Komatsu PW180-11E0 Wheeled Excavator Shop Manual VENBM70001 PDF

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Komatsu PW180-11E0 Wheeled Excavator Shop Manual VENBM70001 – PDF DOWNLOAD

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Komatsu PW180-11E0 Wheeled Excavator Shop Manual VENBM70001 – PDF DOWNLOAD

Language : English
Pages : 2334
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW180-11E0 Wheeled Excavator Shop Manual VENBM70001 – PDF DOWNLOAD

VENBM70001 PW180-11E0 . 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
OTHER INFORMATION . 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 107 engine series (bolts and nuts) 14
Tightening torque for 107 engine series (eye joints) 14
Tightening torque for 107 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
Specifications 28
Weight table 31
1-piece boom 32
2-piece boom 32
Fuel, coolant and lubricants 33
Standard value table for engine . 34
Standard value table for engine: PW180-11E0 . 34
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 43
Abbreviation list . 46
List of abbreviations used in the text 46
List of abbreviations used in the circuit diagrams 48
UREA SCR system . 49
Layout drawing of UREA SCR system . 50
Detailed drawing of AdBlue/DEF tank . 54
UREA SCR system diagram . 55
Function of UREA SCR system . 56
Function of AdBlue/DEF system . 57
Function of AdBlue/DEF injection system . 57
AdBlue/DEF purge function . 58
Function of heating system 58
Inducement strategy . 59
Inducement strategy when the AdBlue/DEF level in the tank becomes low . 60
Inducement strategy when abnormality is found in the AdBlue/DEF quality or in the UREA SCR system devices . 62
Inducement strategy when abnormality is found in the KDPF system by the UREA SCR system devices . 64
Inducement strategy when abnormality is found in the EGR system by the UREA SCR system devices 66
Function of temporary restoration from inducement . 67
Inducement strategy for abnormality recurrence within 40 hours 68
Component parts of UREA SCR system 69
AdBlue/DEF MIXING TUBE 69
SCR assembly 69
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
SPECIFICATIONS 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 94
Automatic idle stop system diagram 94
Function of automatic idle stop system 95
Abrupt engine stop is detected 98
Component parts of engine system 99
Structure of VGT 99
When nozzle ring is “closed” 102
When nozzle ring is “open” 102
Operation of hydraulic actuator . 102
EGR system 103
Structure of EGR valve 103
Function of EGR System 103
Circuit Diagram of EGR system . 104
OPERATION OF EGR SYSTEM . 104
EGR valve . 105
Structure of EGR valve 105
Sectional view 105
Structure . 106
Operation of EGR valve 106
EGR cooler 107
Structure of EGR cooler . 107
General view and sectional view . 107
Detailed drawing of flat tube . 108
Operation of EGR cooler . 108
KCCV system . 109
Layout drawing of KCCV system . 109
General view 109
Function of KCCV system . 110
KCCV ventilator . 111
Structure of KCCV ventilator 111
Function of KCCV ventilator . 111
Operation of KCCV ventilator 112
CDR valve . 112
KDPF 113
Structure of KDPF . 113
General view 113
Structure . 113
Function of KDPF 115
Types of regeneration functions . 117
Cooling system 120
Layout drawing of cooling system 120
Specifications of cooling system 121
Fan speed control system of fan clutch 122
Function of engine output control system of fan clutch 124
At one-touch power maximizing function operation 125
Component parts of cooling system . 126
Fan clutch 126
Power train . 128
Swing circle 130
Specifications 130
Swing machinery & motor . 131
Specification . 132
Operation of swing lock . 133
Relief valve portion 134
Operation . 134
Undercarriage . 136
Transmission 138
Specifications 138
Function 140
Second auxiliary circuit control system . 141
Trailer coupling for pulling trailers . 143
Trailer coupling automatic 143
Trailer coupling ball . 143
Disassembly and assembly of trailer hitch on blade 144
Working with blade 145
Inspect trailer hitch . 146
Calculation of maximum coupling Load 147
Hydraulic quick coupler . 148
Schematic . 148
Operation . 149
Hydraulic quick coupler solenoid valve 149
Specification . 149
Quick coupler error logic . 150
Travel motor 154
Function 155
Operation of travel motor . 156
Clutch control circuit 158
Function 159
Axle 160
Outline . 160
Suspension lock cylinder 163
Specifications 163
Structure and function 163
Circuit . 164
Axle oscillation 165
Braking system 166
Structure and function 167
Gear pump . 168
Specifications 168
Function 168
Priority valve 170
Specification . 170
Function 170
Power brake valve . 172
Specifications 173
Function 173
Accumulator for brake valve . 174
Specifications 174
Structure and function 174
Digging brake valve . 175
Digging brake controller 176
Steering system . 177
Structure and function 177
Joystick steering system 178
Structure and function 179
Steering column JSS . 180
Specifications 181
Steering column . 183
Orbitrol valve 184
Specifications 184
Structure and function 184
Orbitrol valve JSS 185
Specifications 185
Structure and function 185
Hydraulic equipment layout drawings . 186
Hydraulic circuit diagram . 188
Hydraulic tank 189
Specifications 189
Hydraulic pump 190
Function 192
Structure . 192
Operation . 193
LS valve 195
PC valve 196
Function 197
Operation . 198
1. LS valve . 198
2. PC valve . 202
LS(PC)-EPC valve 209
Function 210
Operation . 210
Pilot pressure control (PPC) system . 213
Function 214
Operation . 214
Control main valve 215
Outline . 215
CLSS 230
Outline of CLSS . 230
Features 230
Structure . 230
Basic Principle . 231
Operation for each function and valve . 233
Hydraulic circuit diagram and name of valves 233
1. Unload valve . 235
Function 235
Operation . 235
Operation . 236
Operation . 237
2. Introduction of LS pressure 238
Work equipment valve 238
Function 238
Operation . 238
3. LS bypass plug . 239
Outline . 239
Operation . 239
4. Pressure compensation valve 240
Function 240
Operation . 241
5. Area ratio of pressure compensation valve 242
Function 242
6. Boom regeneration circuit 243
Function 243
Operation . 243
Function 244
Operation . 244
7. Arm regeneration circuit . 245
Function 245
Operation . 245
Function 246
Operation . 246
8. Swing bleeding valve . 247
Function 247
Operation (In fine control operation) . 247
9. Variable type pressure compensation valve (for service) 248
Function 248
Simultaneous operation with work equipment under heavy load (boom RAISE, etc.) 248
10. LS select valve . 249
Function 249
Operation . 249
Centre swivel joint . 250
Travel PPC pedal 251
Work equipment – Swing PPC valve 253
Operation . 255
Solenoid valve block with integrated ATT – EPC 257
ATT EPC valve assembly 259
ON / OFF Solenoid valves (3 way valve) 260
Operation . 260
ON / OFF Solenoid valves (4 way valve) 262
Operation . 262
Hi/ Lo Solenoid valve (4 way valve) . 264
Operation . 264
Attachment PPC valve 266
Function 267
Operation . 267
Bucket to 2ATT 269
Function 269
Activate by switch (RH console of cabin) 270
Boom safety valve . 271
Operation . 272
Boom floating . 273
PPC pressure reduction/ Boom floating logic . 273
Hydraulic cylinder 280
Boom cylinder . 280
Arm cylinder 280
Bucket cylinder . 280
Adjust cylinder . 281
Outrigger cylinder 283
Dozer cylinder 285
Function 286
Work equipment 287
Work equipment 288
1. Dimension of arm . 289
2. Dimension of bucket 291
Tool control 293
Tool control schematic (detail from hydraulic diagram) 294
ECSS 295
ECSS Logic 295
ESS Hydraulic Schematic . 297
ECSS Accumulator position . 298
ECSS Valve 299
ECSS Hydraulic diagram 300
ECSS Function . 301
ECSS Logic 301
ESS Hydraulic Schematic . 303
ECSS Accumulator position . 304
ECSS Valve 305
ECSS Hydraulic diagram 306
Breaker return valve 307
Function 307
Air conditioner . 311
Air conditioner component . 311
Specifications of air conditioner . 314
Electrical wiring diagram . 315
Electrical system . 316
Engine control 316
1. Operation of System 316
2. Component 317
Engine controller . 318
Input and output signals of engine controller . 318
Pump controller . 324
Machine controller 328
Machine control system diagram 332
1. Engine and pump control function . 333
Function 334
Function 338
Function 340
Function 342
Operation . 343
Function 344
Function 348
Function 350
Function 353
Specifications 354
Function 354
Function 355
Operation . 355
Machine monitor system 358
Function of machine monitor . 360
Monitor display . 363
Monitor items and display . 365
Caution monitor . 367
Pilot monitor . 371
Monitor switches 375
Declaration of switch function on keypad 376
Guidance icon and function switch . 378
Operator mode function of machine monitor . 381
Service mode function of machine monitor 383
KOMTRAX system 385
KOMTRAX system diagram 385
Gateway Controller 386
Function of Gateway Controller 386
Communication Terminal 389
KomVision system 390
Layout drawing of KomVision system 390
Chassis part 390
Around cab and floor 391
KomVision system diagram 391
Function of KomVision system 392
KomVision controller 393
Structure of KomVision controller . 393
Structure of KomVision camera . 397
Overload warning device . 398
Outline . 398
Function 398
Structure . 398
Sensor 399
Ambient pressure sensor . 401
Charge (boost) pressure and temperature sensor 402
Coolant temperature sensor 403
Ne (crankshaft) speed sensor 403
Bkup (camshaft) speed sensor 404
Common rail pressure sensor . 404
Exhaust manifold pressure sensor 405
EGR orifice temperature sensor 405
EGR valve lift sensor . 406
KVGT speed sensor . 407
KVGT position sensor 408
Mass air flow and temperature sensor 409
KDPF differential pressure and outlet pressure sensor . 410
KDOC inlet temperature sensor . 411
KDOC outlet temperature sensor 411
Crankcase pressure sensor . 412
Engine oil level sensor . 413
Fuel level sensor . 414
WIF (Water-In-Fuel detection) sensor 415
Coolant level sensor 416
Hydraulic oil temperature sensor 417
Air cleaner clogging sensor . 417
Overload Caution sensor . 418
Swing proximity sensor 419
Brake sensors . 419
Brake accumulator low pressure sensor (CN-P60) 420
Brake stop light sensor (CN-S19) 420
Service brake pressure sensor (CN-S40) 420
Service brake pressure sensor (CN-P62) 420
Park brake pressure sensor (CN-P61) . 421
PPC pressure sensors 421
DPF-SCR Area 422
Pump pressure sensor 423
PPC levers 424
LH PPC lever 424
RH PPC lever 425
1st attachment circuit hydraulic performance (main valve bypassed) 426
Travel system . 427
Travel circuit 427
Travel Motor Performance 428
Auto-grease pump 430
Overview 431
Display and control unit 431
LED-display . 432
Push buttons 432
Three-digit LED display . 433
Check central lubrication system, fill up grease 434
Lubrication diagrams 435
Auto-grease pump with one-piece boom 435
Auto-grease pump with two-piece boom 436
Manual system one-piece boom 437
Manual system two-piece boom 438
STANDARD VALUE TABLE 439
Standard value table for engine related parts . 440
Standard value table for chassis related parts 444
Flow control characteristic of PC valve (STD) . 456
PM clinic service . 457
Check sheet . 458
TESTING AND ADJUSTING . 465
Abbreviation list . 468
List of abbreviations used in the text 468
List of abbreviations used in the circuit diagrams 472
Engine and cooling system . 473
Test engine speed . 473
Method for testing engine speed . 473
Test boost pressure . 476
Method for testing boost pressure on machine monitor 476
Method for testing boost pressure . 477
Test exhaust gas colour . 478
Method for testing exhaust gas colour by handy smoke checker 478
Hod for testing exhaust gas colour by smoke meter . 479
Test and adjust valve clearance . 481
Method for testing valve clearance 481
Method for adjusting valve clearance 482
Test compression pressure . 483
Method for testing compression pressure . 483
Test blow by pressure . 488
Method for testing blow by pressure . 488
Test engine oil pressure 490
Test EGR valve and KVGT oil pressure 491
Method for testing EGR valve and KVGT oil pressure 491
Handling fuel system parts 493
Releasing residual pressure from fuel system 494
Test fuel pressure 494
Method for testing fuel pressure 496
Testing of low-pressure circuit (fuel main filter inlet side) . 496
Testing of low-pressure circuit (pressure difference) . 497
Testing of return circuit . 498
Testing of negative pressure circuit 499
Test fuel discharge, return and leakage . 500
Tools for testing fuel discharge, return and leakage 500
Method for testing fuel discharge, return and leakage . 502
Testing supply pump discharge volume 502
Testing supply pump return rate . 503
Testing of leakage from pressure limiter 504
Testing the fuel return rate from injector 505
Bleeding air from fuel system . 507
Method for bleeding air from fuel system 507
Test fuel circuit for leakage . 508
Method for testing fuel circuit for leakage . 508
Testing method of fuel circuit for leakage at engine low idle . 509
Testing method of fuel circuit for leakage at engine high idle 509
Testing method of fuel circuit for leakage at engine rated speed 510
Handle cylinder cut-out mode operation 511
Handle no-injection cranking operation 511
Test and adjust air conditioner compressor belt tension . 512
Method for checking air conditioner compressor belt . 512
Method for adjusting air conditioner compressor belt 512
Replacing fan belt 514
Method for replacing fan belt . 514
Test cooling fan speed 515
Method for testing cooling fan speed 515
Write ash in soot accumulation correction to engine controller 516
Method for writing ash in soot accumulation correction to engine controller . 516
Test SCR related functions 517
Test AdBlue/DEF pump raised pressure 520
Method for testing AdBlue/DEF pump raised pressure 521
Test injection amount from AdBlue/DEF injector 524
Tools for testing of injection amount from AdBlue/ DEF injector . 524
Method for testing injection amount from AdBlue/DEF injector 525
Test AdBlue/DEF line heater relay 1 . 528
Tools for testing AdBlue/DEF line heater relay 1 528
Method for testing AdBlue/DEF line heater relay 1 . 529
Test AdBlue/DEF line heater relay 2 . 531
Tools for testing AdBlue/DEF line heater relay 2 531
Method for testing AdBlue/DEF line heater relay 2 . 532
Test AdBlue/DEF pump heater relay . 534
Tools for testing AdBlue/DEF pump heater relay 534
Method for testing AdBlue/ DEF pump heater relay 535
Test AdBlue/DEF tank heater valve . 537
Tools for testing AdBlue/DEF tank heater valve 537
Method for testing AdBlue/DEF tank heater valve . 538
Test denitration efficiency of SCR 540
Method for testing denitration efficiency of SCR 541
Clean AdBlue/DEF tank . 544
Testing tools for cleaning of AdBlue/DEF tank . 544
Method for cleaning AdBlue/DEF tank . 544
Measurement of clearance in swing circle bearing 548
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel . 549
Measurement . 549
Adjustment 550
Inspection and adjustment of control circuit oil pressure . 553
Measurement . 553
Procedure for pressure reducing adjustment 554
Inspection and adjustment of pump PC (valve inlet) control oil pressure . 555
Measurement . 555
Adjustment 557
Inspection and adjustment of pump LS differential pressure 559
Measurement . 559
Adjustment 562
Measurement of solenoid valve output pressure . 563
Checking Proportional Control PPC Circuit . 566
Adjustment of work equipment and swing PPC valve 567
Measuring and adjusting quick coupler control valve output pressure . 568
Specification . 569
Testing travel motor relief pressure 570
Measuring travel motor relief pressure 570
Testing propshaft speed . 571
Measuring rotating speed of propshaft . 571
Testing transmission clutch control circuit . 572
Description . 572
Inspection of locations of hydraulic drift of work equipment 574
Release of remaining pressure in hydraulic circuit 576
Measurement of oil leakage 577
Air bleeding of various parts . 580
Inspection procedures for diode . 583
Electrical system . 585
Set and operate machine monitor . 585
Specification . 586
Operator mode . 589
Service mode 594
Table of self-define monitoring . 611
Abnormality record menu . 620
Default menu 634
Diagnostic tests menu . 649
Adjustment menu . 661
KOMTRAX settings menu . 669
Method for starting up KOMTRAX terminal . 673
Inspection and adjustment of ECSS (ACCU pressure) . 679
Maintenance . 679
Inspection and adjustment of Tool control . 684
Troubleshooting . 690
Changing the lubrication interval times . 694
Changing the Joystick steering control 695
Inspection and adjustment digging brake system 696
Adjust rearview camera angle 698
Method for adjusting rear view camera angle . 698
Adjust KomVision camera angle . 701
Tools for adjusting KomVision camera angle 701
Method for adjusting KomVision camera angle . 702
Angle adjustment method for front R.H. camera, rear R.H. camera, and rear L.H. camera . 702
Angle adjustment method for rear camera . 704
Adjust KomVision related items 706
Setting of KomVision (main setting) . 706
Method for setting KomVision (main setting) . 706
Setting of KomVision (camera setting) . 709
Method for setting KomVision (camera setting) . 709
Setting of KomVision (camera calibration) . 709
Method for setting of KomVision (camera calibration) 710
TROUBLESHOOTING . 723
Troubleshooting . 723
Abbreviation list . 724
List of abbreviations used in the text 724
List of abbreviations used in the circuit diagrams 728
Related information on troubleshooting 729
General troubleshooting points 729
Troubleshooting points for UREA SCR system 730
In case failure codes cannot be cleared . 732
Sequence of events in troubleshooting . 742
Checks before troubleshooting . 744
Inspection procedure before troubleshooting . 746
Walk-around check . 746
Preparation for troubleshooting of electrical system 748
Method for disconnecting and connecting connector with special lock . 748
Procedure for testing and troubleshooting . 752
Information described in troubleshooting table 755
Troubleshooting method for open circuit in wiring harness of pressure sensor system . 757
Connector table . 759
Connector contact identification 760
T-Branch box and T-Branch adapter table . 803
T-boxes and T-adapters table 808
Fuse location table . 809
Precautions for cleaning and replacing KDPF (KCSF and KDOC) . 811
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) . 815
Failure code table (Display of code) 816
TROUBLESHOOTING . 831
Troubleshooting when failure code is indicated 831
Troubleshooting by failure code (Display of code) . 842
Failure code [2G00MA] – Brake oil pressure abnormality 842
Circuit diagram related to brake oil pressure switch 842
Failure code [602ENX] – Return filter clogging 843
Failure code [6AZ0ZG] – Quick coupler pressure low 844
Circuit diagram related quick coupler pressure switch . 845
Failure code [6B2JMA] – Travel hydraulic abnormality 846
Failure code [879AKA] – A/C recirculation air temperature sensor open circuit . 847
Failure code [879AKB] – A/C inner sensor short circuit 848
Failure code [879BKA] – A/C outer sensor open circuit . 850
Circuit diagram related to air conditioner fresh air temperature sensor . 851
Failure code [879BKB] – A/C outer sensor short circuit 852
Circuit diagram related to air conditioner fresh air temperature sensor . 853
Failure code [879CKA] – Ventilating sensor open circuit . 854
Failure code [879CKB] – Ventilating sensor short circuit 855
Failure code [879DKZ] – Sunlight sensor open or short circuit . 856
Circuit diagram related to sunlight sensor 857
Failure code [879EMC] – Ventilation damper malfunction 858
Failure code [879FMC] – Air mix damper malfunction 859
Failure code [879GKX] – Refrigerant abnormality . 860
Circuit diagram related to refrigerant (dual) pressure switch . 861
Failure code [989L00] – Engine controller lock caution 1 862
Failure code [989M00] – Engine controller lock caution 2 863
Failure code [989N00] – Engine controller lock caution 3 864
Failure code [A1U0N3] – HC desorb request 1 . 865
Failure code [A1U0N4] – HC desorb request 2 . 866
Failure code [A900FR] – Abrupt engine stop by auto idling stop 3 867
Failure code [A900N6] – Abrupt engine stop by auto idling stop 1 868
Failure code [A900NY] – Abrupt engine stop by auto idling stop 2 869
Failure code [AA10NX] – Air cleaner clogging 870
Failure code [AB00KE] – Charge voltage low 872
Failure code [AQ10N3] – Manual stationary regeneration request (KDOC face plugging) . 874
Failure code [AS00N3] – Manual stationary regeneration request (SCR) 875
Failure code [AS00R2] – Warning 2 . 876
Failure code [AS00R3] – Inducement 1 877
Failure code [AS00R4] – Inducement 2 878
Failure code [AS00R5] – Inducement 3 879
Failure code [AS00R6] – Temporary recovery of inducement 880
Failure code [AS00ZK] – AdBlue/DEF level low error 5 881
Failure code [AS10KM] – AdBlue/DEF Injector overheat warning 882
Failure code [AS10NR] – AdBlue/DEF injector high temperature warning 883
Failure code [AS10NT] – AdBlue/DEF injector overheat caution 884
Failure code [B@BAZG] – Engine oil pressure low . 885
Failure code [B@BAZK] – Engine oil level low 886
Circuit diagram related to engine oil level . 886
Failure code [B@BCNS] – Engine coolant overheat . 887
Failure code [B@BCZK] – Engine coolant level low 888
Circuit diagram related to radiator coolant level switch 889
Failure code [B@HANS] – Hydraulic oil overheat 890
Circuit diagram related to hydraulic oil temperature sensor . 891
Failure code [CA1117] – Engine controller partial data lost error . 892
Failure code [CA115] – Engine neutral and backup speed sensor error . 893
Failure code [CA122] – Charge air press sensor high error . 894
Circuit diagram related to charge air pressure sensor . 895
Failure code [CA123] – Charge air press sensor low error 896
Circuit diagram related to charge air pressure sensor . 897
Failure code [CA131] – Throttle sensor high error . 898
Circuit diagram related to throttle sensor 899
Failure code [CA132] – Throttle sensor low error 900
Circuit diagram related to throttle sensor 901
Failure code [CA144] – Coolant temperature sensor high error 902
Electrical circuit diagram related to coolant temperature sensor 903
Failure code [CA145] – Coolant temperature sensor low error . 904
Electrical circuit diagram related to coolant temperature sensor 905
Failure code [CA153] – Charge air temperature sensor high error . 906
Circuit diagram related to charge temperature sensor 907
Failure code [CA154] – Charge air temperature sensor low error 908
Circuit diagram related to charge temperature sensor 909
Failure code [CA187] – Sensor 2 supply voltage low error 910
Circuit diagram related to sensor 2 supply circuit 911
Failure code [CA221] – Ambient press sensor high error 912
Circuit diagram related to ambient pressure sensor 913
Failure code [CA222] – Ambient press sensor low error . 914
Circuit diagram related to ambient pressure sensor 915
Failure code [CA227] – Sensor 2 supply voltage high error . 916
Failure code [CA234] – Engine overspeed . 917
Failure code [CA238] – NE speed sensor supply voltage error . 918
Circuit diagram (NE speed sensor) . 919
Failure code [CA239] – NE speed sensor supply voltage high error 920
Circuit diagram (NE speed sensor) . 921
Failure code [CA249] – Ambient air temp sensor high error . 922
Circuit diagram related to ambient air temperature sensor . 923
Failure code [CA256] – Ambient air temp sensor low error 924
Circuit diagram related to ambient air temperature sensor . 925
Failure code [CA271] – IMV or PCV 1 short circuit error . 926
Circuit diagram related to IMV/PCV1 . 927
Failure code [CA272] – IMV or PCV 1 open circuit error 928
Circuit diagram related to IMV/PCV1 . 929
Failure code [CA322] – Injector #1 (L#1) open circuit error or short circuit error 930
Circuit diagram related to injector #1 931
Failure code [CA323] – Injector #5 (L#5) open circuit error or short circuit error 932
Circuit diagram related to injector #5 933
Failure code [CA324] – Injector #3 (L#3) open circuit error or short circuit error 934
Circuit diagram related to injector #3 935
Failure code [CA325] – Injector #6 (L#6) open circuit error or short circuit error 936
Circuit diagram related to injector #6 937
Failure code [CA331] – Injector #2 (L#2) open circuit error or short circuit error 938
Circuit diagram related to injector #2 939
Failure code [CA332] – Injector #4 (L#4) open circuit error or short circuit error 940
Circuit diagram related to injector #4 941
Failure code [CA343] – Engine controller internal failure . 942
Failure code [CA351] – Injectors drive circuit error 943
Failure code [CA352] – Sensor 1 supply voltage low error 944
Circuit diagram related to sensor 1 supply circuit 945
Failure code [CA356] – MAF sensor high error 946
Circuit diagram (mass air flow sensor) 947
Failure code [CA357] – MAF sensor low error . 948
Circuit diagram (mass air flow sensor) 949
Failure code [CA386] – sensor 1 supply voltage high error . 949
Failure code [CA428] – Water in fuel sensor high error 950
Circuit diagram related to water-in-fuel sensor . 951
Failure code [CA429] – Water in fuel sensor low error . 952
Circuit diagram related to water-in-fuel sensor . 953
Failure code [CA435] – Engine oil pressure SW error . 954
Circuit diagram related to engine oil pressure switch . 955
Failure code [CA441] – Battery voltage low error 956
Circuit diagram (Engine controller power supply) 957
Failure code [CA442] – Battery voltage high error . 958
Circuit diagram (Engine controller power supply) 959
Failure code [CA449] – Common rail pressure high error 2 960
Failure code [CA451] – Common rail pressure sensor high error . 962
Circuit diagram related to common rail pressure sensor 963
Failure code [CA452] – Common rail pressure sensor low error 964
Circuit diagram related to common rail pressure sensor 965
Failure code [CA488] – Charge air temperature high torque derate 965
Failure code [CA515] – Charge air temperature high torque derate 966
Circuit diagram related to common rail pressure sensor 967
Failure code [CA516] – Common rail pressure sensor supply voltage low error . 968
Circuit diagram related to common rail pressure sensor 969
Failure code [CA553] – Common rail pressure high error 1 969
Failure code [CA555] – Crankcase pressure high error 1 970
Failure code [CA556] – Crankcase pressure high error 3 971
Failure code [CA559] – Common rail pressure low error 1 . 972
Failure code [CA595] – Turbocharger speed high error 2 974
Failure code [CA687] – Turbocharger speed low error . 976
Circuit diagram (turbo speed sensor) 977
Failure code [CA689] – Engine NE speed sensor error . 978
Circuit diagram (NE speed sensor) . 979
Failure code [CA691] – Intake air temperature sensor high error . 980
Circuit diagram (mass air flow sensor) 981
Failure code [CA692] – Intake air temperature sensor low error 982
Failure code [CA697] – Engine controller internal temperature sensor high error . 984
Failure code [CA698] – Engine controller internal temperature sensor low error 985
Failure code [CA731] – Engine backup speed sensor phase error . 986
Failure code [CA778] – Engine backup speed sensor error . 988
Circuit diagram (Bkup (camshaft) speed sensor . 989
Failure code [CA1664] – KDOC abnormality 992
Failure code [CA1669] – AdBlue/DEF level sensor voltage high error 994
Failure code [CA1673] – AdBlue/DEF level low error 3 995
Failure code [CA1677] – AdBlue/DEF temperature sensor low error . 996
Failure code [CA1678] – AdBlue/DEF temperature sensor high error 997
Failure code [CA1682] – AdBlue/DEF pump priming error . 998
Failure code [CA1683] – AdBlue/DEF tank heating valve voltage high error 1000
Circuit diagram related to AdBlue/DEF tank heating valve 1001
Failure code [CA1684] – AdBlue/DEF tank heating valve voltage low error .1002
Circuit diagram related to AdBlue/DEF tank heating valve 1003
Failure code [CA1686] – AdBlue/DEF quality sensor voltage high error 1004
Failure code [CA1691] – Defective regeneration 1006
Failure code [CA1694] – SCR outlet NOx sensor in range error 1008
Failure code [CA1695] – Sensor 5 supply voltage high error 1010
Failure code [CA1696] – Sensor 5 supply voltage low error .1012
Circuit diagram related to AdBlue/DEF pump pressure sensor 1013
Failure code [CA1712] – AdBlue/DEF tank thawing error .1014
Failure code [CA1713] – AdBlue/DEF tank heater valve open stuck error .1016
Failure code [CA1714] – AdBlue/DEF quality sensor out of calibration error 1018
Failure code [CA1715] – AdBlue/DEF quality sensor internal circuit error 1019
Failure code [CA1776] – Sensor supply relay voltage high error 1020
Circuit diagram related to sensor power supply relay circuit 1021
Failure code [CA1777] – Sensor supply relay voltage low error .1022
Circuit diagram related to sensor power supply relay circuit 1023
Failure code [CA1843] – Crankcase pressure sensor high error 1024
Circuit diagram related to crankcase pressure sensor 1025
Failure code [CA1844] – Crankcase pressure sensor low error .1026
Circuit diagram related to crankcase pressure sensor 1027
Failure code [CA1879] – KDPF differential pressure sensor high error 1028
Circuit diagram related to KDPF differential pressure sensor 1029
Failure code [CA1881] – KDPF differential pressure sensor low error .1030
Circuit diagram related to KDPF differential pressure sensor 1031
Failure code [CA1883] – KDPF differential pressure sensor in range error 1032
Circuit diagram related to KDPF differential pressure sensor 1034
Failure code [CA1885] – Turbo outlet NOx sensor circuit error .1036
Failure code [CA1887] – SCR outlet NOx sensor circuit error .1038
Failure code [CA1921] – KDPF soot accumulation high error 1 .1040
Failure code [CA1922] – KDPF soot accumulation high error 2 .1042
Failure code [CA1942] – Crankcase pressure sensor in range error 1045
Failure code [CA1993] – KDPF differential pressure low error 1046
Circuit diagram related to KDPF differential pressure sensor 1047
Failure code [CA2185] – Throttle sensor supply voltage high error .1048
Circuit diagram related to throttle sensor 1048
Failure code [CA2186] – Throttle sensor supply voltage low error 1049
Circuit diagram related to throttle sensor 1049
Failure code [CA2249] – Common rail pressure low error 2 1050
Failure code [CA2271] – EGR valve position sensor high error 1052
Circuit diagram (EGR valve lift sensor) .1053
Failure code [CA2272] – EGR valve position sensor low error .1054
Circuit diagram (EGR valve lift sensor) .1055
Failure code [CA2288] – Turbocharger speed high error 1 .1056
Failure code [CA2311] – IMV solenoid error 1057
Failure code [CA2349] – EGR valve solenoid open circuit error .1058
Circuit diagram (EGR valve solenoid) 1059
Failure code [CA2353] – EGR valve solenoid short circuit error 1060
Circuit diagram (EGR valve solenoid) 1061
Failure code [CA2357] – EGR valve servo error .1062
Failure code [CA2381] – KVGT position sensor high error .1064
Circuit diagram (VGT position sensor) .1065
Failure code [CA2382] – KVGT position sensor low error 1066
Circuit diagram (VGT position sensor) .1067
Failure code [CA2383] – KVGT solenoid open circuit error 1068
Circuit diagram (VGT valve solenoid) 1069
Failure code [CA2386] – KVGT solenoid short circuit error .1070
Circuit diagram (VGT valve solenoid) 1071
Failure code [CA2387] – KVGT servo error 1072
Circuit diagram (intake air heater relay) .1075
Circuit diagram (intake air heater relay) .1077
Failure code [CA2637] – KDOC face plugging 1078
Failure code [CA2639] – Manual stationary regeneration request 1080
Failure code [CA2771] – SCR outlet NOx sensor datalink timeout error 1082
Circuit diagram related to CAN communication 1086
Failure code [CA2777] – Manual stationary regeneration request but KDPF regeneration disable 1087
Failure code [CA2976] – AdBlue/DEF pump temperature sensor signal error .1088
Circuit diagram related to mass air flow sensor .1089
Failure code [CA3133] – KDPF outlet pressure sensor high error 1090
Circuit diagram related to KDPF outlet pressure sensor 1091
Failure code [CA3134] – KDPF outlet pressure sensor low error .1092
Circuit diagram related to KDPF outlet pressure sensor 1093
Failure code [CA3135] – KDPF outlet pressure sensor in range error 1094
Circuit diagram related to KDPF outlet pressure sensor 1096
Failure code [CA3142] – SCR temperature sensor high error .1097
Failure code [CA3143] – SCR temperature sensor low error 1098
Failure code [CA3144] – SCR temperature sensor in rage error 1100
Failure code [CA3146] – SCR outlet temperature sensor high error 1102
Failure code [CA3147] – SCR outlet temperature sensor low error .1103
Failure code [CA3148] – SCR outlet temperature sensor in range error 1104
Failure code [CA3151] – SCR catalyst efficiency low error 2 .1106
Failure code [CA3165] – SCR outlet temperature high error .1110
Failure code [CA3229] – SCR temperature high error 1112
Failure code [CA3231] – SCR temperature high error non regeneration .1114
Failure code [CA3232] – Turbo outlet NOx sensor datalink timeout error 1116
Circuit diagram related to SCR system CAN communication .1118
Failure code [CA3235] – SCR outlet temperature high error – non regeneration 1120
Failure code [CA3239] – AdBlue/DEF line heater 2 voltage high error .1122
Circuit diagram related to AdBlue/DEF line heater .1123
Failure code [CA3241] – AdBlue/DEF line heater 2 voltage low error 1124
Circuit diagram related to AdBlue/DEF line heater .1125
Failure code [CA3242] – AdBlue/DEF tank heating error .1126
Failure code [CA3251] – KDOC inlet temperature high error .1128
Failure code [CA3253] – KDOC temperature error – non regeneration .1130
Failure code [CA3254] – KDOC outlet temperature high error 1 1132
Failure code [CA3255] – KDPF temperature error – non regeneration .1134
Failure code [CA3256] – KDPF outlet temperature high error 1 1136
Failure code [CA3311] – KDOC outlet temperature high error 2 1138
Failure code [CA3312] – KDPF outlet temperature high error 2 1140
Failure code [CA3313] – KDOC inlet temperature sensor low error .1142
Failure code [CA3314] – KDOC inlet temperature sensor high error 1143
Failure code [CA3315] – KDOC inlet temperature sensor in range error 1144
Failure code [CA3316] – KDOC outlet temperature sensor low error 1146
Failure code [CA3317] – KDOC outlet temperature sensor high error .1147
Failure code [CA3318] – KDOC temperature sensor in range error 1148
Failure code [CA3319] – KDPF outlet temperature sensor high error .1150
Failure code [CA3321] – KDPF outlet temperature sensor low error 1151
Failure code [CA3322] – KDPF outlet temperature sensor in range error .1152
Failure code [CA3419] – MAF sensor supply voltage high error 1154
Circuit diagram related to mass air flow sensor .1155
Failure code [CA3421] – MAF sensor supply voltage low error .1156
Circuit diagram related to mass air flow sensor .1157
Failure code [CA3497] – AdBlue/DEF level low error 1 1158
Failure code [CA3498] – AdBlue/DEF level low error 2 1159
Failure code [CA3543] – AdBlue/DEF quality error (SCR catalyst efficiency low) 1160
Failure code [CA3545] – SCR outlet NOx sensor unstable error 1164
Failure code [CA3547] – AdBlue/DEF level low error 4 1166
Failure code [CA3558] – AdBlue/DEF pump voltage high error 1168
Circuit diagram related to AdBlue/DEF pump 1169
Failure code [CA3559] – AdBlue/DEF pump voltage low error .1170
Circuit diagram related to AdBlue/DEF pump 1171
Failure code [CA3562] – AdBlue/DEF line heater relay 1 voltage high error .1172
Circuit diagram related to AdBlue/DEF line heater .1173
Failure code [CA3563] – AdBlue/DEF line heater relay 1 voltage low error 1174
Circuit diagram related to AdBlue/DEF line heater .1175
Failure code [CA3567] – AdBlue/DEF injector open circuit error or short circuit error .1176
Circuit diagram related to AdBlue/DEF injector 1178
Failure code [CA3568] – AdBlue/DEF malfunction 1179
Failure code [CA3571] – AdBlue/DEF pump pressure sensor high error 1182
Circuit diagram related to AdBlue/DEF pump pressure sensor 1183
Failure code [CA3572] – AdBlue/DEF pump pressure sensor low error .1184
Circuit diagram related to AdBlue/DEF pump pressure sensor 1185
Failure code [CA3574] – AdBlue/DEF pump pressure too low error 1186
Failure code [CA3575] – AdBlue/DEF pump pressure too high error .1188
Failure code [CA3577] – AdBlue/DEF FCV voltage high error .1190
Circuit diagram related to AdBlue/DEF FCV .1191
Failure code [CA3578] – AdBlue/DEF FCV voltage low error 1192
Circuit diagram related to AdBlue/DEF FCV .1193
Failure code [CA3582] – SCR catalyst efficiency low error 1 .1194
Failure code [CA3583] – SCR outlet NOx sensor heater warming up error .1198
Failure code [CA3596] – AdBlue/DEF pump pressure unstable error .1200
Failure code [CA3649] – Turbo outlet NOx sensor heater warming up error .1202
Failure code [CA3681] – SCR outlet NOx sensor power voltage error .1204
Circuit diagram related to SCR system CAN communication .1207
Circuit diagram (Engine controller power supply) 1208
Failure code [CA3682] – Turbo outlet NOx sensor power voltage error .1209
Circuit diagram related to SCR system CAN communication .1212
Circuit diagram (Engine controller power supply) 1213
Failure code [CA3713] – AdBlue/DEF line heater 1 voltage high error .1214
Circuit diagram related to AdBlue/DEF line heater .1215
Failure code [CA3717] – SCR outlet NOx sensor voltage mismatch error 1216
Failure code [CA3718] – Turbo outlet NOx sensor voltage mismatch error 1217
Failure code [CA3725] – Turbo outlet NOx sensor unstable error 1218
Failure code [CA3741] – Rail press valve trip error .1220
Failure code [CA3748] – Turbo outlet NOx sensor stuck in range error 1221
Failure code [CA3751] – SCR catalyst degradation error 1222
Failure code [CA3755] – AdBlue/DEF dosing performance degradation error .1224
Failure code [CA3866] – AdBlue/DEF low concentration error 2 1226
Failure code [CA3867] – AdBlue/DEF low concentration error 1 1228
Failure code [CA3868] – AdBlue/DEF tank sensor datalink timeout error .1230
Circuit diagram related to SCR system CAN communication .1232
Failure code [CA3899] – SCR NH3 sensor circuit error 1234
Failure code [CA3911] – SCR NH3 sensor datalink timeout error .1236
Circuit diagram related to SCR system CAN communication .1238
Failure code [CA3912] – SCR NH3 sensor heater warming up error 1240
Failure code [CA3932] – SCR NH3 sensor heater voltage high error 1242
Failure code [CA3933] – SCR NH3 sensor heater voltage low error .1244
Failure code [CA3934] – SCR NH3 sensor power interrupt error 1246
Circuit diagram (ammonia sensor) 1248
Failure code [CA3935] – SCR NH3 sensor trim resistance error 1250
Failure code [CA3936] – SCR NH3 sensor internal circuit error .1252
Failure code [CA4151] – KDOC and KDPF temperature sensor datalink timeout error .1254
Circuit diagram related to SCR system CAN communication .1257
Failure code [CA4152] – SCR temperature sensor datalink timeout error .1258
Circuit diagram related to SCR system CAN communication .1260
Failure code [CA4155] – AdBlue/DEF pump heater relay voltage high error .1262
Electrical circuit diagram related to AdBlue/DEF heater relay .1263
Failure code [CA4156] – AdBlue/DEF pump heater relay voltage low error 1264
Electrical circuit diagram related to AdBlue/DEF heater relay .1265
Failure code [CA4157] – AdBlue/DEF FCV malfunction 1266
Failure code [CA4158] – KDOC and KDPF temperature sensor internal circuit error .1268
Failure code [CA4159] – SCR temperature sensor internal circuit error .1269
Failure code [CA4161] – KDOC and KDPF temperature sensor ECU voltage high error .1270
Circuit diagram related to KDOC/KDPF temperature sensor .1271
Failure code [CA4162] – KDOC and KDPF temperature sensor ECU voltage low error 1272
Circuit diagram related to KDOC/KDPF temperature sensor .1273
Failure code [CA4163] – KDOC and KDPF temperature sensor ECU over temperature error .1274
Failure code [CA4164] – SCR temperature sensor ECU voltage high error .1276
Electrical circuit diagram related to SCR temperature sensor 1277
Failure code [CA4165] – SCR temperature sensor ECU voltage low error 1278
Electrical circuit diagram related to SCR temperature sensor 1279
Failure code [CA4166] – SCR temperature sensor ECU high temperature error .1280
Failure code [CA4168] – AdBlue/DEF pump heater ON stuck error .1282
Electrical circuit diagram related to AdBlue/DEF pump heater 1283
Failure code [CA4169] – AdBlue/DEF pump heater OFF stuck error 1284
Failure code [CA4171] – AdBlue/DEF pump thawing error .1286
Electrical circuit diagram related to AdBlue/DEF pump heater 1287
Failure code [CA4249] – AdBlue/DEF pump temperature sensor 1 in range error .1288
Failure code [CA4251] – AdBlue/DEF pump temperature sensor 2 in range error .1290
Failure code [CA4259] – KDOC and KDPF temperature sensor power interrupt error 1292
Circuit diagram related to KDPF temperature sensor 1293
Failure code [CA4261] – SCR temperature sensor power interrupt error 1294
Electrical circuit diagram related to SCR temperature sensor 1295
Failure code [CA4277] – AdBlue/DEF quality sensor liquid distinction impossible error .1296
Failure code [CA4281] – SCR NH3 sensor stuck response error .1298
Failure code [CA4459] – AdBlue/DEF line heater relay 2 voltage high error .1302
Circuit diagram related to AdBlue/DEF line heater .1303
Failure code [CA4461] – AdBlue/DEF line heater relay 2 voltage low error 1304
Circuit diagram related to AdBlue/DEF line heater .1305
Failure code [CA4658] – AdBlue/DEF flow low error .1306
Failure code [CA4731] – AdBlue/DEF temperature sensor transmission data error .1308
Failure code [CA4732] – AdBlue/DEF level sensor transmission data error .1309
Failure code [CA4739] – AdBlue/DEF level sensor internal circuit error 1310
Failure code [CA4768] – Fuel in AdBlue/DEF tank error .1312
Failure code [CA4769] – AdBlue/DEF level measurement impossible .1314
Failure code [CA4842] – AdBlue/DEF high concentration error .1316
Failure code [CA4952] – System operating lamp short circuit (engine controller) .1318
Circuit diagram related to system operating lamp 1319
Failure code [CA5115] – AdBlue/DEF line heater 1 voltage low error 1320
Circuit diagram related to AdBlue/DEF line heater .1321
Failure code [CA5179] – Engine room temperature sensor high error .1322
Circuit diagram (engine room temperature sensor) 1323
Failure code [CA5181] – Engine room temperature sensor low error 1324
Circuit diagram (engine room temperature sensor) 1325
Failure code [CA5383] – Ash accumulation high error .1326
Failure code [D110KB] – Battery relay output short circuit 1328
Failure code [D19JKZ] – Personal code relay abnormality .1330
Circuit diagram related to personal code relay 1331
Failure code [D19QKB] – Short circuit in refuel pump relay 1332
Circuit diagram related to Refuel pump relay 1333
Failure code [D19QKY] – Hot short circuit in refuel pump relay 1334
Circuit diagram related to Refuel pump relay 1335
Failure code [D1EMKA] – Parking brake relay open circuit 1336
Circuit diagram related to parking brake relay 1337
Failure code [D1EMKB] – Parking brake relay short circuit .1338
Circuit diagram related to parking brake relay 1339
Failure code [D1EMKY] – Parking brake relay hot short circuit .1340
Circuit diagram related to parking brake relay 1341
Failure code [D811MC] – KOMTRAX malfunction .1342
Failure code [D862KA] – GPS antenna open circuit 1343
Configuration diagram of GPS system .1343
Failure code [D8ALKA] – System operating lamp open circuit (KOMTRAX) 1344
Circuit diagram related to system operating lamp 1345
Failure code [D8ALKB] – System operating lamp short circuit (KOMTRAX) .1346
Circuit diagram related to system operating lamp 1347
Failure code [D8AQKR] – CAN2 discon (KOMTRAX) .1348
Circuit diagram related to CAN communication 2 1350
Failure code [DA20MC] – Pump controller malfunction .1352
Failure code [DA22KK] – Pump solenoid power low error .1354
Circuit diagram related to solenoid power supply 1355
Failure code [DA25KP] – 5 V Sensor 1 power voltage low error 1356
Circuit diagram related to 5 V sensor power supply 1 1357
Failure code [DA26KP] – 5 V Sensor 2 power voltage low error 1358
Circuit diagram related to 5 V sensor power supply 2 1359
Failure code [DA29KQ] – Model selection signal mismatch .1360
Circuit diagram related to machine model setting system .1361
Failure code [DA2LKA] – System operating lamp open circuit (pump controller system) .1362
Circuit diagram related to system operating lamp 1363
Failure code [DA2LKB] – System operating lamp short circuit .1364
Circuit diagram related to system operating lamp 1365
Failure code [DA2QKR] – Controller area network 2 defective communication .1366
Circuit diagram (can2 communication) 1368
Failure code [DA2RKR] – Controller area network 1 defective communication .1370
Circuit diagram related to CAN communication 1 1372
Failure code [DA80KB] – Auto grease system monitoring signal short circuit 1374
Circuit diagram related to grease system 1375
Failure code [DAB0KT] – Internal flash memory error (pump controller system) 1376
Failure code [DAC3KB] – Cruise control system power supply short circuit 1378
Circuit diagram related to Cruise control system 1379
Failure code [DAC3KB] – Cruise control system power supply hot short circuit 1380
Circuit diagram related to Cruise control system 1381
Failure code [DAF0KM] – Inconsistency of KomVision setting 1382
Failure code [DAF0MB] – Monitor ROM abnormality .1382
Failure code [DAF0MC] – Monitor malfunction .1383
Failure code [DAF8KB] – Camera power supply short circuit .1384
Circuit diagram related to camera power supply 1385
Failure code [DAF9KQ] – Model selection abnormality .1386
Failure code [DAFGMC] – GPS module malfunction 1387
Failure code [DAFLKA] – System operating lamp open circuit (monitor) 1388
Circuit diagram related to system operating lamp 1389
Failure code [DAFLKB] – System operating lamp short circuit (monitor) .1390
Circuit diagram related to system operating lamp 1391
Failure code [DAFQKR] – CAN 2 defective communication (monitor) .1392
Circuit diagram related to CAN communication 2 1394
Circuit diagram related to engine controller power source .1395
Failure code [DAZ9KQ] – Model selection signal mismatch (air conditioner) .1396
Failure code [DAZQKR] – CAN 2 defective communication (A/C ECU) .1397
Circuit diagram (CAN2 communication) 1399
Failure code [DB2QKR] – CAN2 discon (engine con) 1400
Circuit diagram related to CAN communication 2 1403
Circuit diagram related to engine controller power source .1404
Failure code [DB2RKR] – CAN1 discon (engine con) 1405
Circuit diagram related to CAN communication 1 1408
Circuit diagram related to engine controller power source .1409
Failure code [DB30KR] – Joystick steering controller malfunction 1410
Failure code [DBP0KM] – KomVision setting error .1411
Failure code [DBP0KT] – KomVision controller abnormality 1411
Failure code [DBP5KB] – Camera power supply short circuit .1412
Circuit diagram related to camera power supply 1413
Failure code [DBP5KY] – Camera power hot short circuit 1414
Circuit diagram related to camera power supply 1415
Failure code [DBPQKR] – CAN 2 defective communication (KomVision) .1416
Circuit diagram (CAN2 communication) 1418
Circuit diagram related to KomVision controller power supply 1419
Failure code [DCS0KT] – Internal flash memory error (machine controller system) .1420
Failure code [DCS0MC] – Machine controller malfunction 1421
Failure code [DCS2KK] – Machine controller solenoid power voltage low error .1422
Circuit diagram related to solenoid power supply 1423
Failure code [DCS5KP] – 5 V sensor power supply output 1 voltage low or high 1424
Circuit diagram related to 5 V sensor power supply 1 1425
Failure code [DCS7KP] – 24V sensor power voltage low error 1426
Circuit diagram related to 24V sensor power voltage .1427
Failure code [DCS9KQ] – Model selection signal mismatch (machine controller) 1428
Circuit diagram related to machine model setting system .1429
Failure code [DCSLKA] – System operating lamp open circuit (machine controller) .1430
Circuit diagram related to system operating lamp 1431
Failure code [DCSLKB] – System operating lamp short circuit (machine controller) 1432
Circuit diagram related to system operating lamp 1433
Failure code [DCSQKR] – CAN2 defective communication (machine controller) .1434
Failure code [DCSRKR] – CAN 1 defective communication (machine controller) 1436
Failure code [DDK8KA] – SUSLock forced SW open circuit 1437
Failure code [DDK8KB] – SUSLock forced SW short circuit .1438
Failure code [DDKVKA] – Joystick steering activation SW open circuit 1440
Failure code [DDKVKB] – Joystick steering activation SW short circuit .1441
Failure code [DDNRKA] – W/E lever lock SW open circuit 1442
Circuit diagram related to PPC lock switch 1443
Failure code [DDNRKY] – W/E lever lock SW short circuit .1444
Circuit diagram related to PPC lock switch 1445
Failure code [DDNS00] – Lock lever auto lock release SW ON 1446
Circuit diagram related to PPC lock switch 1447
Failure code [DDP4KX] – Disconnection in travel PPC pressure switch .1448
Circuit diagram for travel PPC pressure switch 1449
Failure code [DDP6L5] – Service brake press SW abnormality 1450
Circuit diagram related to Service brake pressure switch 1451
Failure code [DDQ1KA] – SUSLock mode selection SW open circuit 1452
Circuit diagram related to SUSLock mode selection switch 1453
Failure code [DDQ1KB] – SUSLock mode selection SW short circuit .1454
Circuit diagram related to SUSLock mode selection switch 1455
Failure code [DDWCKZ] – Direction switch abnormality 1456
Circuit diagram for travel direction control switch .1457
Failure code [DDWMKZ] – FBR attachment SW abnormality .1458
Circuit diagram related to FBR attachment switch 1459
Failure code [DFB1KZ] – Service lever potentio 1 open or short circuit 1460
Circuit diagram related to PPC control switches .1461
Failure code [DFB2KZ] – Service lever potentio 2 open or short circuit 1462
Circuit diagram related to PPC control switches .1463
Failure code [DFB3L8] – Service lever 1 potentiometer error .1464
Failure code [DFB4L8] – Service lever 2 potentiometer error .1465
Circuit diagram related to PPC control switches .1467
Failure code [DFB6KZ] – Service lever sub potentio 2 open or short circuit 1468
Circuit diagram related to PPC control switches .1469
Failure code [DGH2KA] – Hydraulic oil temperature sensor open circuit .1470
Circuit diagram related to hydraulic oil temperature sensor .1471
Failure code [DGH2KB] – Hydraulic oil temperature sensor ground fault .1472
Circuit diagram related to hydraulic oil temperature sensor .1473
Failure code [DHA4KA] – Air cleaner clog sensor open circuit 1474
Circuit diagram related to hydraulic oil temperature sensor .1475
Failure code [DHAAMA] – KDPF differential pressure sensor frozen 1476
Failure code [DHACMA] – KDPF outlet pressure sensor frozen 1477
Failure code [DHH2MA] – Return line filter press sensor abnormally 1478
Failure code [DHPAMA] – Front pump pressure sensor defective function .1480
Circuit diagram related to front pump pressure sensor .1481
Failure code [DHS3MA] – Arm IN PPC pressure sensor defective function .1482
Circuit diagram related to arm IN PPC pressure sensor .1483
Failure code [DHS4MA] – Bucket CURL PPC pressure sensor defective function 1484
Circuit diagram related to bucket CURL PPC pressure sensor 1485
Failure code [DHS5KX] – Travel PPC sensor abnormality .1486
Circuit diagram related to Travel PPC sensor 1487
Failure code [DHS8MA] – Boom RAISE PPC pressure sensor defective function .1488
Circuit diagram related to boom RAISE PPC pressure sensor .1489
Failure code [DHS9MA] – Boom LOWER PPC pressure sensor defective function .1490
Circuit diagram related to boom LOWER PPC pressure sensor .1491
Failure code [DHSAMA] – Swing right PPC pressure sensor defective function 1492
Circuit diagram related to swing RIGHT PPC pressure sensor 1493
Failure code [DHSBMA] – Swing left PPC pressure sensor defective function .1494
Circuit diagram related to swing LEFT PPC pressure sensor .1495
Failure code [DHSCMA] – Arm OUT PPC pressure sensor defective function 1496
Circuit diagram related to arm OUT PPC pressure sensor 1497
Failure code [DHSDMA] – Bucket DUMP PPC pressure sensor defective function 1498
Circuit diagram related to arm OUT PPC pressure sensor 1499
Failure code [DHU1KA] – Brake accumulator press sensor open circuit .1500
Circuit diagram related to Brake accumulator press sensor .1501
Failure code [DHU1KY] – Brake accumulator press sensor short circuit 1502
Circuit diagram related to Brake accumulator press sensor .1503
Failure code [DHUCKA] – Parking brake press sensor open circuit .1504
Circuit diagram related to Parking brake press sensor .1505
Failure code [DHUCKY] – Parking brake press sensor short circuit 1506
Circuit diagram related to Parking brake press sensor .1507
Failure code [DHUGKA] – Service brake press sensor open circuit .1508
Circuit diagram related to Service brake press sensor .1509
Failure code [DHUGKY] – Service brake press sensor short circuit 1510
Circuit diagram related to Service brake press sensor .1511
Failure code [DHX1MA] – Overload sensor abnormality .1512
Circuit diagram related to overload caution .1513
Failure code [DKULKA] – PPC lock relay open circuit .1514
Circuit diagram related to PPC lock switch 1515
Failure code [DKULKB] – PPC lock relay short circuit 1516
Circuit diagram related to PPC lock switch 1517
Failure code [DKULKY] – PPC lock relay hot short circuit 1518
Circuit diagram related to PPC lock switch 1519
Failure code [DLM5KA] – Fan speed sensor open circuit .1520
Circuit diagram related to fan clutch .1521
Failure code [DLM5MB] – Fan control: mismatch .1522
Failure code [DLT4KA] – Speed sensor open circuit .1524
Circuit diagram related to transmission speed sensor 1525
Failure code [DLT4KB] – Speed sensor short circuit 1526
Circuit diagram related to transmission speed sensor 1527
Failure code [DR10KA] – KomVision camera open circuit .1528
Circuit diagram related to camera power supply 1529
Failure code [DR12KA] – Disconnection of camera 1 NTSC input 1530
Circuit diagram related to camera power supply 1531
Failure code [DR20KA] – Disconnection of camera 2 NTSC input 1532
Circuit diagram related to camera power supply 1533
Failure code [DR30KA] – Disconnection of camera 3 NTSC input 1534
Circuit diagram related to camera power supply 1535
Failure code [DR31KX] – Camera 3 picture reverse drive input out of range .1536
Circuit diagram related to camera power supply 1537
Failure code [DR40KA] – Disconnection of camera 4 NTSC input 1538
Circuit diagram related to camera power supply 1539
Failure code [DUMBKA] – Operating lamp open circuit (KomVision) .1540
Circuit diagram related to system operating lamp 1541
Failure code [DUMBKB] – Operating lamp short circuit (KomVision) 1542
Circuit diagram related to system operating lamp 1543
Failure code [DV20KB] – Travel alarm short circuit 1544
Circuit diagram related to travel alarm .1545
Failure code [DW44KA] – Travel F/R solenoid open circuit 1546
Circuit diagram related to travel F/R solenoid 1547
Failure code [DW44KB] – Travel F/R solenoid short circuit .1548
Circuit diagram related to travel F/R solenoid 1549
Failure code [DW44KY] – Travel F/R solenoid hot short circuit .1550
Circuit diagram related to travel F/R solenoid 1551
Failure code [DW45KA] – Swing parking brake solenoid open circuit .1552
Circuit diagram related to swing parking brake 1553
Failure code [DW45KB] – Swing parking brake solenoid short circuit 1554
Circuit diagram related to swing parking brake 1555
Failure code [DW45KY] – Swing parking brake solenoid hot short circuit 1556
Circuit diagram related to swing parking brake 1557
Failure code [DW4AKA] – Disconnection in suspension lock solenoid .1558
Circuit diagram related to suspension lock solenoid .1559
Failure code [DW4AKB] – Short circuit in suspension lock solenoid .1560
Circuit diagram related to suspension lock solenoid .1561
Failure code [DW4AKY] – SUSLock sol hot short circuit .1562
Circuit diagram related to suspension lock solenoid .1563
Failure code [DW4CKY] – PPC lock solenoid hot short circuit .1564
Circuit diagram related to PPC lock switch 1565
Failure code [DW4MKA] – Disconnection in creep solenoid .1566
Circuit diagram related to creep solenoid .1566
Failure code [DW4MKB] – Short circuit in creep solenoid .1567
Circuit diagram related to creep solenoid .1567
Failure code [DW4MKY] – Hot short circuit in creep solenoid .1568
Circuit diagram related to creep solenoid .1569
Failure code [DW4YKA] – Disconnection in high gear solenoid .1570
Circuit diagram related to High gear solenoid .1571
Failure code [DW4YKB] – Short circuit in high gear solenoid .1572
Circuit diagram related to High gear solenoid .1573
Failure code [DW4YKY] – High gear hot short circuit .1574
Circuit diagram related to High gear solenoid .1575
Failure code [DW4ZKA] – Disconnection in low gear solenoid 1576
Circuit diagram related to Low gear solenoid 1577
Failure code [DW4ZKB] – Short circuit in low gear solenoid 1578
Circuit diagram related to Low gear solenoid 1579
Failure code [DW4ZKY] – Low gear hot short circuit 1580
Circuit diagram related to Low gear solenoid 1581
Failure code [DW91KA] – Travel neutral sol open circuit .1582
Circuit diagram for travel neutral solenoid .1583
Failure code [DW91KB] – Travel neutral sol short circuit 1584
Circuit diagram for travel neutral solenoid .1585
Failure code [DW91KY] – Travel neutral sol hot short circuit 1586
Circuit diagram for travel neutral solenoid .1587
Failure code [DWA2KA] – Attachment single or 2-way change solenoid open circuit (breaker mode relay) 1588
Circuit diagram related to breaker mode relay .1589
Failure code [DWA2KB] – Attachment single or 2-way change solenoid short circuit (breaker mode relay) .1590
Circuit diagram related to breaker mode relay .1591
Failure code [DWA2KY] – Attachment single or 2-way change solenoid hot short circuit (breaker mode relay) .1592
Circuit diagram related to breaker mode relay .1593
Failure code [DWB1KA] – Outrigger selection sol relay open circuit 1594
Circuit diagram related to outrigger/boom operation relay .1595
Failure code [DWB1KB] – Outrigger selection sol relay short circuit .1596
Circuit diagram related to outrigger/boom operation relay .1597
Failure code [DWB2KA] – Disconnection in 1st outrigger solenoid .1598
Circuit diagram for outrigger solenoid 1599
Failure code [DWB2KB] – Outrigger sol.1 short circuit .1600
Circuit diagram related to 1st outrigger solenoid .1601
Failure code [DWB2KY] – Outrigger sol.1 hot short circuit .1602
Circuit diagram related to 1st outrigger solenoid .1603
Failure code [DWB3KA] – Outrigger sol.2 open circuit 1604
Circuit diagram related to 2nd outrigger solenoid .1605
Failure code [DWB3KB] – Outrigger sol.2 short circuit .1606
Circuit diagram related to 2nd outrigger solenoid .1607
Failure code [DWB3KY] – Outrigger sol.2 hot short circuit .1608
Circuit diagram related to 2nd outrigger solenoid .1609
Failure code [DWB4KA] – Outrigger sol.3 open circuit 1610
Circuit diagram related to 2nd outrigger solenoid .1611
Failure code [DWB4KB] – Outrigger sol.3 short circuit .1612
Circuit diagram related to 3rd outrigger solenoid .1613
Failure code [DWB4KY] – Outrigger sol.3 hot short circuit .1614
Circuit diagram related to 3rd outrigger solenoid .1615
Failure code [DWB5KA] – Outrigger sol.4 open circuit 1616
Circuit diagram related to 4th outrigger solenoid .1617
Failure code [DWB5KB] – Outrigger sol.4 short circuit .1618
Circuit diagram related to 4th outrigger solenoid .1619
Failure code [DWB5KY] – Outrigger sol.4 hot short circuit .1620
Circuit diagram related to 4th outrigger solenoid .1621
Failure code [DWK0KA] – 2-stage relief solenoid open circuit 1622
Circuit diagram related to 2-stage relief solenoid system .1623
Failure code [DWK0KB] – 2-stage relief solenoid short circuit .1624
Circuit diagram related to 2-stage relief solenoid system .1625
Failure code [DWK0KY] – 2-stage relief solenoid hot short circuit .1626
Circuit diagram related to 2-stage relief solenoid system .1627
Failure code [DWK2KA] – 2-stage back pressure solenoid open circuit .1628
Circuit diagram related to 2-stage back pressure solenoid .1629
Failure code [DWK2KB] – 2-stage back pressure solenoid short circuit 1630
Circuit diagram related to 2-stage back pressure solenoid .1631
Failure code [DWK2KY] – 2-stage back pressure solenoid hot short circuit 1632
Circuit diagram related to 2-stage back pressure solenoid .1633
Failure code [DWKSKA] – Boom float sol open circuit .1634
Circuit diagram related to boom float solenoid 1635
Failure code [DWKSKB] – Boom float sol short circuit 1636
Circuit diagram related to boom float solenoid 1637
Failure code [DWKSKY] – Boom float sol hot short circuit 1638
Circuit diagram related to boom float solenoid 1639
Failure code [DWMAKA] – Two piece boom suspension sol open circuit 1640
Circuit diagram related to two piece boom suspension solenoid .1641
Failure code [DWMAKB] – Two piece boom suspension sol short circuit .1642
Circuit diagram related to two piece boom suspension solenoid .1643
Failure code [DWMAKY] – Two piece boom suspension sol hot short circuit .1644
Circuit diagram related to two piece boom suspension solenoid .1645
Failure code [DWMBKA] – Work equipment PPC reduction solenoid open circuit 1646
Circuit diagram related to PPC reduction 1647
Failure code [DWMBKB] – Work equipment PPC reduction solenoid short circuit .1648
Circuit diagram related to PPC reduction 1649
Failure code [DWMBKY] – Work equipment PPC reduction solenoid hot short circuit .1650
Circuit diagram related to PPC reduction 1651
Failure code [DWMCKA] – Auxiliary hydraulic circuit 1 solenoid open circuit .1652
Circuit diagram related to Auxiliary hydraulic circuit 1 and 2 1652
Failure code [DWMCKB] – Auxiliary hydraulic circuit 1 solenoid short circuit 1653
Circuit diagram related to Auxiliary hydraulic circuit 1 and 2 1653
Failure code [DWMCKY] – Auxiliary hydraulic circuit 1 solenoid hot short circuit 1654
Circuit diagram related to Auxiliary hydraulic circuit 1 and 2 1655
Failure code [DWMDKB] – Auxiliary hydraulic circuit 2 solenoid short circuit 1656
Circuit diagram related to Auxiliary hydraulic circuit 1 and 2 1657
Failure code [DWMDKY] – Auxiliary hydraulic circuit 2 solenoid hot short circuit 1658
Circuit diagram related to Auxiliary hydraulic circuit 1 and 2 1659
Failure code [DWN5KA] – Fan clutch solenoid open circuit 1660
Circuit diagram related to fan clutch .1661
Failure code [DWN5KB] – Fan clutch solenoid short circuit .1662
Circuit diagram related to fan clutch .1663
Failure code [DWN5KY] – Fan clutch solenoid hot short circuit .1664
Circuit diagram related to fan clutch .1665
Failure code [DXA8KA] – Pump PC-EPC solenoid open circuit .1666
Circuit diagram related to PC-EPC solenoid system .1667
Failure code [DXA8KB] – Pump PC-EPC solenoid short circuit 1668
Circuit diagram related to PC-EPC solenoid system .1669
Failure code [DXE0KA] – LS-EPC solenoid open circuit 1670
Circuit diagram related to LS-EPC solenoid system .1671
Failure code [DXE0KB] – LS-EPC solenoid short circuit .1672
Circuit diagram related to LS-EPC solenoid system .1673
Failure code [DXE7KA] – Attachment flow regulating EPC 2 solenoid open circuit 1674
Circuit diagram related to ATT flow rate adjustment EPC .1675
Failure code [DXE7KB] – Attachment flow regulating EPC 2 solenoid short circuit .1676
Circuit diagram related to ATT flow rate adjustment EPC .1677
Failure code [DXE7KY] – Attachment flow regulating EPC 2 solenoid hot short circuit .1678
Circuit diagram related to ATT flow rate adjustment EPC .1679
Failure code [DXE8KA] – Attachment flow regulating EPC 3 solenoid open circuit 1680
Circuit diagram related to ATT flow rate adjustment EPC .1681
Failure code [DXE8KB] – Attachment flow regulating EPC 3 solenoid short circuit .1682
Circuit diagram related to ATT flow rate adjustment EPC .1683
Failure code [DXE8KY] – Attachment flow regulating EPC 3 solenoid hot short circuit .1684
Circuit diagram related to ATT flow rate adjustment EPC .1685
Failure code [DXE9KA] – Attachment flow regulating EPC 4 solenoid open circuit 1686
Circuit diagram related to ATT flow rate adjustment EPC .1687
Failure code [DXE9KB] – Attachment flow regulating EPC 4 solenoid short circuit .1688
Circuit diagram related to ATT flow rate adjustment EPC .1689
Failure code [DXE9KY] – Attachment flow regulating EPC 4 solenoid hot short circuit .1690
Circuit diagram related to ATT flow rate adjustment EPC .1691
Failure code [DXEAKA] – Attachment flow regulating EPC 5 solenoid open circuit 1692
Circuit diagram related to ATT flow rate adjustment EPC .1693
Failure code [DXEAKB] – Attachment flow regulating EPC 5 solenoid short circuit .1694
Circuit diagram related to ATT flow rate adjustment EPC .1695
Failure code [DXEAKY] – Attachment flow regulating EPC 5 solenoid hot short circuit .1696
Circuit diagram related to ATT flow rate adjustment EPC .1697
Failure code [DXEKKA] – Attachment variable press EPC1 open circuit .1698
Circuit diagram related to Attachment variable press EPC1 and 2 .1699
Failure code [DXEKKB] – Attachment variable press EPC1 short circuit 1700
Circuit diagram related to Attachment variable press EPC1 and 2 .1701
Failure code [DXEKKY] – Attachment variable press EPC1 hot short circuit 1702
Circuit diagram related to Attachment variable press EPC1 and 2 .1703
Failure code [DXELKA] – Attachment variable press EPC2 open circuit .1704
Circuit diagram related to Attachment variable press EPC1 and 2 .1705
Failure code [DXELKB] – Attachment variable press EPC2 short circuit 1706
Circuit diagram related to Attachment variable press EPC1 and 2 .1707
Failure code [DXELKY] – Attachment variable press EPC2 hot short circuit 1708
Circuit diagram related to Attachment variable press EPC1 and 2 .1709
Failure code [DXK3KA] – Travel pedal throttle EPC solenoid open circuit .1710
Failure code [DXK3KB] – Travel pedal throttle EPC solenoid short circuit 1711
Failure code [DY20KA] – Wiper motor open circuit 1712
Circuit diagram related to wiper 1713
Failure code [DY20MA] – Wiper motor defective function 1714
Circuit diagram related to wiper 1715
Failure code [DY2CKB] – Washer motor short circuit 1716
Circuit diagram related to windshield washer drive system .1717
Failure code [DY2DKB] – Wiper motor (normal rotation) short circuit .1718
Circuit diagram related to wiper 1719
Failure code [DY2EKB] – Wiper motor (reverse rotation) short circuit 1720
Circuit diagram related to wiper 1721
Failure code [F7FQKR] – CAN2 discon (ID Key Con) 1722
Circuit diagram (CAN2 communication) 1724
Failure code [F820KX] – Quick coupler LSC lock state analog signal over range .1726
Failure code [F821KX] – Quick coupler LSC system state analog signal over range .1727
Failure code [F822MA] – Quick coupler LSC system abnormality 1728
Troubleshooting of central lubrication system (CLS) .1729
Trouble .1729
Troubleshooting during grease pump operation 1731
Pump element 1732
Check power supply 1733
Changing the control unit .1733
Troubleshooting – grease system faults 1734
Venting of the system .1735
General assembly advice .1736
Troubleshooting of engine (S-mode) 1737
Information mentioned in troubleshooting table (S-mode) .1737
S-1 Engine does not crank when starting switch is turned to start position 1738
S-2 Engine cranks but no exhaust gas comes out 1739
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1740
S-4 Engine startability is poor .1741
S-5 Engine does not pick up smoothly 1743
S-6 Engine stops during operation .1745
S-7 Engine runs rough or is unstable 1746
S-8 Engine lacks power 1747
S-9 KDPF gets clogged in a short time .1749
S-10 Engine oil consumption is excessive 1750
S-11 Oil becomes contaminated quickly .1751
S-12 Fuel consumption is excessive 1752
S-13 Oil is in coolant (or coolant spurts back or coolant level goes down) 1753
S-14 Oil pressure drops .1754
S-15 Fuel mixes into engine oil .1755
S-16 Water mixes into engine oil (milky) 1756
S-17 Coolant temperature rises too high (overheating) .1757
S-18 Unusual noise is heard .1758
S-19 Vibration is excessive .1759
S-20 Air cannot be bled from fuel circuit .1760
S-21 Active regeneration is executed frequently .1761
S-22 Active regeneration takes time .1762
S-23 White smoke is exhausted during active regeneration 1763
S-24 AdBlue/DEF consumption is excessive 1764
S-25 There is unusual smell (irritating odor) .1765
S-26 Foreign materials enter AdBlue/DEF (AdBlue/DEF increases) 1766
DISASSEMBLY AND ASSEMBLY (preliminary version) 1767
FRONT AXLE 1767
Note 1768
Table of contents .1769
Preface .1771
General 1772
Examples of gear-tooth contact pattern for the Gleason gear-tooth system 1774
Conversion table 1778
Tightening torques for screws .1780
Special tools .1781
Commercial tools 1793
1. Disassembly steering .1798
2. Disassembly output .1801
2.1 Disassembly planetary carrier .1801
2.2 Disassembly brake .1802
2.3 Disassembly hub .1804
2.4 Disassembly knuckle housing .1805
2.5 Disassembly output assy .1807
3. Disassembly input 1808
4. Disassembly differential .1812
4.1 DZ-500 and D-500 1812
4.2 DZ-750 and D-750 1815
5. Reassembly differential 1817
5.1 DZ-500 and D-500 1817
5.2 DZ-750 and D-750 1821
6. Reassembly input .1825
6.1 Install input pinion 1825
6.1.1 Determine thickness of the shim to obtain a correct contact pattern .1825
6.1.2 Setting of rolling torque of the input pinion bearing .1827
6.2 Setting instructions for bevel gear set backlash and bearing rolling torque of the differential bearing .1829
6.2.1 Check of backlash pattern of the bevel gear set .1831
6.3 Mount shaft seal ring (input flange) 1833
7. Reassembly output 1834
7.1 Preassembly axle housing 1834
7.2 Reassembly knuckle housing 1835
7.3 Reassembly hub 1839
7.4 Reassembly disk brake .1841
7.4.1 Make leakage test of multi-disk brake .1844
7.4.2 Adjust and check piston stroke 1845
7.5 Reassembly planetary carrier 1847
7.6 Reassembly output assy 1848
7.7 Reassembly pivot bearing 1849
8. Reassembly steering 1850
8.1 Preassemble steering 1850
8.2 Mount steering 1853
8.3 Track setting and checking 1855
8.4 Steering angle setting 1856
8.5 Check leakage of steering .1857
REAR AXLE .1858
Note 1859
Table of contents .1860
Preface .1862
General .1863
Examples of gear-tooth contact pattern for the Gleason gear-tooth system 1865
Conversion table 1869
Denomination of standard dimensions .1870
Tightening torques for screws .1871
Special tools .1872
Commercial tools 1879
1. Disassembly of output 1884
1.1 Disassembly of planetary carrier 1884
1.2 Disassembly of brake 1885
1.3 Disassembly of hub 1887
1.4 Disassembly of output assy 1889
2. Disassembly of input .1890
2.1 Version with HL transmission 1890
2.2 Standard version 1892
3. Disassembly differential .1895
3.1 DZ-500 und D-500 1895
3.2 DZ-750 und D-750 1898
4. Reassembly differential .1900
4.1 DZ-500 und D-500 1900
4.2 DZ-750 und D-750 1904
5. Reassembly of input 1908
5.1 Version with HL-transmission 1908
5.1.1 Determination of shims for setting the bearing rolling torque (differential bearing) and the backlash (bevel gear set) 1908
5.2 Standard version (without HL transmission) 1913
5.2.1 Reinstallation of input pinion 1913
5.2.2 Adjust backlash of crown wheel set and bearing rolling torque of differential bearing .1916
5.2.3 Fitting of shaft seal ring (input flange) .1920
6. Reassembly of output .1921
6.1 Reassembly of hub carrier .1921
6.2 Reassembly of hub (Hub bearing SET-RIGHT) .1921
6.3 Reassembly of multi-disk brake 1924
6.3.1 Leakage test of multi-disk brake 1927
6.3.2 Adjustment and check of piston stroke .1928
6.4 Reassembly of planetary carrier .1929
6.5 Reassembly of output assy .1930
TRANSMISSION 1931
Note 1932
Table of contents .1933
Preface .1935
General 1936
Conversion table 1938
Denomination of standard dimensions .1939
Torque limits for screws 1940
Special tools .1941
Commercial tools 1950
1. Separate HL-Transmission from axle housing .1955
2. Disassembly – Brake/Clutch/Planetary carrier .1956
2.1 Lubrication pump and shift interlock 1956
2.1.1 Version “Lubrication pump” 1956
2.2 Speed sensor 1957
2.3 Emergency release (Parking Brake) .1957
2.4 Input housing and modulation valve 1958
2.5 Brake and clutch 1959
2.6 Planetary carrier .1965
3. Disassembly – Output .1968
3.1 Version “Axle attachment” .1968
3.2 Version “Separate Installation” .1972
4. Reassembly – Output 1975
4.1 Version “Axle attachment” .1975
4.1.1 Determine shim for pinion gap .1977
4.1.2 Determine adjusting ring for rolling torque/pinion bearing 1981
4.1.3 Check rolling torque of pinion bearing 1982
4.1.4 Shaft seal output flange 1983
4.1.5 Check the pinion gap 1984
4.2 Version “Separate installation” .1985
4.2.1 Shaft seal output flange 1988
5. Reassembly – Brake/Clutch/Planety carrier 1991
5.1 Planetary carrier .1991
5.2 Brake and clutch 1995
5.2.1 Disc components brake and clutch 1997
5.2.1.1 Version “HL-290” 1997
5.2.1.3 Version “HL-250” 1997
5.2.2 Adjust and check the disc clearance/piston stroke of brake and clutch .1999
5.3 Install modulation valve and input housing 2006
5.4 Emergency release (Parking brake) .2008
5.4.1 Check emergency release for leak tightness 2009
5.4.2 Check the multi-disk brake and multi-disc clutch for leak tightness as well as closing pressure .2010
5.5 Speed sensor 2011
5.6 Lubrication pump/shift interlock 2011
6. Disassembly – Lubrication pump/shift interlock and valve block .2013
6.1 Version “with” lubrication pump .2013
6.2 Version “with” hydr. shift interlock 2016
6.3 Disassembly valve block .2019
7. Reassembly Lubrication pump 2021
8. Reassembly shift interlock .2027
9. Valve block (shifting low gear – high gear) 2035
10. Mount HL-Transmission to axle .2036
MAINTENANCE STANDARD 2037
Abbreviation list .2038
List of abbreviations used in the text 2038
Engine and cooling system .2042
Maintenance standard of engine mount 2042
Maintenance standard of cooling system 2043
Power train .2045
Maintenance standard of swing circle 2045
Maintenance standard of swing machinery .2046
Axles .2047
Wheels/Tyres 2048
Gear box 2049
Prop shaft 2051
Orbitrol valve (STD/JSS) 2052
Trailer preparation .2053
Cabin mounting 2055
Hydraulic system 2058
Maintenance standard of hydraulic tank 2058
Main pump .2059
Maintenance standard of pilot valve .2060
Control valve .2061
Maintenance standard of anti-drop valve for 1. boom LH 2062
Maintenance standard of anti-drop valve for 1. boom RH 2064
Maintenance standard of anti-drop valve for 2. boom .2066
Maintenance standard of anti-drop valve for arm/bucket 2068
Maintenance standard of work equipment and swing PPC valve 2070
Solenoid valve block 2076
Swivel joint 2077
Work equipment 2078
Work equipment linkage 2078
1. Dimension of arm .2080
2. Dimension of bucket 2082
Hydraulic cylinder 2084
Boom cylinder .2084
Arm cylinder 2084
Bucket cylinder .2084
Adjust cylinder .2085
Appendix 2087
Abbreviation list .2090
List of abbreviations used in the text 2090
List of abbreviations used in the circuit diagrams 2094
Air conditioner system 2095
Precautions for refrigerant .2095
Air conditioner component .2096
Specifications of air conditioner .2098
Configuration and function of refrigeration cycle .2099
Outline of refrigeration cycle 2100
Component parts of air conditioner system .2102
Air conditioner unit 2102
Configuration diagram of air conditioner unit .2102
Component parts of air conditioner unit .2106
Function of evaporator as air conditioner unit component 2107
Function of heater core as air conditioner unit component .2107
Function of evaporator temperature sensor as air conditioner unit component .2107
Function of servo motor as air conditioner unit component .2107
Structure of expansion valve as air conditioner unit component 2108
Air conditioner controller 2110
Structure of air conditioner controller .2110
Compressor 2111
Structure of compressor .2111
Specifications of compressor 2111
Function of compressor 2111
Condenser .2112
Structure of condenser 2112
Specifications of condenser .2112
Function of condenser .2112
Sensors for air conditioner system 2114
Structure of sunlight sensor 2114
Function of sunlight sensor .2114
Structure of ambient temperature sensor .2114
Function of ambient temperature sensor 2115
Explanation of procedure for testing and troubleshooting of air conditioner .2116
Circuit diagram and arrangement of connector pins for air conditioner .2118
Air conditioner system diagram 2120
Input and output signals of air conditioner controller 2121
Function of air conditioner controller 2122
Installation locations of air conditioner parts and arrangement of connectors .2123
Fuses layout in the fuse boxes 2124
Air conditioner controller and connectors layout 2124
Air conditioner unit and connectors layout 2125
Sunlight sensor connectors layout .2125
Machine monitor connectors layout .2125
Dual pressure switch connectors layout 2125
Air conditioner compressor connectors layout 2126
Outside air temperature sensor connectors layout 2126
Testing air leakage (DUCT) 2127
Method for testing air leakage (DUCT) .2127
Testing air conditioner using self-diagnosis function .2129
How to open the electrical system abnormality record screen in service mode of the machine monitor 2130
Test vent (mode) changeover .2131
Testing FRESH/RECIRC air changeover .2133
Method for testing FRESH/RECIRC air changeover 2133
Test sunlight sensor 2134
Method for testing sunlight sensor 2134
Test (dual) pressure switch for refrigerant .2135
Method for testing (dual) pressure switch for refrigerant .2135
Test relays .2136
Method for testing relays .2136
Air conditioner troubleshooting chart 1 .2137
Air conditioner troubleshooting chart 2 .2138
Information described in troubleshooting table 2141
Failure code [879AKA] A/C recirculation air temperature sensor open circuit .2142
Failure code [879AKB] A/C recirculation air temperature sensor short circuit 2143
Failure code [879BKA] A/C fresh air temperature sensor open circuit .2144
Circuit diagram related to air conditioner fresh air temperature sensor .2145
Failure code [879BKB] A/C fresh air temperature sensor short circuit 2146
Circuit diagram related to air conditioner fresh air temperature sensor .2147
Failure code [879CKA] Ventilating sensor open circuit .2148
Failure code [879CKB] Ventilating sensor short circuit 2149
Failure code [879DKZ] Sunlight sensor open circuit or short circuit .2150
Circuit diagram related to sunlight sensor 2151
Failure code [879EMC] Ventilation damper malfunction 2152
Failure code [879FMC] Air mix damper malfunction 2153
Failure code [879GKX] Refrigerant pressure input signal out of range 2154
Circuit diagram related to refrigerant (dual) pressure switch .2155
A-1 Troubleshooting for power supply system (air conditioner does not operate) 2156
Circuit diagram related to air conditioner power supply .2157
A-2 Troubleshooting for compressor and refrigerant system (air is not cooled) .2159
Circuit diagram related to compressor and refrigerant system 2161
A-3 Troubleshooting for blower motor system (no air comes out or air flow is abnormal) 2162
Circuit diagram related to blower motor system 2163
A-4 Troubleshooting for FRESH/RECIRC air changeover .2164
Circuit diagram related to fresh/recirc air changeover 2165
Troubleshooting using gauge pressure 2166
Connection of service tool 2168
Method for connecting service tool 2169
Precautions for disconnection .2170
Precautions for connection 2171
Handle compressor oil .2172
Management of compressor oil (DENSO: ND-OIL8 for R134a) .2172
The quantity of compressor oil when the compressor is replaced 2172
Method for replacing desiccant 2174
Joystick Steering .2176
Overview of failure groups and descriptions .2176
Error handling 2178
1 Malfunction of Pump controller 2178
1.1 Joystick activation signals have the same value .2178
2 Malfunction of SASA-sensor 2178
2.1 CRC .2178
2.2 CAN Count .2178
2.3 CAN Timeout .2178
2.4 Sensor chip .2178
2.5 Steering angle 2178
2.6 CAN Input Message .2178
2.7 Power .2178
2.8 CPU .2178
2.9 Memory 2178
2.10 Temperature 2178
2.11 Angle Not Available (from CAN) .2178
2.12 RPM Not Available (from CAN) .2178
2.13 CAN Redundant 2178
2.14 Sensor .2178
2.15 RAM Corruption .2178
3 Malfunction of Hall-sensor 2179
3.1 Joystick signals out of range .2179
3.2 Joystick redundant signals mismatch .2179
3.3 Joystick out of neutral when activating steering system .2179
3.4 No signal available .2179
4 Malfunction of PVES (electrical activation) Orbitrol 2179
4.1 Steering valve feedback value out of range (beneath 25% UDC or above 75% UDC) .2179
4.2 Steering valve feedback (SP) value and control value (US) mismatch 2179
4.3 Error pin (C2p01) high signal, also indicated on PVES-SP LED: .2180
5 Wiring-failure 2180
5.1 Joystick signals out of range .2180
5.2 Joystick redundant signals mismatch .2180
5.3 Joystick Mode signals have the same value .2180
5.4 Cut Off valve current output and feedback mismatch 2180
5.5 Steering valve supply current output and feedback mismatch 2180
5.6 Steering valve control duty output and feedback mismatch 2180
5.7 Steering valve control 2180
5.8 Steering valve supply .2180
5.9 Steering valve failure signal .2180
5.10 Cut Off valve outputs 2180
5.11 Joystick mode switch reference .2180
5.12 Failure LED output .2180
5.13 Joystick mode inputs .2181
5.14 Joystick active inputs .2181
5.15 Joystick signals .2181
5.16 Steering valve failure signal input 2181
5.17 Steering valve position feedback input .2181
6 Miscellaneous .2181
6.1 CAN time out 2181
6.2 Joystick calibration failure 2181
6.3 SASA Sensor CAN Timeout .2181
6.4 CAN bus failure .2181
6.5 Bus Off .2181
6.6 Driver Error 2181
6.7 Passive Mode Error 2181
6.8 Overflow 2181
6.9 Joystick Mode signals have the same value .2181
6.10 Joystick steering profile parameters out of range 2181
7 Failure of SC024-120 2181
7.1 HWPCBVoltages.InRange .2181
7.2 OS.CrcStatus 2181
7.3 OS.ChecksumFailure 2181
7.4 SafetyLayer.Failure .2181
7.5 Battery power outside of allowable ranges .2181
7.6 Sensor power outside of specified ranges 2181
7.7 NVMem.Status 2182
8 Error descriptions 2184
8.1 Inputs 1 2184
8.2 Inputs 2 2187
8.3 Safety function 1 .2188
8.4 Outputs 1 .2189
8.5 Outputs 2 .2193
8.6 Joystick controller internal 2195
8.7 Error Counters Page 1 .2196
8.8 Error Counters Page 2 .2205
9 Acronyms 2210
OTHER .2211
Hydraulic circuit diagram .2215
Hydraulic circuit diagram (1/3) .2215
Hydraulic circuit diagram (2/3) .2217
Hydraulic circuit diagram (3/3) .2219
Wiring diagram 2221
Contents 2221
Contents 2222
1-0 Power Supply 2223
1-1 Grounding .2224
1-2 Model Select 2225
2-0 Engine PW180 2226
2-1 Engine PW180 2227
2-2 Engine Power Supply, Air Intake .2228
2-3 Engine Start 2229
2-4 2nd Engine Stop, Operating Lamp .2230
2-5 ADBlue/DEF Datalink .2231
2-6 ADDBlue/DPF Power .2232
3-0 Refueling System, Fuel Dial .2233
3-1 Brake .2234
3-2 EPC .2235
3-3 Cruise Control 2236
3-4 Travel 2237
3-5 SUS-Lock, Speed SNR, Joystick POTI 2238
3-6 Sensors Engine & Oil 2239
4-0 Quick Coupler, Pressure Sensor 2240
4-1 PPC Reduction, Floating, Pressure Sensor 2241
4-2 Swing Lock, Pressure Sensor, Joystick SW 2242
4-3 Bucket/2ATT switching .2243
5-0 Lower Attachments .2244
5-1 Roto-tilt .2245
5-2 Boom/Stabiliser, Auxilary Circuit, Breaker 2246
6-0 Road Light 2247
6-1 Indicator, Side Light, Stop Light .2248
6-2 Arm Marker Light + QC Signal Boom .2249
6-3 Beacon, Trailer (Opt) .2250
6-4 Worklamp 2251
6-5 Worklamp 2252
6-6 Camera SW, Service-con., Komnet .2253
6-7 Gateway Controller 2254
6-8 KomVision .2255
7-0 Air Condition, Heated Mirror 2256
7-1 Radio, 12V, Cigar Lighter, Room Lamp 2257
7-2 PPC-Lock, Starter Cut, Seat .2258
7-3 ID-Key 2259
7-4 Horn, Travel Alarm 2260
7-5 Wiper .2261
8-0 CLS .2262
9-0 Joystick Steering .2263
10-0 Fan Clutch, Tool Control .2264
11-0 ECSS .2265
12-0 Digging Brake 2266
Wiring Harness List W1-1 2267
Connector List W2-1 .2268
Connector List W2-2 .2269
Connector List W2-3 .2270
Connector List W2-4 .2271
Connector List W2-5 .2272
Connector List W2-6 .2273
Connector List W2-7 .2274
Pin Location List W3-1 2275
Pin Location List W3-2 2276
Pin Location List W3-3 2277
Pin Location List W3-4 2278
Pin Location List W3-5 2279
Pin Location List W3-6 2280
Pin Location List W3-7 2281
Pin Location List W3-8 2282
Pin Location List W3-9 2283
Pin Location List W3-10 .2284
Pin Location List W3-11 .2285
Pin Location List W3-12 .2286
Pin Location List W3-13 .2287
Pin Location List W3-14 .2288
Pin Location List W3-15 .2289
Pin Location List W3-16 .2290
Pin Location List W3-17 .2291
Pin Location List W3-18 .2292
Pin Location List W3-19 .2293
Pin Location List W3-20 .2294
Pin Location List W3-21 .2295
Pin Location List W3-22 .2296
Pin Location List W3-23 .2297
Pin Location List W3-24 .2298
Pin Location List W3-25 .2299
Pin Location List W3-26 .2300
Pin Location List W3-27 .2301
Pin Location List W3-28 .2302
Pin Location List W3-29 .2303
Pin Location List W3-30 .2304
Pin Location List W3-31 .2305
Pin Location List W3-32 .2306
Pin Location List W3-33 .2307
Pin Location List W3-34 .2308
Pin Location List W3-35 .2309
Pin Location List W3-36 .2310
Pin Location List W3-37 .2311
Pin Location List W3-38 .2312
Pin Location List W3-39 .2313
Pin Location List W3-40 .2314
Pin Location List W3-41 .2315
Pin Location List W3-42 .2316
Pin Location List W3-43 .2317
Parts List W4-1 .2318
Parts List W4-2 .2319
Parts List W4-3 .2320
Parts List W4-4 .2321
Parts List W4-5 .2322
Connector diagram .2323
Connector diagram 1/12 2323
Connector table for revolving frame harness 1 .2323
Connector diagram 2/12 2324
Connector table for revolving frame harness 2 .2324
Connector diagram 3/12 2325
Connector table for operator‘s cab wiring harness (Part 1/2) 2325
Connector diagram 4/12 2326
Connector table for operators cab wiring harness (Part 2/2) .2326
Connector diagram (5/12) 2327
Connector table switch group 2327
Connector diagram (6/12) 2328
Connector table steering 2328
Connector diagram (7/12) 2329
Connector table various wiring harness 2329
Connector diagram (8/12) 2330
Connector table optionally wiring harness (Part 1/3) 2330
Connector diagram (9/12) 2331
Connector table optionally wiring harness (Part 2/3) 2331
Connector diagram (10/12) .2332
Connector diagram (11/12) .2333
Connector diagram (12/12) .2334

DESCRIPTION:

Komatsu PW180-11E0 Wheeled Excavator Shop Manual VENBM70001 – PDF DOWNLOAD

• MACHINE MODEL                    SERIAL NUMBER
• PW180-11E0                              H75251 AND UP

General:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under- standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under- stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical Information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
General
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure. but also serves as reference material for troubleshooting.
Testing, adjusting and troubleshooting
This section explains checks to be made before and after per- forming repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
Disassembly and assembly
This section explains the order to be followed when removing. Installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standard
This section gives the judgement standards when Inspecting dis- assembled parts.

G.B 31/12/24