow regulating EPC 2 solenoid short circuit 1556
Failure code [DXE7KY] – Attachment flow regulating EPC 2 solenoid hot short circuit 1558
Failure code [DXE8KA] – Attachment flow regulating EPC 3 solenoid open circuit .1560
Failure code [DXE8KB] – Attachment flow regulating EPC 3 solenoid short circuit 1562
Failure code [DXE8KY] – Attachment flow regulating EPC 3 solenoid hot short circuit 1564
Failure code [DXE9KA] – Attachment flow regulating EPC 4 solenoid open circuit .1566
Failure code [DXE9KB] – Attachment flow regulating EPC 4 solenoid short circuit 1568
Failure code [DXE9KY] – Attachment flow regulating EPC 4 solenoid hot short circuit 1570
Failure code [DXEAKA] – Attachment flow regulating EPC 5 solenoid open circuit .1572
Failure code [DXEAKB] – Attachment flow regulating EPC 5 solenoid short circuit 1574
Failure code [DXEAKY] – Attachment flow regulating EPC 5 solenoid hot short circuit 1576
Failure code [DXEKKA] – Attachment variable press EPC1 open circuit 1578
Failure code [DXEKKB] – Attachment variable press EPC1 short circuit .1580
Failure code [DXEKKY] – Attachment variable press EPC1 hot short circuit .1582
Failure code [DXELKA] – Attachment variable press EPC2 open circuit 1584
Failure code [DXELKB] – Attachment variable press EPC2 short circuit .1586
Failure code [DXELKY] – Attachment variable press EPC2 hot short circuit .1588
Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit 1590
Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit .1591
Failure code [DY20KA] – Wiper motor open circuit .1592
Failure code [DY20MA] – Wiper motor defective function .1594
Failure code [DY2CKB] – Washer motor short circuit .1596
Failure code [DY2DKB] – Wiper motor (normal rotation) short circuit 1598
Failure code [DY2EKB] – Wiper motor (reverse rotation) short circuit .1600
Failure code [F7FQKR] – CAN2 discon (ID Key Con) .1602
Failure code [F820KX] – Quick coupler LSC lock state analog signal over range 1606
Failure code [F821KX] – Quick coupler LSC system state analog signal over range 1607
Failure code [F822MA] – Quick coupler LSC system abnormality .1608
Troubleshooting of central lubrication system (CLS) 1609
Trouble 1609
Troubleshooting during grease pump operation .1611
Pump element .1612
Check power supply .1613
Changing the control unit 1613
Troubleshooting – grease system faults .1614
Venting of the system 1615
General assembly advice 1616
Troubleshooting of engine (S-mode) .1617
S-1 Engine does not crank when starting switch is turned to start position .1618
S-2 Engine cranks but no exhaust gas comes out .1619
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) .1620
S-4 Engine startability is poor 1621
S-5 Engine does not pick up smoothly .1623
S-6 Engine stops during operation 1625
S-7 Engine runs rough or is unstable .1626
S-8 Engine lacks power .1627
S-9 Exhaust smoke is black .1629
S-10 Engine oil consumption is excessive .1631
S-11 Oil becomes contaminated quickly 1632
S-12 Fuel consumption is excessive .1633
S-13 Oil is in coolant (or coolant spurts back or coolant level goes down) .1634
S-14 Oil pressure drops 1635
S-15 Fuel mixes into engine oil 1636
S-16 Water mixes into engine oil (milky) .1637
S-17 Coolant temperature rises too high (overheating) 1638
S-18 Unusual noise is heard 1639
S-19 Vibration is excessive 1640
S-20 Air cannot be bled from fuel circuit 1641
S-21 Active regeneration is executed frequently 1642
S-22 Active regeneration takes time 1643
S-23 White smoke is exhausted during active regeneration .1644
S-24 AdBlue/DEF consumption is excessive .1645
S-25 There is unusual smell (irritating odor) 1646
S-26 Foreign materials enter AdBlue/DEF (AdBlue/DEF increases) .1647
TROUBLESHOOTING 779
Troubleshooting when failure code is indicated . 779
DISASSEMBLY AND ASSEMBLY (preliminary version) .1649
FRONT AXLE .1649
Note .1650
Table of contents 1651
Preface 1653
General .1654
Examples of gear-tooth contact pattern for the Gleason gear-tooth system .1656
Conversion table .1660
Denomination of standard dimensions 0
Tightening torques for screws 1662
Special tools 1663
Commercial tools .1675
1. Disassembly steering 1680
2. Disassembly output 1683
2.1 Disassembly planetary carrier 1683
2.2 Disassembly brake 1684
2.3 Disassembly hub 1686
2.4 Disassembly knuckle housing 1687
2.5 Disassembly output assy 1689
3. Disassembly input .1690
4. Disassembly differential 1694
4.1 DZ-500 and D-500 .1694
4.2 DZ-750 and D-750 .1697
5. Reassembly differential .1699
5.1 DZ-500 and D-500 .1699
5.2 DZ-750 and D-750 .1703
6. Reassembly input 1707
6.1 Install input pinion .1707
6.1.1 Determine thickness of the shim to obtain a correct contact pattern 1707
6.1.2 Setting of rolling torque of the input pinion bearing 1709
6.2 Setting instructions for bevel gear set backlash and bearing rolling torque of the differential bearing 1711
6.2.1 Check of backlash pattern of the bevel gear set 1713
6.3 Mount shaft seal ring (input flange) .1715
7. Reassembly output .1716
7.1 Preassembly axle housing .1716
7.2 Reassembly knuckle housing .1717
7.3 Reassembly hub .1721
7.4 Reassembly disk brake 1723
7.4.1 Make leakage test of multi-disk brake 1726
7.4.2 Adjust and check piston stroke .1727
7.5 Reassembly planetary carrier .1729
7.6 Reassembly output assy .1730
7.7 Reassembly pivot bearing .1731
8. Reassembly steering .1732
8.1 Preassemble steering .1732
8.2 Mount steering .1735
8.3 Track setting and checking .1737
8.4 Steering angle setting .1738
8.5 Check leakage of steering 1739
REAR AXLE 1740
Note .1741
Table of contents 1742
Preface 1744
General 1745
Examples of gear-tooth contact pattern for the Gleason gear-tooth system .1747
Conversion table .1751
Denomination of standard dimensions 1752
Tightening torques for screws 1753
Special tools 1754
Commercial tools .1761
1. Disassembly of output .1766
1.1 Disassembly of planetary carrier .1766
1.2 Disassembly of brake .1767
1.3 Disassembly of hub .1769
1.4 Disassembly of output assy .1771
2. Disassembly of input 1772
2.1 Version with HL transmission .1772
2.2 Standard version .1774
3. Disassembly differential 1777
3.1 DZ-500 und D-500 .1777
3.2 DZ-750 und D-750 .1780
4. Reassembly differential 1782
4.1 DZ-500 und D-500 .1782
4.2 DZ-750 und D-750 .1786
5. Reassembly of input .1790
5.1 Version with HL-transmission .1790
5.1.1 Determination of shims for setting the bearing rolling torque (differential bearing) and the backlash (bevel gear set) .1790
5.2 Standard version (without HL transmission) .1795
5.2.1 Reinstallation of input pinion .1795
5.2.2 Adjust backlash of crown wheel set and bearing rolling torque of differential bearing 1798
5.2.3 Fitting of shaft seal ring (input flange) 1802
6. Reassembly of output 1803
6.1 Reassembly of hub carrier 1803
6.2 Reassembly of hub (Hub bearing SET-RIGHT) 1803
6.3 Reassembly of multi-disk brake .1806
6.3.1 Leakage test of multi-disk brake .1809
6.3.2 Adjustment and check of piston stroke 1810
6.4 Reassembly of planetary carrier 1811
6.5 Reassembly of output assy 1812
TRANSMISSION .1813
Note .1814
Table of contents 1815
Preface 1817
General .1818
Conversion table .1820
Denomination of standard dimensions 1821
Torque limits for screws .1822
Special tools 1823
Commercial tools .1832
1. Separate HL-Transmission from axle housing 1837
2. Disassembly – Brake/Clutch/Planetary carrier 1838
2.1 Lubrication pump and shift interlock .1838
2.1.1 Version “Lubrication pump” .1838
2.2 Speed sensor .1839
2.3 Emergency release (Parking Brake) 1839
2.4 Input housing and modulation valve .1840
2.5 Brake and clutch .1841
2.6 Planetary carrier 1847
3. Disassembly – Output 1850
3.1 Version “Axle attachment” 1850
3.2 Version “Separate Installation” 1854
4. Reassembly – Output .1857
4.1 Version “Axle attachment” 1857
4.1.1 Determine shim for pinion gap 1859
4.1.2 Determine adjusting ring for rolling torque/pinion bearing .1863
4.1.3 Check rolling torque of pinion bearing .1864
4.1.4 Shaft seal output flange .1865
4.1.5 Check the pinion gap .1866
4.2 Version “Separate installation” 1867
4.2.1 Shaft seal output flange .1870
5. Reassembly – Brake/Clutch/Planety carrier .1873
5.1 Planetary carrier 1873
5.2 Brake and clutch .1877
5.2.1 Disc components brake and clutch .1879
5.2.1.1 Version “HL-290” .1879
5.2.1.2 Version “HL-270” . 0
5.2.1.3 Version “HL-250” .1879
5.2.2 Adjust and check the disc clearance/piston stroke of brake and clutch 1881
5.3 Install modulation valve and input housing .1888
5.4 Emergency release (Parking brake) 1890
5.4.1 Check emergency release for leak tightness .1891
5.4.2 Check the multi-disk brake and multi-disc clutch for leak tightness as well as closing pressure 1892
5.5 Speed sensor .1893
5.6 Lubrication pump/shift interlock .1893
6. Disassembly – Lubrication pump/shift interlock and valve block 1895
6.1 Version “with” lubrication pump 1895
6.2 Version “with” hydr. shift interlock .1898
6.3 Disassembly valve block 1901
7. Reassembly Lubrication pump .1903
8. Reassembly shift interlock 1909
9. Valve block (shifting low gear – high gear) .1917
10. Mount HL-Transmission to axle 1918
MAINTENANCE STANDARD .1919
Abbreviation list 1920
List of abbreviations used in the text .1920
Engine and cooling system 1924
Maintenance standard of engine mount .1924
Maintenance standard of cooling system .1925
Power train 1927
Maintenance standard of swing circle .1927
Maintenance standard of swing machinery 1928
Axles 1929
Gear box .1930
Prop shaft .1932
Orbitrol valve (STD/JSS) .1933
Trailer preparation 1934
Cabin mounting .1936
Hydraulic system .1939
Maintenance standard of hydraulic tank .1939
Main pump 1940
Maintenance standard of LS-EPC valve .1941
Maintenance standard of PC-EPC valve .1942
Control valve 1943
Maintenance standard of anti-drop valve for 1. boom LH .1944
Maintenance standard of anti-drop valve for 1. boom RH .1946
Maintenance standard of anti-drop valve for 2. boom 1948
Maintenance standard of anti-drop valve for arm/bucket .1950
Maintenance standard of work equipment and swing PPC valve .1952
Solenoid valve block .1958
Work equipment .1960
Work equipment linkage .1960
1. Dimension of arm 1962
2. Dimension of bucket .1964
Hydraulic cylinder .1966
Boom cylinder 1966
Arm cylinder .1966
Bucket cylinder 1966
Adjust cylinder 1967
Appendix .1969
Abbreviation list 1972
List of abbreviations used in the text .1972
List of abbreviations used in the circuit diagrams .1976
Air conditioner system .1977
Precautions for refrigerant 1977
Air conditioner component 1978
Specifications of air conditioner 1980
Outline of refrigeration cycle .1982
Component parts of air conditioner system 1984
Air conditioner unit .1984
Configuration diagram of air conditioner unit 1984
Component parts of air conditioner unit 1988
Function of evaporator as air conditioner unit component .1989
Function of heater core as air conditioner unit component 1989
Function of evaporator temperature sensor as air conditioner unit component 1989
Function of servo motor as air conditioner unit component 1989
Structure of expansion valve as air conditioner unit component .1990
Air conditioner controller .1992
Structure of air conditioner controller 1992
Compressor .1993
Structure of compressor 1993
Specifications of compressor .1993
Function of compressor .1993
Condenser 1994
Structure of condenser .1994
Specifications of condenser 1994
Function of condenser 1994
Sensors for air conditioner system .1996
Structure of sunlight sensor .1996
Function of sunlight sensor 1996
Structure of ambient temperature sensor 1996
Function of ambient temperature sensor .1997
Explanation of procedure for testing and troubleshooting of air conditioner 1998
Circuit diagram and arrangement of connector pins for air conditioner 2000
Air conditioner system diagram .2002
Input and output signals of air conditioner controller .2003
Function of air conditioner controller .2004
Installation locations of air conditioner parts and arrangement of connectors 2005
Fuses layout in the fuse boxes .2006
Air conditioner controller and connectors layout .2006
Air conditioner unit and connectors layout .2007
Sunlight sensor connectors layout 2007
Machine monitor connectors layout 2007
Dual pressure switch connectors layout .2007
Air conditioner compressor connectors layout .2008
Outside air temperature sensor connectors layout .2008
Testing air leakage (DUCT) .2009
Method for testing air leakage (DUCT) 2009
Testing air conditioner using self-diagnosis function 2011
How to open the electrical system abnormality record screen in service mode of the machine monitor .2012
Test vent (mode) changeover 2013
Testing FRESH/RECIRC air changeover 2015
Method for testing FRESH/RECIRC air changeover .2015
Test sunlight sensor .2016
Method for testing sunlight sensor .2016
Test (dual) pressure switch for refrigerant 2017
Method for testing (dual) pressure switch for refrigerant 2017
Test relays 2018
Method for testing relays 2018
Air conditioner troubleshooting chart 1 2019
Air conditioner troubleshooting chart 2 2020
Information described in troubleshooting table .2023
Failure code [879AKA] A/C recirculation air temperature sensor open circuit 2024
Failure code [879AKB] A/C recirculation air temperature sensor short circuit .2025
Failure code [879BKA] A/C fresh air temperature sensor open circuit 2026
Failure code [879BKB] A/C fresh air temperature sensor short circuit .2028
Failure code [879CKA] Ventilating sensor open circuit 2030
Failure code [879CKB] Ventilating sensor short circuit .2031
Failure code [879DKZ] Sunlight sensor open circuit or short circuit 2032
Failure code [879EMC] Ventilation damper malfunction .2034
Failure code [879FMC] Air mix damper malfunction .2035
Failure code [879GKX] Refrigerant pressure input signal out of range .2036
A-1 Troubleshooting for power supply system (air conditioner does not operate) .2038
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) 2041
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) .2044
A-4 Troubleshooting for FRESH/RECIRC air changeover 2046
Troubleshooting using gauge pressure .2048
Connection of service tool .2050
Method for connecting service tool .2051
Precautions for disconnection 2052
Precautions for connection .2053
Handle compressor oil 2054
Management of compressor oil (DENSO: ND-OIL8 for R134a) 2054
The quantity of compressor oil when the compressor is replaced .2054
Method for replacing desiccant .2056
Joystick Steering 2058
Overview of failure groups and descriptions 2058
Error handling .2060
OTHER 2095
Hydraulic circuit diagram 2099
Hydraulic circuit diagram (1/3) 2099
Hydraulic circuit diagram (2/3) 2101
Hydraulic circuit diagram (3/3) 2103
Electric circuit diagram 2105
Contents .2105
1-0 Power Supply .2107
1-1 Grounding 2108
1-2 Model Select .2109
2-0 Engine PW180 .2110
2-1 Engine PW180 .2111
2-2 Engine PW148, PW158, PW160 .2112
2-3 Engine PW148, PW158, PW160 .2113
2-4 Engine Power Supply, Air Intake 2114
2-5 Engine Start .2115
2-6 2nd ENGINE STOP, OPERATING LAMP 2116
2-7 ADBLUE/DEF DATALINK 2117
2-8 ADDBLUE/DPF POWER 2118
3-0 REFUELING SYSTEM, FUEL DIAL 2119
3-1 BRAKE 2120
3-2 EPC 2121
3-3 CRUISE CONTROL .2122
3-4 TRAVEL .2123
3-5 SUS-LOCK, SPEEDSNR, JOYSTICK POTI 2124
3-6 SENSORS ENGINE & OIL .2125
4-0 QUICK COUPLER, PRESSURE SENSOR .2126
4-1 PPC REDUCTION, FLOATING, PRESSURE SENSOR .2127
4-2 SWING LOCK, PRESSURE SENSOR, JOYSTICK SW .2128
4-3 BUCKET/2ATT SWITCHING 2129
5-0 LOWER ATTACHMENTS 2130
5-1 ROTO-TILT 2131
5-2 BOOM/STABILISER, AUXILARY CIRCUIT, BREAKER .2132
6-0 ROAD LIGHT .2133
6-1 INDICATOR, SIDE LIGHT, STOP LIGHT 2134
6-2 ARM MARKER LIGHT + QC SIGNAL BOOM 2135
6-3 BEACON, TRAILER (OPT) 2136
6-4 WORKLAMP .2137
6-5 WORKLAMP .2138
6-6 CAMERA SW, SERVICE-CON., KOMTRAX, KOMNET .2139
6-7 KOMVISION 2140
7-0 AIR CONDITION, HEATED MIRROR .2141
7-1 RADIO, 12V, CIGAR LIGHTER, ROOM LAMP .2142
7-2 PPC-LOCK, STARTER CUT, SEAT 2143
7-3 ID-KEY .2144
7-4 HORN, ALARM 2145
7-5 WIPER 2146
8-0 CLS 2147
9-0 JOYSTICK STEERING 2148
10-0 FAN CLUTCH, TOOL CONTROL 2149
11-0 ECSS 2150
Harness Summary 2151
Harness Summary 2152
Connector List .2153
Connector List .2154
Connector List .2155
Connector List .2156
Connector List .2157
Connector List .2158
Connector List .2159
Pin Location List 2160
Pin Location List 2161
Pin Location List 2162
Pin Location List 2163
Pin Location List 2164
Pin Location List 2165
Pin Location List 2166
Pin Location List 2167
Pin Location List 2168
Pin Location List 2169
Pin Location List 2170
Pin Location List 2171
Pin Location List 2172
Pin Location List 2173
Pin Location List 2174
Pin Location List 2175
Pin Location List 2176
Pin Location List 2177
Pin Location List 2178
Pin Location List 2179
Pin Location List 2180
Pin Location List 2181
Pin Location List 2182
Pin Location List 2183
Pin Location List 2184
Pin Location List 2185
Pin Location List 2186
Pin Location List 2187
Pin Location List 2188
Pin Location List 2189
Pin Location List 2190
Pin Location List 2191
Pin Location List 2192
Pin Location List 2193
Pin Location List 2194
Pin Location List 2195
Pin Location List 2196
Pin Location List 2197
Pin Location List 2198
Pin Location List 2199
Pin Location List 2200
PARTS LIST .2201
PARTS LIST .2202
PARTS LIST .2203
PARTS LIST .2204
PARTS LIST .2205
Connector diagram 2207
Connector diagram 1/10 .2207
Connector table for revolving frame harness 1 2207
Connector diagram 2/10 .2208
Connector table for revolving frame harness 2 2208
Connector diagram 3/10 .2209
Connector table for operator‘s cab wiring harness (Part 1/2) .2209
Connector diagram 4/10 .2210
Connector table for operators cab wiring harness (Part 2/2) 2210
Connector diagram (5/10) .2211
Connector table switch group .2211
Connector diagram (6/10) .2212
Connector table steering .2212
Connector diagram (7/10) .2213
Connector table various wiring harness .2213
Connector diagram (8/10) .2214
Connector table optionally wiring harness (Part 1/3) .2214
Connector diagram (9/10) .2215
Connector table optionally wiring harness (Part 2/3) .2215
Connector diagram (10/10) 2216

DESCRIPTION:

Komatsu PW160-11 Wheeled Excavator Shop Manual VENBM69002 – PDF DOWNLOAD

• MACHINE MODEL   SERIAL NUMBER
• PW160-11                  H65051 AND UP