Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000

Shop Manual VENBM75000
Komatsu PW168-11E1 Excavator Shop Manual VENBM75000 PDF
PW168-11E1
MACHINE MODEL
PW168-11E1
SERIAL NUMBER
H68051 AND UP
• This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local Komatsu distributor for those items you may require.
• Materials and specifications are subject to change without notice.
• PW168-11E1 mount the SAA4D107E-5 engine.
• For details of the engine, see the 107 Series Engine Shop Manual.
© 2024
All Rights Reserved
Printed in Europe 2024-01
PW140-7 VEBM410101
Contents
Contents
00 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Abbreviation List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
Foreword, Safety, Basic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
How to Read the Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
Safety Notice for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
Preparations for Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
Precautions During Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
Hoisting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
Coating Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12
Standard Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14
Standard Tightening Torque of Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14
Tightening Torque of Hose Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
Tightening Torque of Split Flange Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type) . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15
Tightening Torque for 107 Engine Series (bolts and nuts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-16
Tightening Torque for 107 Engine Series (Eye Joints) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-16
Tightening Torque for 107 Engine Series (Tapered Screws). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-16
Electric Wire Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17
Classification by Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17
Classification by Color and Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-17
Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-18
Method of Using the Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-18
Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-24
01 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specification Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Working Range: 1-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fuel, Coolant, Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
10 Structure and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
UREA SCR System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Layout Drawing of UREA SCR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
UREA SCR System Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Component Parts of ATS System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
SCR Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
KDPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
BOOT-UP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Layout Drawing of BOOT-UP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
System Operating Lamp System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Engine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Layout Drawing of Engine System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
Auto-Deceleration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Engine Automatic Warm-up System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Overheat Prevention System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
Turbocharger Protection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
PW168-11E1 VENBM75000 TOC-1

Contents
Automatic Idle Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61

Component Parts of Engine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
Crankcase Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
Exhaust Throttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69
Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Engine Output Control System of Fan Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
Component Parts of Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Machine Monitor System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
KomVision System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
KOMTRAX System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Component Parts of Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
KomVision Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
Machine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
Machine Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PPC Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
Layout Drawing of Power Train System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
Component Parts of Power Train System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
Travel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
Swivel Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
Braking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-182
Power Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
Suspension Lock Cylinder (Axle Lock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-202
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
Swing Machinery & Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
Operation of Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
Relief Valve Portion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
Work Equipment – Swing PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-216
Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Calculation of Maximum Coupling Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Automatic Trailer Coupling for Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-219
Automatic Trailer Coupling for Outrigger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-223
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-228
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
Layout Drawing of Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
CLSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
Component Parts of Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235
Pilot Pressure Control (PPC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-258
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-260
Hydraulic Circuit Diagram and Name of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-275
Solenoid Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-291
ATT EPC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-293
2nd Auxiliary Circuit in the Undercarriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-323
Hydraulic Quick Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-325
Full Hydraulic Quick Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-328
ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330
Work Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-336
Dimension of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-338
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-340
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-346
Air Conditioner Component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-346
Specifications of Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-347
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-348
TOC-2 PW168-11E1 VENBM75000

Contents
Ambient Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350

Charge (Boost) Pressure and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-351
Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-352
Ne (Crankshaft) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-352
Bkup (Camshaft) Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-353
Common Rail Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-353
Exhaust manifold Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-354
TBAP Ambient Pressure and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-355
KDPF Differential Pressure and Outlet Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-356
KDOC Inlet Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-357
Engine Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-358
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-359
WIF (Water-In-Fuel Detection) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-360
Coolant Level Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-361
Hydraulic Oil Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
Air Cleaner Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-362
Overload Caution Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-363
Swing Proximity Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-364
Brake Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-364
Main Valve Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-367
Block Pressure Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-367
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-369
Auto-Grease Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-369
Lubrication Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-374
Additional Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-378
20 Standard Value Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Standard Value Table for Engine Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard Value Table for Chassis Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
PM Clinic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
30 Testing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Engine and Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Examine Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Examine Boost Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Examine Exhaust Gas Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
Examine and Adjust Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
Examine Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Examine Blowby Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Examine Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Examine Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
How to Examine Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
Examine Fuel Discharge, Return and Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
How to Examine Fuel Discharge, Return, and Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Bleed Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
Examine Fuel Circuit for Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Examine and Adjust Air Conditioner Compressor Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Replace the Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Examine cooling fan speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
Write Correction for Ash in Soot Accumulation to Engine Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Examine SCR Related Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
Examine DEF Pump Raised Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
How to Examine DEF Pump Raised Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
Examine Injection Volume from DEF Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
How to Examine Injection Volume from DEF Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
Examine DEF Line Heater Relay 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
How to Examine DEF Line Heater Relay 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Examine DEF Line Heater Relay 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Examine DEF Pump Heater Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63

Contents
Examine DEF Tank Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66

Examine SCR Denitration Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
Clean DEF Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
Bleed Air from Coolant Circuit of DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-77
Examine Swing Circle Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . . . . . . . . . . . . . . . . . . . . 30-80
Examine Oil Pressure of Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-84
Examine and Adjust Oil Pressure in Pump PC Control Circuit (Valve Inlet) . . . . . . . . . . . . . . . . . . . . . . . . . 30-86
Examine and Adjust Pump LS Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
How to Examine Solenoid Valve Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Adjust of Work Equipment and Swing PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
How to Examine Quick Coupler Control Valve Output Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-98
Examine Travel Motor Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
Examine Propshaft Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
Examine Transmission Clutch Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Examine Parts Which Cause Hydraulic Drift of Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
Release of Remaining Pressure in Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
Examine Oil Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
Air bleeding of various parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
Examine Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Set and Operate Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-115
Method for Starting up KOMTRAX Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
Examine and adjust ECSS (ACCU Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
Examine and Adjust Tool Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-214
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
Examine Lubrication Interval Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-224
How to Chang the Joystick Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
How to Adjust Digging Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
Procedure to Adjust Rearview Camera Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
Method for adjusting rear view camera angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
Adjust KomVision camera angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
How to Adjust Rearview Camera Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-232
Adjust KomVision Related Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
Setting of KomVision (main setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-233
Setting of KomVision (Camera Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
Setting of KomVision (Camera Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
40 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Related Information to Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
General Troubleshooting Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
Sequence of Events in Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-15
Connector table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
T-Branch Box and T-Branch Adapter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-75
Fuse Location Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-84
Failure Code Table (Display of Code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-88
Failure Code [2G00MA] – Brake Oil Pressure Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-127
Failure Code [602ENX] – Return Filter Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
Failure Code [6AZ0MA] – Quick Coupler System Defective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-129
Failure Code [6AZ0ZG] – Quick Coupler Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
Failure Code [6B2JMA] – Travel hydraulic abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132
Failure Code [879AKA] – A/C Recirculation Air Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . 40-133
Failure Code [879AKB] – A/C Inner Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
Failure Code [879BKA] – A/C Outer Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
Failure Code [879BKB] – A/C Outer Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
Failure Code [879CKA] – Ventilating Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
Failure Code [879CKB] – Ventilating Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-141
Failure Code [879DKZ] – Sunlight Sensor Open Or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142

Contents
Failure Code [879EMC] – Ventilation Damper Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144

Failure Code [879FMC] – Air Mix Damper Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-145
Failure Code [879GKX] – Refrigerant Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
Failure Code [989L00] – Engine Controller Lock Caution 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
Failure Code [989M00] – Engine Controller Lock Caution 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-149
Failure Code [989N00] – Engine Controller Lock Caution 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
Failure Code [A1U0N3] – HC Desorb Request 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-151
Failure Code [A1U0N4] – HC Desorb Request 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
Failure Code [A900FR] – Abrupt Engine Stop by Auto Idling Stop 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-153
Failure Code [A900N6] – Abrupt Engine Stop by Auto Idling Stop 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
Failure Code [A900NY] – Abrupt Engine Stop by Auto Idling Stop 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-155
Failure Code [AA10NX] – Air Cleaner Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156
Failure Code [AB00KE] – Charge Voltage Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
Failure Code [AQ10MB] – Manual Stationary Regeneration Request 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160
Failure Code [AQ10N3] – Manual Stationary Regeneration Request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-161
Failure Code [AS00R2] – Warning 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-162
Failure Code [AS00R3] – Inducement 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-163
Failure Code [AS00R6] – Temporary Recovery Of Inducement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
Failure Code [AS00ZK] – DEF Level Low Error 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-167
Failure Code [AS10KM] – DEF Injector Overheat Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
Failure Code [AS10NR] – DEF Injector High Temperature Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-169
Failure Code [AS10NT] – DEF Injector Overheat Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
Failure Code [B@BAZG] – Engine Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-171
Failure Code [B@BAZK] – Engine Oil Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
Failure Code [B@BCNS] – Engine Coolant Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-173
Failure Code [B@BCQA] – Engine Coolant Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
Failure Code [B@BCZK] – Engine Coolant Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
Failure Code [B@HANS] – Hydraulic Oil Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
Failure Code [CA115] – Engine Neutral and Backup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . 40-180
Failure Code [CA122] – Charge Air Press Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
Failure Code [CA123] – Charge Air Press Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
Failure Code [CA131] – Throttle Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
Failure Code [CA132] – Throttle Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
Failure Code [CA144] – Coolant Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
Failure Code [CA145] – Coolant Temperature Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
Failure Code [CA153] – Charge Air Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
Failure Code [CA154] – Charge Air Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
Failure Code [CA187] – Sensor 2 Supply Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
Failure Code [CA227] – Sensor 2 Supply Voltage High Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
Failure Code [CA234] – Engine Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202
Failure Code [CA238] – NE Speed Sensor Supply Voltage Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-203
Failure Code [CA239] – NE Speed Sensor Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
Failure Code [CA249] – Ambient Air Temp Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
Failure Code [CA256] – Ambient Air Temp Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
Failure Code [CA271] – PCV 1 Short Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210
Failure Code [CA272] – PCV 1 Open Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
Failure Code [CA322] – Injector #1 (L#1) Open Circuit Error or Short Circuit Error . . . . . . . . . . . . . . . . . . 40-214
Failure Code [CA343] – Engine Controller Internal Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
Failure Code [CA351] – Injectors Drive Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
Failure Code [CA352] – Sensor 1 Supply Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
Failure Code [CA386] – Sensor 1 Supply Voltage High Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226

Contents
Failure Code [CA428] – Water In Fuel Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228

Failure Code [CA429] – Water In Fuel Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
Failure Code [CA435] – Engine Oil Pressure SW Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
Failure Code [CA441] – Battery Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
Failure Code [CA442] – Battery Voltage High Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
Failure Code [CA451] – Common Rail Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
Failure Code [CA452] – Common Rail Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
Failure Code [CA488] – Charge Air Temperature High Torque Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-241
Failure Code [CA515] – Charge Air Temperature High Torque Derate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
Failure Code [CA516] – Common Rail Pressure Sensor Supply Voltage Low Error . . . . . . . . . . . . . . . . . . 40-244
Failure Code [CA553] – Common Rail Pressure High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-245
Failure Code [CA555] – Crankcase Pressure High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-246
Failure Code [CA556] – Crankcase Pressure High Error 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-247
Failure Code [CA559] – Common Rail Pressure Low Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
Failure Code [CA689] – Engine NE Speed Sensor Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
Failure Code [CA691] – Intake Air Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
Failure Code [CA692] – Intake Air Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
Failure Code [CA697] – Engine Controller Internal Temperature Sensor High Error . . . . . . . . . . . . . . . . . 40-256
Failure Code [CA698] – Engine Controller Internal Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . 40-257
Failure Code [CA731] – Engine Backup Speed Sensor Phase Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
Failure Code [CA741] – Compressor Inlet Press Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
Failure Code [CA742] – Compressor Inlet Press Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
Failure Code [CA743] – Compressor Inlet Press Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
Failure Code [CA778] – Engine Backup Speed Sensor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-265
Failure Code [CA1117] – Engine Controller Partial Data Lost Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
Failure Code [CA1664] – KDOC Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
Failure Code [CA1669] – DEF Level Sensor Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-274
Failure Code [CA1673] – DEF Level Low Error 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-275
Failure Code [CA1677] – DEF Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-276
Failure Code [CA1678] – DEF Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-277
Failure Code [CA1682] – DEF Pump Priming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-278
Failure Code [CA1683] – DEF Tank Heating Valve Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280
Failure Code [CA1684] – DEF Tank Heating Valve Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-282
Failure Code [CA1686] – DEF Quality Sensor Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-284
Failure Code [CA1695] – Sensor 5 Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-285
Failure Code [CA1696] – Sensor 5 Supply Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286
Failure Code [CA1712] – DEF Tank Thawing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-288
Failure Code [CA1713] – DEF Tank Heater Valve Open Stuck Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
Failure Code [CA1714] – DEF Quality Sensor Out Of Calibration Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
Failure Code [CA1715] – DEF Quality Sensor Internal Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-293
Failure Code [CA1776] – Sensor Supply Relay Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
Failure Code [CA1777] – Sensor Supply Relay Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
Failure Code [CA1843] – Crankcase Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
Failure Code [CA1844] – Crankcase Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
Failure Code [CA1879] – KDPF Differential Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
Failure Code [CA1881] – KDPF Differential Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
Failure Code [CA1883] – KDPF Differential Pressure Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . 40-306
Failure Code [CA1885] – Turbo Outlet NOx Sensor Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
Failure Code [CA1887] – SCR Outlet NOx Sensor Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
Failure Code [CA1921] – KDPF Soot Load High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
Failure Code [CA1922] – KDPF Soot Load High Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
Failure Code [CA1942] – Crankcase Pressure Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-319
Failure Code [CA1993] – KDPF Differential Pressure Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
Failure Code [CA2185] – Throttle Sensor Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
Failure Code [CA2186] – Throttle Sensor Supply Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
Failure Code [CA2311] – IMV Solenoid Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-325

Contents
Failure Code [CA2373] – Exhaust Manifold Pressure Sensor High Error. . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
Failure Code [CA2374] – Exhaust Manifold Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
Failure Code [CA2554] – Exhaust Manifold Pressure Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . 40-330
Failure Code [CA2555] – Intake Air Heater Relay Open Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
Failure Code [CA2556] – Intake Air Heater Relay Short Circuit Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
Failure Code [CA2637] – KDOC Face Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
Failure Code [CA2639] – Manual Stationary Regeneration Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
Failure Code [CA2771] – SCR Outlet NOx Sensor Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . 40-340
Failure Code [CA2973] – Charge Air Pressure Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-343
Failure Code [CA2976] – DEF Pump Temperature Sensor Signal Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
Failure Code [CA3133] – KDPF Outlet Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
Failure Code [CA3134] – KDPF Outlet Pressure Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
Failure Code [CA3135] – KDPF Outlet Pressure Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
Failure Code [CA3142] – SCR Temperature Sensor High Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
Failure Code [CA3143] – SCR Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-355
Failure Code [CA3144] – SCR Temperature Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
Failure Code [CA3146] – SCR Outlet Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
Failure Code [CA3147] – SCR Outlet Temperature Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-359
Failure Code [CA3148] – SCR Outlet Temperature Sensor In Range Error. . . . . . . . . . . . . . . . . . . . . . . . 40-360
Failure Code [CA3151] – SCR Catalyst Efficiency Low Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-362
Failure Code [CA3165] – SCR Outlet Temperature High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-368
Failure Code [CA3228] – Turbo Outlet NOx Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-370
Failure Code [CA3229] – SCR Temperature High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-372
Failure Code [CA3231] – SCR Temperature High Error Non Regeneration. . . . . . . . . . . . . . . . . . . . . . . . 40-374
Failure Code [CA3232] – Turbo Outlet NOx Sensor Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . 40-376
Failure Code [CA3235] – SCR Outlet Temperature High Error - Non Regeneration . . . . . . . . . . . . . . . . . 40-380
Failure Code [CA3239] – DEF Line Heater 2 Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-382
Failure Code [CA3241] – DEF Line Heater 2 Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-384
Failure Code [CA3242] – DEF Tank Heating Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386
Failure Code [CA3251] – KDOC Inlet Temperature High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388
Failure Code [CA3253] – KDOC Temperature Error - Non Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . 40-390
Failure Code [CA3254] – KDOC Outlet Temperature High Error 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-392
Failure Code [CA3255] – KDPF Temperature Error - Non Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . 40-394
Failure Code [CA3256] – KDPF Outlet Temperature High Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-396
Failure Code [CA3311] – KDOC Outlet Temperature High Error 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-398
Failure Code [CA3312] – KDPF Outlet Temperature High Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-400
Failure Code [CA3313] – KDOC Inlet Temperature Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-402
Failure Code [CA3314] – KDOC Inlet Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-403
Failure Code [CA3315] – KDOC Inlet Temperature Sensor In Range Error. . . . . . . . . . . . . . . . . . . . . . . . 40-404
Failure Code [CA3316] – KDOC Outlet Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-406
Failure Code [CA3317] – KDOC Outlet Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
Failure Code [CA3318] – KDOC Outlet Temperature Sensor In Range Error . . . . . . . . . . . . . . . . . . . . . . 40-408
Failure Code [CA3319] – KDPF Outlet Temp Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-410
Failure Code [CA3321] – KDPF Outlet Temperature Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-411
Failure Code [CA3322] – KDPF Outlet Temperature Sensor In Range Error. . . . . . . . . . . . . . . . . . . . . . . 40-412
Failure Code [CA3419] – MAF Sensor Supply Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-414
Failure Code [CA3421] – MAF Sensor Supply Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-416
Failure Code [CA3545] – SCR Outlet NOx Sensor Unstable Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-420
Failure Code [CA3558] – DEF Pump Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-424
Failure Code [CA3559] – DEF Pump Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-426
Failure Code [CA3562] – DEF Line Heater Relay 1 Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-428
Failure Code [CA3563] – DEF Line Heater Relay 1 Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-430
Failure Code [CA3567] – DEF Injector Open Circuit Error Or Short Circuit Error. . . . . . . . . . . . . . . . . . . . 40-432

Contents
Failure Code [CA3568] – DEF Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-435

Failure Code [CA3571] – DEF Pump Pressure Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-440
Failure Code [CA3572] – DEF Pump Pressure Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-442
Failure Code [CA3574] – DEF Pump Pressure Too Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-444
Failure Code [CA3575] – DEF Pump Pressure Too High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-446
Failure Code [CA3577] – DEF FCV Voltage High Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-448
Failure Code [CA3578] – DEF FCV Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-450
Failure Code [CA3583] – SCR Outlet NOx Sensor Heater Warming Up Error . . . . . . . . . . . . . . . . . . . . . . 40-452
Failure Code [CA3596] – DEF Pump Pressure Unstable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-454
Failure Code [CA3649] – Turbo Outlet NOx Sensor Heater Warming Up Error . . . . . . . . . . . . . . . . . . . . . 40-458
Failure Code [CA3681] – SCR Outlet NOx Sensor Power Voltage Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-460
Failure Code [CA3682] – Turbo Outlet NOx Sensor Power Voltage Error. . . . . . . . . . . . . . . . . . . . . . . . . . 40-465
Failure Code [CA3713] – DEF Line Heater 1 Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
Failure Code [CA3717] – SCR Outlet NOx Sensor Voltage Mismatch Error . . . . . . . . . . . . . . . . . . . . . . . . 40-472
Failure Code [CA3718] – Turbo Outlet NOx Sensor Voltage Mismatch Error . . . . . . . . . . . . . . . . . . . . . . . 40-473
Failure Code [CA3725] – Turbo Outlet NOx Sensor Unstable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-474
Failure Code [CA3741] – Rail Press Valve Trip Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476
Failure Code [CA3748] – Turbo Outlet NOx Sensor Stuck In Range Error . . . . . . . . . . . . . . . . . . . . . . . . . 40-478
Failure Code [CA3755] – DEF Dosing Performance Degradation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-480
Failure Code [CA3866] – DEF Low Concentration Error 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-482
Failure Code [CA3867] – DEF Low Concentration Error 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-486
Failure Code [CA3868] – DEF Tank Sensor Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-488
Failure Code [CA4151] – KDOC and KDPF Temperature Sensor Datalink Timeout Error . . . . . . . . . . . . . 40-491
Failure Code [CA4152] – SCR Temperature Sensor Datalink Timeout Error . . . . . . . . . . . . . . . . . . . . . . . 40-494
Failure Code [CA4155] – DEF Pump Heater Relay Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498
Failure Code [CA4156] – DEF Pump Heater Relay Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-500
Failure Code [CA4157] – DEF FCV Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-502
Failure Code [CA4158] – KDOC and KDPF Temperature Sensor Internal Circuit Error . . . . . . . . . . . . . . . 40-504
Failure Code [CA4159] – SCR Temperature Sensor Internal Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . 40-505
Failure Code [CA4161] – KDOC and KDPF Temperature Sensor ECU Voltage High Error . . . . . . . . . . . . 40-506
Failure Code [CA4162] – KDOC and KDPF Temperature Sensor ECU Voltage Low Error . . . . . . . . . . . . 40-508
Failure Code [CA4163] – KDOC and KDPF Temperature Sensor ECU Over Temperature Error. . . . . . . . 40-510
Failure Code [CA4164] – SCR Temperature Sensor ECU Voltage High Error . . . . . . . . . . . . . . . . . . . . . . 40-512
Failure Code [CA4165] – SCR Temperature Sensor ECU Voltage Low Error. . . . . . . . . . . . . . . . . . . . . . . 40-514
Failure Code [CA4166] – SCR Temperature Sensor ECU High Temperature Error . . . . . . . . . . . . . . . . . . 40-516
Failure Code [CA4168] – DEF Pump Heater ON Stuck Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-518
Failure Code [CA4169] – DEF Pump Heater OFF Stuck Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
Failure Code [CA4171] – DEF Pump Thawing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
Failure Code [CA4249] – DEF Pump Temperature Sensor 1 In Range Error . . . . . . . . . . . . . . . . . . . . . . . 40-524
Failure Code [CA4251] – DEF Pump Temperature Sensor 2 In Range Error . . . . . . . . . . . . . . . . . . . . . . . 40-526
Failure Code [CA4259] – KDOC and KDPF Temperature Sensor Power Interrupt Error . . . . . . . . . . . . . . 40-528
Failure Code [CA4261] – SCR Temperature Sensor Power Interrupt Error . . . . . . . . . . . . . . . . . . . . . . . . 40-530
Failure Code [CA4277] – DEF Quality Sensor Liquid Distinction Impossible Error . . . . . . . . . . . . . . . . . . . 40-534
Failure Code [CA4459] – DEF Line Heater Relay 2 Voltage High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-536
Failure Code [CA4461] – DEF Line Heater Relay 2 Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-538
Failure Code [CA4731] – DEF Temperature Sensor Transmission Data Error . . . . . . . . . . . . . . . . . . . . . . 40-540
Failure Code [CA4732] – DEF Level Sensor Transmission Data Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-541
Failure Code [CA4739] – DEF Level Sensor Internal Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-542
Failure Code [CA4768] – Fuel in DEF Tank Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544
Failure Code [CA4769] – DEF Level Measurement Impossible. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
Failure Code [CA4842] – DEF High Concentration Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-548
Failure Code [CA4952] – System Operating Lamp Short Circuit (Engine Controller) . . . . . . . . . . . . . . . . . 40-550
Failure Code [CA5115] – DEF Line Heater 1 Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-552
Failure Code [CA5179] – Engine Room Temperature Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-556
Failure Code [CA5181] – Engine Room Temperature Sensor Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . 40-558
Failure Code [CA5271] – Exhaust Throttle Valve Motor Driver Voltage High Error . . . . . . . . . . . . . . . . . . . 40-560

Contents
Failure Code [CA5272] – Exhaust Throttle Valve Motor Driver Voltage Low Error. . . . . . . . . . . . . . . . . . . 40-562
Failure Code [CA5273] – Exhaust Throttle Valve Motor Driver Open Error . . . . . . . . . . . . . . . . . . . . . . . . 40-564
Failure Code [CA5274] – Exhaust Throttle Valve Position Sensor In Range Error. . . . . . . . . . . . . . . . . . . 40-566
Failure Code [CA5275] – Exhaust Throttle Valve Position Sensor High Error . . . . . . . . . . . . . . . . . . . . . . 40-568
Failure Code [CA5276] – Exhaust Throttle Valve Position Sensor Low Error. . . . . . . . . . . . . . . . . . . . . . . 40-570
Failure Code [CA5383] – Ash Accumulation High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-572
Failure Code [CA5631] – Manual Stationary Regeneration Request (Automatic Regeneration Uncompleted) 40-573
Failure Code [CA5632] – Manual Stationary Regeneration Request but Regeneration Disable . . . . . . . . 40-574
Failure Code [CA5655] – SCR Catalyst Degradation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-575
Failure Code [CA5689] – SCR Outlet NOx Sensor Tamparing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580
Failure Code [CA5715] – KDPF Delta P Sensor In Range Dither Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-582
Failure Code [CA5716] – KDPF Outlet Press Sensor In Range Dither Error . . . . . . . . . . . . . . . . . . . . . . . 40-586
Failure Code [CA5838] – SCR Outlet NOx Sensor Self-Diag Stuck In-range Error . . . . . . . . . . . . . . . . . . 40-590
Failure Code [CA5864] – DEF Pump Short to Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-592
Failure Code [CA5865] – DEF Pump Short to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-594
Failure Code [CA5938] – Manual Stationary Regeneration Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-596
Failure Code [CA6513] – DEF Pump Thawing Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-597
Failure Code [CA6771] – Aftertreatment Tempe Sens Auto Defective Misconfiguration . . . . . . . . . . . . . . 40-598
Failure Code [D109KA] – ECSS Relay Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-602
Failure Code [D109KB] – ECSS Relay Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-604
Failure Code [D109KY] – ECSS Relay Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
Failure Code [D109MA] – ECSS Relay Defective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
Failure Code [D110KB] – Battery Relay Output Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-610
Failure Code [D19JKZ] – Personal Code Relay Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
Failure Code [D19QKB] – Short Circuit in Refuel Pump Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-614
Failure Code [D19QKY] – Hot Short Circuit in Refuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
Failure Code [D1EMKA] – Parking Brake Relay Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-618
Failure Code [D1EMKB] – Parking Brake Relay Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
Failure Code [D1EMKY] – Parking Brake Relay Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-622
Failure Code [D1EMMA] – Parking Brake Relay Defective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
Failure Code [D811MC] – KOMTRAX Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-626
Failure Code [D862KA] – GPS Antenna Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-627
Failure Code [D8ALKA] – System Operating Lamp Open Circuit (KOMTRAX) . . . . . . . . . . . . . . . . . . . . . 40-628
Failure Code [D8ALKB] – System Operating Lamp Short Circuit (KOMTRAX) . . . . . . . . . . . . . . . . . . . . . 40-630
Failure Code [D8AQKR] – CAN2 Discon (KOMTRAX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632
Failure Code [D8ARKR] – CAN1 Defective Communication (Gateway Controller) . . . . . . . . . . . . . . . . . . 40-636
Failure Code [D8G1KT] – Malfunction (Gateway Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
Failure Code [D8G6KT] – Malfunction (Communication Terminal). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
Failure Code [DA20MC] – Pump Controller Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-641
Failure Code [DA22KK] – Pump Solenoid Power Low Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-642
Failure Code [DA22KT] – Pump Controller Solenoid Power Controller Internal Failure . . . . . . . . . . . . . . . 40-644
Failure Code [DA25KP] – 5 V Sensor 1 Power Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-646
Failure Code [DA26KP] – 5 V Sensor 2 Power Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-648
Failure Code [DA27KP] – 24V Sensor Power Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-650
Failure Code [DA29KQ] – Model Selection Signal Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-652
Failure Code [DA2JKT] – Pump Controller Solenoid Return Circuit Controller Internal Failure . . . . . . . . . 40-654
Failure Code [DA2JKY] – Pump Controller Solenoid Return Circuit Hot Short Circuit . . . . . . . . . . . . . . . . 40-655
Failure Code [DA2LKA] – System Operating Lamp Open Circuit (Pump Controller System). . . . . . . . . . . 40-656
Failure Code [DA2LKB] – System Operating Lamp Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-658
Failure Code [DA2QKR] – Controller Area Network 2 Defective Communication . . . . . . . . . . . . . . . . . . . 40-660
Failure Code [DA2RKR] – Controller Area Network 1 Defective Communication. . . . . . . . . . . . . . . . . . . . 40-664
Failure Code [DA80KB] – Auto Grease System Monitoring Signal Short Circuit . . . . . . . . . . . . . . . . . . . . 40-668
Failure Code [DAB0KT] – Internal Flash Memory Error (Pump Controller System) . . . . . . . . . . . . . . . . . . 40-670
Failure Code [DAC3KB] – Cruise Control System Power Supply Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-672
Failure Code [DAC3KY] – Cruise Control System Power Supply Hot Short Circuit . . . . . . . . . . . . . . . . . . 40-674
Failure Code [DAF0KM] – Inconsistency of KomVision Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-676

Contents
Failure Code [DAF0MB] – Monitor ROM Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-676

Failure Code [DAF0MC] – Monitor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-677
Failure Code [DAF7KB] – Fuel Ref-Meter Power Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-678
Failure Code [DAF8KB] – Camera Power Supply Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-679
Failure Code [DAF9KQ] – Model Selection Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-681
Failure Code [DAFGMC] – GPS Module Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-682
Failure Code [DAFLKA] – System Operating Lamp Open Circuit (Monitor) . . . . . . . . . . . . . . . . . . . . . . . . 40-683
Failure Code [DAFLKB] – System Operating Lamp Short Circuit (Monitor). . . . . . . . . . . . . . . . . . . . . . . . . 40-686
Failure Code [DAFQKR] – CAN 2 Defective Communication (Monitor). . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-688
Failure Code [DAFSMC] – Fuel Ref-Meter Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-692
Failure Code [DAZ9KQ] – Model Selection Signal Mismatch (Air Conditioner) . . . . . . . . . . . . . . . . . . . . . . 40-693
Failure Code [DAZQKR] – CAN 2 Defective Communication (A/C ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-694
Failure Code [DB2QKR] – CAN2 Discon (Engine Con) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-697
Failure Code [DB2RKR] – CAN1 Discon (Engine Con) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-702
Failure Code [DB30KR] – Joystick Steering Controller Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-707
Failure Code [DBP0KM] – KomVision Setting Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-708
Failure Code [DBP0KT] – KomVision Controller Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-709
Failure Code [DBP5KB] – Camera Power Supply Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-710
Failure Code [DBP5KY] – Camera Power Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-712
Failure Code [DBPQKR] – CAN 2 Defective Communication (KomVision) . . . . . . . . . . . . . . . . . . . . . . . . . 40-714
Failure Code [DCS0KT] – Internal Flash Memory Error (Machine Controller System) . . . . . . . . . . . . . . . . 40-718
Failure Code [DCS0MC] – Machine Controller Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-719
Failure Code [DCS2KK] – Machine Controller Solenoid Power Voltage Low Error . . . . . . . . . . . . . . . . . . . 40-720
Failure Code [DCS2KT] – Machine Controller Solenoid Power Controller Internal Failure . . . . . . . . . . . . . 40-722
Failure Code [DCS5KP] – 5V Sensor 1 Power Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-724
Failure Code [DCS6KP] – 5V Sensor 2 Power Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-726
Failure Code [DCS7KP] – 24V Sensor Power Voltage Low Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-728
Failure Code [DCS9KQ] – Model Selection Signal Mismatch (Machine Controller) . . . . . . . . . . . . . . . . . . 40-730
Failure Code [DCSJKT] – Machine Controller Solenoid Return Circuit Controller Internal Failure . . . . . . . 40-732
Failure Code [DCSJKY] – Machine Controller Solenoid Return Circuit Hot Short Circuit . . . . . . . . . . . . . . 40-733
Failure Code [DCSLKA] – System Operating Lamp Open Circuit (Machine Controller) . . . . . . . . . . . . . . . 40-734
Failure Code [DCSLKB] – System Operating Lamp Short Circuit (Machine Controller) . . . . . . . . . . . . . . . 40-736
Failure Code [DCSQKR] – CAN 2 Defective Communication (Machine Controller) . . . . . . . . . . . . . . . . . . 40-738
Failure Code [DCSRKR] – CAN 1 Defective Communication (Machine Controller) . . . . . . . . . . . . . . . . . . 40-740
Failure Code [DDB6KA] – Parking Brake SW Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-742
Failure Code [DDB6KB] – Parking Brake SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-744
Failure Code [DDC4KA] – ECSS SW Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-746
Failure Code [DDC4KB] – ECSS SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-748
Failure Code [DDJ1KA] – Quick Coupler Inductive Sensor 1 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-750
Failure Code [DDJ2KA] – Quick Coupler Inductive Sensor 2 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-752
Failure Code [DDK8KA] – SUSLock Forced SW Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-754
Failure Code [DDK8KB] – SUSLock Forced SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-756
Failure Code [DDKVKA] – Joystick Steering Activation Sw Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-758
Failure Code [DDKVKB] – Joystick Steering Activation SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-759
Failure Code [DDNRKA] – W/E Lever Lock SW Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-760
Failure Code [DDNRKY] – W/E Lever Lock SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-762
Failure Code [DDNS00] – Lock Lever Auto Lock Release SW ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-764
Failure Code [DDP4KX] – Disconnection in Travel PPC Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 40-766
Failure Code [DDQ1KA] – SUSLock Mode Selection SW Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-768
Failure Code [DDQ1KB] – SUSLock Mode Selection SW Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-770
Failure Code [DDWCKZ] – Direction Switch Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-772
Failure Code [DDWMKZ] – FBR Attachment SW Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-774
Failure Code [DFB1KZ] – Service Lever Potentio 1 Open or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-776
Failure Code [DFB2KZ] – Service Lever Potentio 2 Open or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-778
Failure Code [DFB3L8] – Service Lever 1 Potentiometer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-780
Failure Code [DFB4L8] – Service Lever 2 Potentiometer Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-781
TOC-10 PW168-11E1 VENBM75000

Contents
Failure Code [DFB6KZ] – Service Lever Sub Potentio 2 Open or Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-784
Failure Code [DGH2KA] – Hydraulic Oil Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . 40-786
Failure Code [DGH2KB] – Hydraulic Oil Temperature Sensor Ground Fault . . . . . . . . . . . . . . . . . . . . . . . 40-788
Failure Code [DHA4KA] – Air Cleaner Clog Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-790
Failure Code [DHAAMA] – KDPF Differential Pressure Sensor Frozen . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-792
Failure Code [DHACMA] – KDPF Outlet Pressure Sensor Frozen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-793
Failure Code [DHH2MA] – Return Line Filter Press Sensor Abnormally . . . . . . . . . . . . . . . . . . . . . . . . . . 40-794
Failure Code [DHPAMA] – Front Pump Pressure Sensor Defective Function . . . . . . . . . . . . . . . . . . . . . . 40-796
Failure Code [DHS3MA] – Arm IN PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . . . . . . . 40-798
Failure Code [DHS4MA] – Bucket CURL PPC Pressure Sensor Defective Function. . . . . . . . . . . . . . . . . 40-800
Failure Code [DHS5KX] – Travel PPC Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-802
Failure Code [DHS8MA] – Boom RAISE PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . . 40-804
Failure Code [DHS9MA] – Boom LOWER PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . 40-806
Failure Code [DHSAMA] – Swing Right PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . . . 40-808
Failure Code [DHSBMA] – Swing Left PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . . . . 40-810
Failure Code [DHSCMA] – Arm OUT PPC Pressure Sensor Defective Function. . . . . . . . . . . . . . . . . . . . 40-812
Failure Code [DHSDMA] – Bucket DUMP PPC Pressure Sensor Defective Function . . . . . . . . . . . . . . . . 40-814
Failure Code [DHT8KA] – S/T Oil Pressure Sensor Open Circuit or Ground Fault . . . . . . . . . . . . . . . . . . 40-816
Failure Code [DHT8KB] – S/T Oil Pressure Sensor Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-818
Failure Code [DHT8ZG] – S/T Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-820
Failure Code [DHTFKA] – Service Brake Press Sensor 2 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-822
Failure Code [DHTFKY] – Service Brake Press Sensor 2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-824
Failure Code [DHTFL8] – Service Brake Press Sensor Defective Function . . . . . . . . . . . . . . . . . . . . . . . . 40-826
Failure Code [DHU1KA] – Brake Accumulator Press Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-828
Failure Code [DHU1KY] – Brake Accumulator Press Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . 40-830
Failure Code [DHUCKA] – Parking Brake Press Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-832
Failure Code [DHUCKY] – Parking Brake Press Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-834
Failure Code [DHUGKA] – Service Brake Press Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-836
Failure Code [DHUGKY] – Service Brake Press Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-838
Failure Code [DHX1MA] – Overload Sensor Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-840
Failure Code [DKULKA] – PPC Lock Relay Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-842
Failure Code [DKULKB] – PPC Lock Relay Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-844
Failure Code [DKULKY] – PPC Lock Relay Hot Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-846
Failure Code [DLM5KA] – Fan Speed Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-848
Failure Code [DLM5MB] – Fan Control: Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-850
Failure Code [DLT4KA] – Speed Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-852
Failure Code [DLT4KB] – Speed Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-854
Failure Code [DR10KA] – KomVision Camera Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-856
Failure Code [DR12KA] – Disconnection of Camera 1 NTSC Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-858
Failure Code [DR21KX] – Camera 2 Picture Rev. Drive Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-862
Failure Code [DR31KX] – Camera 3 Picture Reverse Drive Input Out of Range . . . . . . . . . . . . . . . . . . . . 40-866
Failure Code [DUMBKA] – Operating Lamp Open Circuit (KomVision) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-870
Failure Code [DUMBKB] – Operating Lamp Short Circuit (KomVision) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-872
Failure Code [DV00KA] – Buzzer Output Open Circuit (KomVision) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-874
Failure Code [DV00KB] – Buzzer Output Short Circuit (KomVision) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-875
Failure Code [DV20KB] – Travel Alarm Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-876
Failure Code [DW44KA] – Travel F/R Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-878
Failure Code [DW44KB] – Travel F/R Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-880
Failure Code [DW44KY] – Travel F/R Solenoid Hot Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-882
Failure Code [DW45KA] – Swing Parking Brake Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 40-884
Failure Code [DW45KB] – Swing Parking Brake Solenoid Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . 40-886
Failure Code [DW45KY] – Swing Parking Brake Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . 40-888
Failure Code [DW4AKA] – SUSLock Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-890
PW168-11E1 VENBM75000 TOC-11

Contents
Failure Code [DW4AKB] – SUSLock Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-892

Failure Code [DW4AKY] – SUSLock Sol Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-894
Failure Code [DW4BKA] – Parking Brake Sol Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-896
Failure Code [DW4BKB] – Parking Brake Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-898
Failure Code [DW4BKY] – Parking Brake Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-900
Failure Code [DW4CKY] – PPC Lock Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-902
Failure Code [DW4MKA] – Disconnection in Creep Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-904
Failure Code [DW4MKB] – Short Circuit in Creep Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-905
Failure Code [DW4MKY] – Hot Short Circuit in Creep Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-906
Failure Code [DW4YKA] – High Gear Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-908
Failure Code [DW4YKB] – High Gear Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-910
Failure Code [DW4YKY] – High Gear Sol Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-912
Failure Code [DW4ZKA] – Low Gear Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-914
Failure Code [DW4ZKB] – Low Gear Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-916
Failure Code [DW4ZKY] – Low Gear Sol Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-918
Failure Code [DW91KA] – Travel Neutral Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-920
Failure Code [DW91KB] – Travel Neutral Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-922
Failure Code [DW91KY] – Travel Neutral Sol Hot Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-924
Failure Code [DWA2KA] – Attachment Single or 2-Way Change Solenoid Open Circuit (Breaker Mode Relay) . 40-926
Failure Code [DWA2KB] – Attachment Single or 2-Way Change Solenoid Short Circuit (Breaker Mode Relay) . 40-928
Failure Code [DWA2KY] – Attachment Single or 2-Way Change Solenoid Hot Short Circuit (Breaker Mode Relay)40-930
Failure Code [DWB1KA] – Outrigger Selection Sol Relay Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-932
Failure Code [DWB1KB] – Outrigger Selection Sol Relay Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-934
Failure Code [DWB2KA] – Disconnection in 1st Outrigger Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-936
Failure Code [DWB2KB] – Outrigger Sol.1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-938
Failure Code [DWB2KY] – Outrigger Sol.1 Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-940
Failure Code [DWB3KA] – Outrigger Sol.2 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-942
Failure Code [DWK0KA] – 2-Stage Relief Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-960
Failure Code [DWK0KB] – 2-Stage Relief Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-962
Failure Code [DWK0KY] – 2-Stage Relief Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-964
Failure Code [DWK2KA] – Variable Back Pressure Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-966
Failure Code [DWK2KB] – Variable Back Pressure Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-968
Failure Code [DWK2KY] – Variable Back Pressure Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-970
Failure Code [DWKSKA] – Boom Float Sol Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-972
Failure Code [DWKSKB] – Boom Float Sol Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-974
Failure Code [DWKSKY] – Boom Float Sol Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-976
Failure Code [DWMBKA] – Work Equipment PPC Reduction Solenoid Open Circuit . . . . . . . . . . . . . . . . . 40-978
Failure Code [DWMBKB] – Work Equipment PPC Reduction Solenoid Short Circuit . . . . . . . . . . . . . . . . . 40-980
Failure Code [DWMBKY] – Work Equipment PPC Reduction Solenoid Hot Short Circuit . . . . . . . . . . . . . . 40-982
Failure Code [DWMCKA] – Auxiliary Hydraulic Circuit 1 Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . 40-984
Failure Code [DWMCKB] – Auxiliary Hydraulic Circuit 1 Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-986
Failure Code [DWMCKY] – Auxiliary Hydraulic Circuit 1 Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . 40-988
Failure Code [DWMDKB] – Auxiliary Hydraulic Circuit 2 Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . 40-990
Failure Code [DWMDKY] – Auxiliary Hydraulic Circuit 2 Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . 40-992
Failure Code [DWN5KA] – Fan Clutch Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-994
Failure Code [DWN5KB] – Fan Clutch Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-996
Failure Code [DWN5KY] – Fan Clutch Solenoid Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-998
Failure Code [DXA8KA] – Pump PC-EPC Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1000
TOC-12 PW168-11E1 VENBM75000

Contents
Failure Code [DXA8KB] – Pump PC-EPC Solenoid Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1002

Failure Code [DXE0KA] – LS-EPC Solenoid Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1004
Failure Code [DXE0KB] – LS-EPC Solenoid Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1006
Failure Code [DXE7KA] – Attachment Flow Regulating EPC 2 Solenoid Open Circuit . . . . . . . . . . . . . . 40-1008
Failure Code [DXE7KB] – Attachment Flow Regulating EPC 2 Solenoid Short Circuit . . . . . . . . . . . . . . 40-1010
Failure Code [DXE7KY] – Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit . . . . . . . . . . . 40-1012
Failure Code [DXEAKA] – Attachment Flow Regulating EPC 5 Solenoid Open Circuit . . . . . . . . . . . . . . 40-1026
Failure Code [DXEAKB] – Attachment Flow Regulating EPC 5 Solenoid Short Circuit . . . . . . . . . . . . . . 40-1028
Failure Code [DXEAKY] – Attachment Flow Regulating EPC 5 Solenoid Hot Short Circuit . . . . . . . . . . . 40-1030
Failure Code [DXEKKA] – Attachment Variable Press EPC1 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . 40-1032
Failure Code [DXEKKB] – Attachment Variable Press EPC1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . . 40-1034
Failure Code [DXEKKY] – Attachment Variable Press EPC1 Hot Short Circuit . . . . . . . . . . . . . . . . . . . . 40-1036
Failure Code [DXELKA] – Attachment Variable Press EPC2 Open Circuit . . . . . . . . . . . . . . . . . . . . . . . 40-1038
Failure Code [DXELKB] – Attachment Variable Press EPC2 Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . 40-1040
Failure Code [DXELKY] – Attachment Variable Press EPC2 Hot Short Circuit . . . . . . . . . . . . . . . . . . . . 40-1042
Failure Code [DXK3KA] – Travel Pedal Throttle EPC Solenoid Open Circuit. . . . . . . . . . . . . . . . . . . . . . 40-1044
Failure Code [DXK3KB] – Travel Pedal Throttle EPC Solenoid Short Circuit. . . . . . . . . . . . . . . . . . . . . . 40-1045
Failure Code [DY20KA] – Wiper Motor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1046
Failure Code [DY20MA] – Wiper Motor Defective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1048
Failure Code [DY2CKB] – Washer Motor Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1050
Failure Code [DY2DKB] – Wiper Motor (Normal Rotation) Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-1052
Failure Code [DY2EKB] – Wiper Motor (Reverse Rotation) Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 40-1054
Failure Code [F311KA] – Centralized Warning Lamp Signal 1 Open Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1056
Failure Code [F311KB] – Centralized Warning Lamp Signal 1 Short Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1058
Failure Code [F312KA] – Centralized Warning Lamp Signal 2 Open Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1060
Failure Code [F312KB] – Centralized Warning Lamp Signal 2 Short Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1062
Failure Code [F313KA] – Communication Terminal Startup Signal Open Circuit . . . . . . . . . . . . . . . . . . . 40-1064
Failure Code [F313KB] – Communication Terminal Startup Signal Short Circuit . . . . . . . . . . . . . . . . . . . 40-1066
Failure Code [F314KA] – Software Update Signal Open Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1068
Failure Code [F314KB] – Software Update Signal Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1070
Failure Code [F315KA] – Engine Controller WAKE Signal Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-1072
Failure Code [F315KB] – Engine Controller WAKE Signal Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . 40-1074
Failure Code [F315KY] – Engine Controller WAKE Signal Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1076
Failure Code [F316KA] – 3rd Party Component Startup Signal Open Circuit. . . . . . . . . . . . . . . . . . . . . . 40-1078
Failure Code [F316KB] – 3rd Party Component Startup Signal Short Circuit . . . . . . . . . . . . . . . . . . . . . . 40-1080
Failure Code [F316KY] – 3rd Party Component Startup Signal Hot Short Circuit . . . . . . . . . . . . . . . . . . 40-1082
Failure Code [F318KB] – Communication Terminal Power Supply 1 Short Circuit. . . . . . . . . . . . . . . . . . 40-1084
Failure Code [F318KY] – Communication Terminal Power Supply 1 Hot Short Circuit . . . . . . . . . . . . . . 40-1086
Failure Code [F31AKB] – Ethernet Power Supply Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1088
Failure Code [F31AKY] – Ethernet Power Supply Hot Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1090
Failure Code [F31BKB] – 5V Sensor Power Supply Short Circuit (Gateway Controller) . . . . . . . . . . . . . 40-1092
Failure Code [F31BKY] – 5V Sensor Power Supply Hot Short Circuit (Gateway Controller) . . . . . . . . . . 40-1094
Failure Code [F31CKB] – 12V Sensor Power Supply Short Circuit (Gateway Controller) . . . . . . . . . . . . 40-1096
Failure Code [F31CKY] – 12V Sensor Power Supply Hot Short Circuit (Gateway Controller) . . . . . . . . . 40-1098
Failure Code [F31DKB] – 24V Sensor Power Supply Short Circuit (Gateway Controller) . . . . . . . . . . . . 40-1100
Failure Code [F31DKY] – 24V Sensor Power Supply Hot Short Circuit (Gateway Controller) . . . . . . . . . 40-1102
Failure Code [F31EKB] – 24V Sensor Power Supply Booster Output Short Circuit (Gateway Controller) 40-1104
Failure Code [F31EKY] – 24V Sensor Power Supply Booster Output Hot Short Circuit (Gateway Controller)40-1106
Failure Code [F7FQKR] – CAN2 Discon (ID Key Con) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1108
Failure Code [F7G0MC] – ID Key Receiving Antenna Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1112
PW168-11E1 VENBM75000 TOC-13

Contents
Troubleshooting of Central Lubrication System (CLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1113

Troubleshooting of Engine (S-Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1121
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position . . . . . . . . . . . . . . . . . . . . . 40-1122
S-2 Engine Cranks but No Exhaust Smoke Comes Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1123
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start). . . . . . . . . 40-1124
S-4 Engine Startability is Unsatisfactory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1125
S-5 Engine Does Not Pick Up Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1127
S-6 Engine Stops During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1129
S-7 Engine Runs Rough or is Not Stable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1130
S-8 Engine Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1131
S-9 Exhaust Smoke is Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1133
S-10 Engine Oil Consumption Is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1134
S-11 Oil Becomes Dirty Quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1135
S-12 Fuel Consumption Is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1136
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) . . . . . . . . . . . . . . . . . . . . . 40-1137
S-14 Oil Pressure Drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1138
S-15 Fuel Mixes into Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1139
S-16 Water Mixes into Engine Oil (Milky). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1140
S-17 Coolant Temperature Rises Too High (Overheating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1141
S-18 Unusual Noise is Heard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1142
S-19 Vibration is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1143
S-20 Air Cannot be Bled from Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1144
S-21 Active Regeneration is Executed Frequently. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1145
S-22 Active Regeneration Takes Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1146
S-23 White Smoke is Exhausted During Active Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1147
S-24 DEF Consumption is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1148
S-25 There is Unusual Smell (Irritating Odor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1149
S-26 Foreign Materials Enter DEF (DEF Increases) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1150
60 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Engine and Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Maintenance Standard of Engine Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Maintenance Standard of Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-3
Power Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Maintenance Standard of Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-5
Maintenance Standard of Swing Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-6
Axles and Prop Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-7
Orbitrol Valve (STD/JSS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-8
Trailer Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10
Cabin Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-12
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15
Maintenance Standard of Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15
Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16
Maintenance Standard of LS-EPC valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17
Maintenance Standard of PC-EPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19
Maintenance Standard of Anti-Drop Valve for 1. Boom LH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20
Maintenance Standard of Anti-Drop Valve for 1. Boom RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22
Maintenance Standard of Anti-Drop Valve for 2. Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24
Maintenance Standard of Anti-Drop Valve for Arm/Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26
Maintenance Standard of Work Equipment and Swing PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28
Solenoid Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-34
Work Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-36
Work Equipment Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-36
Dimension of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-38
Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40
Boom Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40
Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40
TOC-14 PW168-11E1 VENBM75000

Contents
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40

Adjust Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41
Outrigger Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-42
Dozer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-44
Bellow Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-46
80 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Precautions Before Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
Air Conditioner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Precautions for Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-5
Air Conditioner Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-6
Specifications of Air Conditioner Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-8
Outline of Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10
Component parts of Air Conditioner System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Air Conditioner Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Component Parts of Air Conditioner Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-15
Air Conditioner Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-19
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-21
Air Conditioner Related Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-23
Function of Sunlight Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-23
Explanation of Procedure for Testing and Troubleshooting of Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . 80-25
Circuit Diagram and Configuration of Connector Pins of Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-27
System Diagram of Air Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-29
Input and Output Signals of Air Conditioner Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30
Locations of Air Conditioner Parts and Layout of Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-32
Examine Air Leakage (Duct) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-36
How to Examine Air Leakage (Duct) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-36
Examine Air Conditioner with Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-38
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor . . . . . . . . . . 80-39
Examine vent (mode) Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40
Examine FRESH/RECIRC Air Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-42
How to Examine FRESH/RECIRC Air Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-42
Examine Sunlight Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-43
How to Examine Sunlight Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-43
Examine Refrigerant (Dual) Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-44
How to Examine (Dual) Pressure Switch for Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-44
Test Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-45
How to Examine Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-45
Air Conditioner Troubleshooting Chart 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-46
Air Conditioner Troubleshooting Chart 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-47
Information Shown in Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50
Failure Code [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . 80-51
Failure Code [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . 80-52
Failure Code [879BKA] A/C Fresh Air Temperature Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 80-53
Failure Code [879BKB] A/C Fresh Air Temperature Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 80-55
Failure Code [879CKA] Ventilating Sensor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-57
Failure Code [879CKB] Ventilating Sensor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-58
Failure Code [879DKZ] Sunlight Sensor Open Circuit or Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-59
Failure Code [879EMC] Ventilation Damper Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-61
Failure Code [879FMC] Air Mix Damper Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-62
Failure Code [879GKX] Refrigerant Pressure Input Signal Out of Range . . . . . . . . . . . . . . . . . . . . . . . . . . 80-63
A-1 Troubleshooting for Power Supply System (Air Conditioner Does not Operate) . . . . . . . . . . . . . . . . . . 80-65
A-2 Troubleshooting for Compressor and Refrigerant System (Air is not Cooled) . . . . . . . . . . . . . . . . . . . . 80-68
A-3 Troubleshooting for Blower Motor System (no Air comes out or Air Flow is Abnormal). . . . . . . . . . . . . 80-71
A-4 Troubleshooting for FRESH/RECIRC Air Changeover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-73
Troubleshooting by Gauge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-75
Connect Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-77
PW168-11E1 VENBM75000 TOC-15

Contents
How to Connect Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-78

Precautions for Disconnection and Connection of Air Conditioner Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-79
Handle Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-81
How to Replace Desiccant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-83
Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-85
Overview of Failure Groups and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-85
Error Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-87
90 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
Hydraulic Circuit Diagram (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-12
1-0 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
1-1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-14
1-2 Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
2-0 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-16
2-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
2-2 Engine Power Supply, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
2-3 Engine Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
2-4 2nd Engine Stop, Operating Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-20
2-5 DEF Datalink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
2-6 ADDBlue/DPF power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-22
3-0 Refueling System, Fuel Dial. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
3-1 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-24
3-2 EPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
3-3 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-26
3-4 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
3-5 SUS-Lock, Speed Snr, Joystick POTI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-28
3-6 Sensors Engine & Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
4-0 Quick Coupler, Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-30
4-1 PPC Reduction, Floating, Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
4-2 Swing Lock, Pressure Sensor, Joystick SW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-32
4-3 Bucket/2ATT Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
5-0 Lower Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-34
5-1 Roto-Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
5-2 Boom/Stabiliser, Auxilary Circuit, Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-36
6-0 Road Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
6-1 Indicator, Side Light, Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-38
6-2 Arm Marker Light & QC Signal Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39
6-3 Beacon, Trailer (Opt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-40
6-4 Worklamp Revo Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
6-5 Worklamp Revo Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-42
6-6 Worklamp on Cabin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
6-7 Camera SW, Service-Con., KOMNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-44
6-8 GATEWAY Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
6-9 KomVision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-46
7-0 Air Condition, Heated Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
7-1 Radio, 12V Socket, Cigar Lighter, Room Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-48
7-2 PPC-Lock, Starter Cut, Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
7-3 ID-key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-50
7-4 Horn, Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-51
7-5 Wiper, Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-52
8-0 CLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
9-0 Joystick Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-54
10-0 Fan Clutch, Tool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
TOC-16 PW168-11E1 VENBM75000

Contents
11-0 ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-56

12-0 Digging Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
Wiring Harness List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-58
Connector List W2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
Connector List W2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-60
Connector List W2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-61
Connector List W2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-62
Connector List W2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-63
Connector List W2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-64
Connector List W2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-65
Connector List W2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-66
Pin Location List W3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-67
Pin Location List W3-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-76
Pin Location List W3-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100
PW168-11E1 VENBM75000 TOC-17

Contents

Parts List W4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-115
Parts List W4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-116
Parts List W4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-117
Parts List W4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-118
Parts List W4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-119
Connector Diagram 1/12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-121
Revolving Frame Harness 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-121
Revolving Frame Harness 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-122
Operator‘s Cab Wiring Harness (Part 1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-123
Operators Cab Wiring Harness (Part 2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-124
Connector Diagram (5/12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-125
Connector Table Switch Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-125
Connector Table Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-126
Connector Table Various Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-127
Connector Table Optionally Wiring Harness (Part 1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-128
Connector Diagram (10/12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-130
Brake Valve A., Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-132
TOC-18 PW168-11E1 VENBM75000

00 Foreword
Abbreviation List
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the
manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of Abbreviations Used in the Text
Purpose of use (major

Abbrevia-
Actual word spelled out applicable machine (*1), Explanation
tion
or component/system)
When the tires skid (wheels stop rotating), the brakes are
Travel and brake
ABS Anti-skid Brake System released, and when the wheels start to rotate, the brakes
(HD, HM)
are applied again.
Automatic Idling Set-
AISS ting Engine This function automatically sets the idle speed.
A lever is used to perform the steering operations instead

Advanced Joystick Steering
AJSS of a steering wheel. Moreover, it shifts gear and changes
Steering System (WA)
direction (FORWARD or REVERSE).
When the accelerator pedal is released while the machine
Automatic Retarder Travel and brake
ARAC is traveling downhill, this function automatically applies the
Accelerator Control (HD, HM)
retarder with a constant braking force.
When the accelerator pedal is released while the machine
Automatic Retarder Travel and brake is traveling downhill, this function automatically applies the
ARSC
Speed Control (HD, HM) retarder to ensure that the machine speed does not accel-
erate above the speed set by the operator.
When the tires spin on soft ground surfaces, this function
Automatic Spin Regu- Travel and brake
ASR automatically uses the optimum braking force to drive both
lator (HD, HM)
wheels.
Exhaust gas aftertreat-
ATS After-treatment System A device to clean the exhaust gas.
ment system
A device that can be fixed onto the standard machine in

ATT Attachment Work equipment
order to enable it to do different jobs.
When the retarder is not being used, this valve bypasses

Brake cooling oil con- Brake
BCV part of the brake cooling oil to reduce the load on the
trol valve (HD)
hydraulic pump.
Controller Area Net- Communication and elec- One of communication standards that is used in the net-
CAN
work tronic control work on the machine.
A regulator valve which is installed to KCCV ventilator. It is

Crankcase Depression
CDR Engine written as CDR valve and it is not
Regulator
used independently.
This system can simultaneously actuate multiple actuators
Closed-center Load
CLSS Hydraulic system regardless of the load (provides better combined operation
Sensing System
than OLSS).
PW168-11E1 VENBM75000 00-1

Abbreviation List Foreword

Abbrevia-
tion
Engine controller electronically controls supply pump, com-
CRI Common Rail Injection Engine mon rail, and injector. This function maintains optimum fuel
injection amount and fuel injection timing.
Electronic control device uses the signals from the sensors

Electronic Control
ECM Electronic control system on the machine. These signals indicate the optimum actua-
Module
tion to the actuators. (Same as ECU)
Proportional electromagnetic valve that gradually increases

Electronic Control Transmission
ECMV oil pressure to engage clutch and reduces transmission
Modulation Valve (D, HD, WA, etc)
shock.
Electronically Con- This system ensures smooth high-speed travel by absorb-

Travel
ECSS trolled ing vibration of machine during travel with hydraulic spring
(WA)
Suspension System effect of accumulator.
Electronic control device uses the signals from the sensors

ECU Electronic Control Unit Electronic control system on the machine. These signals indicate the optimum actua-
tion to the actuators. (Same as ECM)
This function recirculates part of exhaust gas to combustion

Exhaust Gas Recircu-
EGR Engine chamber in order to reduce combustion temperature, con-
lation
trols emission of NOx.
This system allows data (filter, oil replacement interval, mal-

Equipment Manage-
functions on machine, failure code,
EMMS ment Monitoring Sys- Machine monitor
and failure history) from each sensor on the machine to
tem
be checked on the monitor.
Electromagnetic Pro- This mechanism allows actuators to be operated in propor-

EPC Hydraulic system
portional Control tion to the current supplied.
Falling Object Protec- This structure protects the operator's head from falling
FOPS tive Cab and canopy objects.
Structure This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- Global Positioning System: This system uses satellites to
GPS (KOMTRAX, KOMTRAX
tem determine the current location on the earth.
Plus)
Communication Global Navigation Satellite System: This system uses sat-

Global Navigation Sat-
GNSS (KOMTRAX, KOMTRAX ellites such as GPS, GALILEO, etc. to determine the cur-
ellite System
Plus) rent location on the earth.
This function uses a combination of hydraulic motor and

Hydrostatic Steering Steering bevel shaft to control difference in travel speed of right and
HSS
System (D) left tracks. Accordingly machine can turn without using
steering clutch.
This function uses a combination of hydraulic pump and

Hydro Static Transmis- Transmission
HST hydraulic motor for stepless shifting of the speed range
sion (D, WA)
without using gears.
Information and Com- Communication and elec- A general term for the engineering and its socially applied
ICT
munication Technology tronic control technology of information processing and communication.
00-2 PW168-11E1 VENBM75000

Foreword Abbreviation List

Abbrevia-
tion
This valve is installed at inlet port of pump, and it adjusts

IMA Inlet Metering Actuator Engine fuel intake amount in order to control fuel discharged vol-
ume of supply pump. (Same as IMV)
Inertial Measurement This is a device to detect the angle (or angular velocity) and
IMU Engine
Unit acceleration of the 3 axes that control motions.
This valve is installed at inlet port of pump, and it adjusts

IMV Inlet Metering Valve Engine fuel intake amount in order to control fuel discharged vol-
ume of supply pump. (Same as IMA)
This mechanism separates oil in blowby gas and returns it

Komatsu Closed
KCCV Engine to the intake side to combust it there. It primarily consists of
Crank- case Ventilation
filters.
Komatsu Catalyzed This filter captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
Komatsu Diesel Oxida- The catalyst is used for purifying exhaust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muffler.
This component is used to purify the exhaust gas. KDOC

Komatsu Diesel Partic-
KDPF Engine (catalyst) and KCSF (filter to capture soot) are built-in it.
ulate Filter
It is installed in place of the conventional muffler.
This function recovers the drive force of the wheels by

braking automatically with the optimum force and at the
Komatsu Traction Con- Travel and brake
KTCS same time activates the inter-axle differential lock when the
trol System (HM)
wheels idle while the machine travels on the soft ground
road.
Image display equipment such as a monitor which assem-
LCD Liquid Crystal Display Machine monitor
bles in the liquid crystal element.
It refers to semiconductor element that emits light when the

LED Light Emitting Diode Electronic parts
voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- One of communication standards that is used in the net-
LIN
work tronic control work on the machine.
Function that detects differential pressure of pump and con-

LS Load Sensing Hydraulic system
trols discharged volume corresponding to load.
Low Voltage Differen- Communication and elec- One of communication standards that is used in the net-
LVDS tial tronic control work on the machine.
This indicates engine intake air flow. It is not used inde-

MAF Mass Air Flow Engine pendently but it is used as combined with sensor. Mass air
flow sensor can be called as MAF sensor.
Service that allows transmission and reception of short

Multimedia Messaging
MMS Communication messages consisting of characters or voice or images
Service
between cell phones.
Characteristics of electrical or hydraulic circuits. Circuit is

Electrical system,
NC Normally Closed normally closed if it is not actuated, and it opens when it is
Hydraulic system
actuated.
PW168-11E1 VENBM75000 00-3

Abbreviation List Foreword

Abbrevia-
tion
Characteristics of electrical or hydraulic circuits. Circuit is
Electrical system,
NO Normally Open normally open if it is not actuated, and it closes when it is
Hydraulic system
actuated.
Open-center Load Hydraulic system that can operate multiple actuators at the
OLSS Hydraulic system
Sensing System same time, regardless of the load.
PC Pressure Compensa- Hydraulic system A function used to correct oil pressure.
System in which a controller instantly analyses data from

Palm command con- Steering
PCCS each lever, pedal, and dial, and performs optimum elec-
trol system (D)
tronic control of the engine and transmission.
This valve is installed at inlet port of pump and it adjusts

Pre-stroke Control
PCV Engine fuel intake amount in order to control fuel discharged vol-
Valve
ume of supply pump.
Proportional Pressure This system is used for controlling proportional pressure. It

PPC Hydraulic system
Control moves actuators in proportion to the oil pressure.
Piston Pump and Hydraulic system

PPM Piston type hydraulic pump and motor.
Motor (D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism.
Power Tilt and power Work equipment This function performs hydraulic control of the tilt and pitch
PTP
Pitch dozer (D) of the bulldozer blade.
If a machine tips over, this structure protects the operator

Roll-Over Protective wearing a seatbelt from being crushed. (Operator Protec-
ROPS Cab and canopy
Structure tive structure when tipping)
This performance is standardized as ISO 3471.
It is exhaust gas purifier using urea water converts nitro-

gen oxides (NOx) to harmless nitrogen and water by oxi-
Selective Catalytic Re-
SCR Urea SCR system dation-reduction reaction. It may also be mentioned as
duction
exhaust gas purification catalyst or part of the name of
related devices.
Le Systeme Interna- Abbreviation for "Le Systeme International d' Uni- tes". It is
SI tional d' Unites (Inter- Unit the universal unit system and "a single unit for a single
national unit system) quantity" is the basic principle applied.
It refers to an actuator consisting of a solenoid and an iron

SOL Solenoid Electrical system core that is moved by the magnetic force when the solenoid
is energized.
TWV 2-Way Valve Hydraulic system Solenoid valve that switches over direction of flow.
*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
00-4 PW168-11E1 VENBM75000

Foreword Abbreviation List
List of Abbreviations Used in the Circuit Diagrams
Abbreviation Actual word spelled out

A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
PW168-11E1 VENBM75000 00-5

Foreword, Safety, Basic Information Foreword
Foreword, Safety, Basic Information
How to Read the Shop Manual

• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in ac-
cordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps
Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors
installed to the product show “DEF” as “DEF” in the service mode. Thus, be sure to recognize that “DEF” and
“DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the same
as the terminology in the shop manual.
00-6 PW168-11E1 VENBM75000

Foreword Foreword, Safety, Basic Information
Composition of the Shop Manual

This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword

This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function

This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshoot-
ing.
20 Standard Value Table

This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting

This section describes the measuring tools and measuring methods for testing and adjusting as well as the ad-
justing method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. De-
scriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly

This section describes the special tools, work procedures, and safety precautions necessary for removal, installa-
tion, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
PW168-11E1 VENBM75000 00-7

Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark

This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.

This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.

This signal indicates a potentially hazardous situation which will result in injury
Caution
or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
4 Weight requires great attention to a selection of wires and working posture for slinging
work.
This signal indicates the tightening torque for portions which requires special
3 Tightening torque
care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in

2 Coat
assembling work.
5 Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.
6 Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal Word
Signal word for notice and remark describes the following.
Symbol Item Remark

If the precaution of this signal word is not observed, the machine damage or
NOTICE Notice
shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.
Safety Notice for Operation

Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the
servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
The symbol mark is indicated for such matters that require special precautions. The work indicated with this
warning mark should be performed according to the instructions with special attention. Should a hazardous
situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary meas-
ures.
00-8 PW168-11E1 VENBM75000

Foreword Foreword, Safety, Basic Information
Safety Considerations
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General Precautions
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to
the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
• Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting any step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in
their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smoking. Never smoke while working.
Preparations for Work

1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks
to prevent the machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not pos-
sible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
PW168-11E1 VENBM75000 00-9

4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is im-
possible to use the handrails, ladders or steps, use a stand to provide safe footing.
Precautions During Work

1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to pre-
vent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for
the oil and water to cool before carrying out any work on the oil or water circuits.
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) ter-
minal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free
from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the cor-
rect places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do
not work with any part still raised by the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two
bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause elec-
trical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up im-
mediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when
washing electrical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when
the machine is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so
be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are
correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective
parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check
that they are installed correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a
hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
00-10 PW168-11E1 VENBM75000

FOREWORD Hoisting Instructions
Hoisting Instructions
Hoisting
Heavy parts (25kg or more) must be lift-

ed with a hoist, etc. In the DISASSEM-
BLY AND ASSEMBLY section, every
part weigthing 25 kg or more is indicat- 4 100% 88% 79% 71% 41%
ed clearly with the symbol: SAD00479
5. Do not sling a heavy load with one rope alone,

If a part cannot be smoothly removed from the ma- but sling with two or more ropes symmetrically
chine by hoisting, the following checks should be wound on to the load
made:
1. Check for removal of all bolts fastening the part

to the relative parts. Slinging with one rope may cause turning of the
load during hoisting, untwisting of the rope, or
2. Check for existence of another part causing in- slipping of the rope from its original winding po-
terface with the part to be removed. sition on the load, which can result in a danger-
ous accident
Wire Ropes
3. Use adequate ropes depending on the weight of 6. Do not sling a heavy load with ropes forming a
parts to be hoisted, referring to the table below: wide hanging angle from the hook. When hoist-
ing a load with two or more ropes, the force sub-
Wire ropes jected to each rope will increase with the hanging
(Standard “Z” or “S” twist ropes without galvanizing) angles. The table below shows the variation of
Rope diameter Allowable load allowable load (kg) when hoisting is made with
mm kN tons two ropes, each of which is allowed to sling up to
10 9.8 1.0 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to
11.2 13.7 1.4
2000 kg of total weight can be suspended. This
12.5 15.7 1.6
weight becomes 1000 kg when two ropes make
14 21.6 2.2 a 120° hanging angle. On the other hand, two
16 27.5 2.8 ropes are subject to an excessive force as large
18 35.3 3.6 as 4000 kg if they sling a 2000 kg load at a lifting
20 43.1 4.4 angle of 150°.
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
The allowable load value is estimated to be 1/6

or 1/7 of the breaking strength of the rope used.
4. Sling wire ropes from the middle portion of the

hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during hoist-
ing, and a serious accident can result. Hooks
have maximum strength at the middle portion
PW168-11E1 VENBM75000 00-11

Coating Materials FOREWORD
Coating Materials
The recommended coating shop manuals are listed be-
materials prescribed in the low.
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber cush-

LT-1A 790-129-9030 150 g Tube
ions and cork plugs from coming out
• Used in places requiring an immediately effec-
tive, strong adhesive.
20 g Polyethylene
LT-1B 790-129-9050 • Used for plastics (except polyethylene, polypro-
(2 pes.) container
pylene, tetrafluoroethylene, and vinyl chloride),
rubber, metal and non-metal.
• Features: Resistance to heat, chemicals

Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant purposes
container
for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass or
LT-3 Hardening Can
and hardening plastic.
agent:
agent)
500 g
Adhesives
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing en-
790-126-9120 75 g Tube
MH 705 gine.
• Quick hardening type adhesive.

Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 50 g
container • Used mainly for adhesion of metals, rubbers,
1735
plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30 min-
Polyethylene
alpha 790-129-9130 2g utes).
container
201 • Used mainly for adhesion of rubbers, plastics
and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tempera-
648-50 container
ture.
• Used as adhesive or sealant for gaskets and

LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
• Features: Resistance to heat
sealant
Gasket
• Used as sealant for flange surfaces and bolts at

high temperature locations; used to prevent sei-
LG-3 790-129-9070 1 kg Can zure.
• Used as sealant for heat resistant gasket for at
high temperature locations such as engine pre-
combustion chamber, exhaust pipe.
00-12 PW168-11E1 VENBM75000

FOREWORD Coating Materials
Category Code Part No. Quantity Container Main applications, features
• Features: Resistance to water, oil

• Used as sealant for flange surface, thread.
• Also possible to use as sealant for flanges with
LG-4 790-129-9020 200 g Tube
large clearance.
• Used as sealant for mating surfaces of final
drive case, transmission case.
• Used as sealant for various threads, pipe joints,

Polyethylene flanges.
LG-5 790-129-9080 1 kg
container • Used as sealant for tapered plugs, elbows, nip-
sealant
Gasket
ples of hydraulic piping.
• Features: Silicon based, resistant to heat, cold.

LG-6 09940-00011 250 g Tube • Used as sealant for flange surface, thread.
• Used as sealant for oil pan, final drive case, etc.
• Features: Silicon based, quick hardening type.

LG-7 09920-00150 150 g Tube • Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
• Used as heat-resisting sealant for repairing en-
bond 790-129-9090 100 g Tube
gines.
1211
• Used as lubricant for sliding parts (to prevent

LM-G 09940-00051 60 g Can
Molybdenum
disulphide
squeaking).
lubricant
• Used to prevent seizure or scuffing of the thread

LM-P 09940-00040 200 g Tube when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
• Used for normal temperature, light load bearing
G2-CA SYG2-400CA-A Various Various
Grease
at places in contact with water or steam.

SYG2-160CA
SYG2-160CNCA
disulphide lubricant
Molybdenum
400 g
SYG2-400M Belows type • Used for places with heavy load.
(10 per case)
PW168-11E1 VENBM75000 00-13

Standard Tightening Torque FOREWORD
Standard Tightening Torque
Standard Tightening Torque of Bolts and

Nuts
The following charts give the standard tightening torques of bolts
and nuts. Exceptions are given in DISASSEMBLY AND ASSEM-
BLY.
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 13.2 ± 1.4 1.35 ± 0.15
8 13 31.4 ± 2.9 3.20 ± 0.3
10 17 65.7 ± 6.8 6.70 ± 0.7
12 19 112 ± 9.8 11.5 ± 1.0
14 22 177 ± 19 18 ± 2.0
16 24 279 ± 29 28.5 ± 3
18 27 383 ± 39 39 ± 4
20 30 549 ± 58 56 ± 6
22 32 745 ± 78 76 ± 8
24 36 927 ± 98 94.5 ± 10
27 41 1320 ± 140 135 ± 15

30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30

39 60 3280 ± 340 335 ± 35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5

10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-14 PW168-11E1 VENBM75000

FOREWORD Standard Tightening Torque
Tightening Torque of Hose Nuts

Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
Tightening Torque of Split Flange Bolts

Use these torques for split flange bolts.
Thread diameter Width across flat Tightening torque

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
Tightening Torques for Hoses (Taper Seal Type and Face Seal Type)
• Unless there are special instructions, tighten the hoses (ta-
per the hoses (taper seal type and face seal type) to the
torque below.
• Apply the following torque when the threads are coated

(wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Nominal No. -
Width Thread
No. of Number of
across flat Range Target Thread size (mm) diameter (mm)
hose threads, type of
(Referenced)
thread
34 - 54 {3.5 - 5.5} - 9/16 - 18UN 14.3
02 19 44 {4.5}
34 - 63 {3.5 - 6.5} 14 - -
22 54 - 93 {5.5 - 9.5} 74 {7.5} - 11/16 - 16UN 17.5
03
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 - -
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 13/16 - 16UN 20.6
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 - 3/16 - 12UN 30.2
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 - -
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 - -
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 - -
PW168-11E1 VENBM75000 00-15

Standard Tightening Torque FOREWORD
Tightening Torque for 107 Engine Series

(bolts and nuts)
• Unless there are special instructions, tighten the metric bolts
and nuts of the 107 engine series to the torque below.
Thread diameter Tightening torque
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8±2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20

12 77 ± 12 7.85 ± 1.22 24 ± 2 2.45 ± 0.41
14 - - 36 ± 5 3.67 ± 0.51

(Eye Joints)
Use these torque values for eye joints (unit: mm).
mm Nm kgm
6 8±2 0.81 ± 0.20

8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

(Tapered Screws)
Use these torque values for tapered screws (unit: inch).

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
00-16 PW168-11E1 VENBM75000

FOREWORD Electric Wire Code
Electric Wire Code

In the wiring diagrams, various colors and symbols are em-
ployed to indicate the thickness of wires. This wire code table
will help you understand WIRING DIAGRAMS.
EXAMPLE:
05WB indicates a cable having a nominal number 05 and white
coating with black stripe.
Classification by Thickness
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of Cross sec- Applicable circuit
number (mm) rating (A)
strands strand (mm) tion (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting
Classification by Color and Code

Prior- Circuits
Charging Ground Starting Lighting Instrument Signal Other
ity Classification
Code W B B R Y G L
Primary
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
PW168-11E1 VENBM75000 00-17

Conversion Tables FOREWORD
Conversion Tables
Method of Using the Conversion Table

The Conversion Table in this section is provided to enable sim-
ple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from milli-

meters to inches.
1. Convert 55 mm into inches.
a. Locate the number 50 in the vertical column at the left

side, take this as (1), then draw a horizontal line from
(1).
b. Locate the number 5 in the row across the top, take this
as (2), then draw a perpendicular line down from (2).
c. Take the point where the two lines cross as (3). This
point (3) gives the value when converting from millime-
ters to inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
a. The number 550 does not appear in the table, so divide

by 10 (move the decimal one place to the left) to convert
it to 55 mm.
b. Carry out the same procedure as above to convert 55

mm to 2.165 inches.
c. The original value (550 mm) was divided by 10, so multi-

ply 2.165 inches by 10 (move the decimal one place to
the right) to return to the original value. This gives 550
mm = 21.65 inches.
(2)
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(3)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(1)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-18 PW168-11E1 VENBM75000

FOREWORD Conversion Tables
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
PW168-11E1 VENBM75000 00-19

Litre to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Litre to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-20 PW168-11E1 VENBM75000

kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
PW168-11E1 VENBM75000 00-21

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-22 PW168-11E1 VENBM75000

Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a
Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the
center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is
desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures
and read the corresponding Centigrade temperature in the col-
umn at the left. If it is desired to convert from Centigrade to Fahr-
enheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit tem-
perature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PW168-11E1 VENBM75000 00-23

Units FOREWORD
Units
In this manual, the measuring units are indicated with Interna-
tional System of units (SI).
As for reference, conventionally used Gravitational System of

units are indicated in parentheses { }.
Example
• N {kg}
• Nm {kgm}
• MPa {kg/cm²}
• kPa {mmH2O}
• kPa {mmHg}
• kw/rpm {HP/rpm}
• g/kwh {g/HPh}
00-24 PW168-11E1 VENBM75000

01 SPECIFICATION
Specification Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Weight Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
2-Piece Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fuel, Coolant, Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
PW168-11E1 VENBM75000 01-1

Specification Dimension Drawings Specification
Specification Dimension Drawings
Dimensions
Value will vary depending on attachment specification.
The values in the following tables refer to a machine with bucket without quick coupler.
Description 2.55 m axle 2.75 m axle
A Overall length (Driving position)

B Overall height (Driving position)
See next page
C Overall length (Transport position)
D Overall height (Transport position)
Radius of upper structure 1850 mm
E
Radius of tail structure 1850 mm
F Front and rear track 1942 mm 2142 mm
G Overall width 2550 mm 2750 mm
H Height of cabin (without option) 3110 mm
I Overall width of upper structure 2490 mm
J Ground clearance 463 mm (Transmission 378mm)
K Wheel base 2600 mm
L Height bottom edge counterweight 1240 mm
M Additional length (outrigger) 570 mm
M1 Additional length (outrigger with trailer hitch) 820 mm
N Additional length (blade) 507 mm
N1 Additional length (blade with trailer hitch) 703 mm
01-2 PW168-11E1 VENBM75000

Specification Specification Dimension Drawings
1-piece boom 2-piece boom

Arm Drive position Transport position Drive position Transport position
A (mm) B (mm) C (mm) D (mm) A (mm) B (mm) C (mm) D (mm)
2.1m 7676 3905 8034 3078 5890 3949 7880 2710
2.5 m 7676 3905 8034 3078 6031 3999 7900 2791
3.0 m 7777 3847 8037 3078 6115 3949 7890 3005
PW168-11E1 VENBM75000 01-3

Working Ranges Specification
Working Ranges
Working Range: 1-Piece Boom

Arm length (mm) 2100 2500 3000

A Max. digging height 8764 8972 9319
B Max. dumping height 6439 6653 6968
C Max. digging depth 4884 5269 5719
D Min. swing radius 3097 3060 3108
E Max. digging reach at ground level (GL) 8517 8894 9383
F Max. digging reach 8698 9065 9553
* 1316 mm. The length between the arm pin and the bucket cutting edge varies depending on the attachment.
01-4 PW168-11E1 VENBM75000

Specification Working Ranges
Working Range: 2-Piece Boom

Arm length (mm) 2100 2500 3000

A Max. digging height 9613 9912 10360
B Max. dumping height 7034 7335 7766
C Max. digging depth 5062 5455 5963
D Min. swing radius 2329 2423 2698
E Max. digging reach GL 8324 8774 9259
F Max. digging reach 8593 8969 9473
* 1316 mm. The length between the arm pin and the bucket cutting edge varies depending on the attachment.
PW168-11E1 VENBM75000 01-5

Specifications
Mono boom Two-piece boom

Arm Undercarriage attachment type
Axle 2.55 m Axle 2.75 m Axle 2.55 m Axle 2.75 m
Without 15721 15768 15980 16027
Front or rear blade 16468 16535 16727 16794
Front and rear blade 17215 17302 17474 17561
2.1 m
Front or rear outrigger 16763 16896 17022 17155
Outriggers and blade 17510 17663 17769 17922
4 outriggers 17805 18024 18064 18283
Without 15773 15820 16032 16079
2.5 m
4 outriggers 17857 18076 18116 18335
Without 15897 15944 16156 16203
3.0 m
4 outriggers 17981 18200 18240 18459
Weight will vary depending on specification
Weight with Tire 10.00-20 16PR NB38 MITAS
 Operator (75 kg)

 Operating fluids
 Filled fuel tank
 Bucket (475 kg) without quick coupler
01-6 PW168-11E1 VENBM75000

Specification Working Ranges
Performance PW168-11E1
Bucket capacity (standard bucket) SAE 0.64 m³

Engine model KOMATSU SAA4D107E-5 diesel engine
110 kW / 2000 rpm (ISO 14396)
Engine power
106 kW / 2000 rpm (ISO 9249)
Creep speed 2.5 km/h
Low speed 10 km/h
Travel speed
35 km/h
High speed
20 km/h
Swing speed 11.5 rpm
Starting motor 24 V, 4.5 kW
Alternator 24 V, 85 A
Battery 12 V, 125Ah x 2
PW168-11E1 VENBM75000 01-7

Machine model PW168-11E1
Serial Number H68051 and up
Model SAA4D107E-5
Type 4-cylinder, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger
No. of cylinders - bore x stroke mm 4 - 107 x 124
Piston displacement l {cc} 4.5 {4458}
Flywheel horsepower kW/rpm 110.3/2000

Performance
Max. torque Nm/rpm 640/1500

Engine
Max. speed at no load rpm 2060

Min. speed at no load rpm 1050
Starting motor 24V, 4.5 kW

Alternator 24V, 85 A
Battery 12V, 125 Ah x 2
Radiator core type Triple Cooler

Hydraulic
Type HPV125 (140), variable swash plate

pump
Delivery l/min
Set pressure MPa (kg/cm²) Piston type: 34.8 {355}
1-Piece Boom 6-spool + 2 service spool type

Control
Type
valve
Control method 2-Piece Boom 7-spool + 2 service spool type
Travel motor A6VM140 HAXT/63W-VZB388H-S, Piston type

Hydraulic
(with counter balance valve)

motor
Swing motor MSF 85P, Piston type

(with safety valve, holding brake)
Type Boom Arm Bucket
L.H. R.H.
Double acting Double acting
1-Piece Boom
Double acting piston piston

Hydraulic system
piston
Inside diameter of cylinder mm 115 115 105

Diameter of piston rod mm 75 80 70
Stroke mm 964 1175 885
Hydraulic cylinder
Max. distance between pins mm 2518 2877 2263

Min. distance between pins mm 1554 1702 1378
Type Adjust Boom Arm Bucket
Double L.H R.H

Double acting Double acting
acting
2 Piece Boom
Double acting piston piston

piston piston
Inside diameter of cylinder mm 160 115 115 105

Diameter of piston rod mm 100 75 80 75
Stroke mm 753 964 1175 885
Max. distance between pins mm 2,024 2518 2877 2263
Min. distance between pins mm 1271 1554 1702 1378
Hydraulic tank Closed box type
Hydraulic filter Tank return side
Hydraulic cooler
01-8 PW168-11E1 VENBM75000

Specification Weight Table
Weight Table
This weight table is for use when handling components or

when transporting the machine.
Unit: kg

Engine assembly 440
Hydraulic pump 124

Radiator oil cooler assembly 95
Hydraulic tank, filter assembly (excluding hydraulic oil) 184
Fuel tank (excluding fuel) 143

Revolving frame 1598
Operator’s cab (including main inner components, e.g. Seat, Steering etc.) 840
Mechanical 45
Operator’s seat
Air Suspension 48
Counterweight 3131
Swing machinery 180

Control valve 1 PB / 2 PB 136/137
Travel motor 75
centre swivel joint 132
PW168-11E1 VENBM75000 01-9

Weight Table Specification
1-Piece Boom
Unit: kg
Boom assembly 1014

2.1 m 303
Arm assembly
2.5 m 341
(without piping)
3.0 m 462
Boom cylinders 139 x 2
Arm cylinder 143
Bucket cylinder 97
Boom foot pin 30
foot 6x2
Boom cylinder pins
head 20
Arm cylinder pins (foot and head) 7x2
Boom/Arm pivot pin 12
Bucket linkage and pins 115
01-10 PW168-11E1 VENBM75000

Specification Weight Table
2-Piece Boom
Unit: kg

1st Boom 416
Boom assembly
2nd Boom 624
2.1 m 303
Arm assembly 2.5 m 341
3.0 m 462
Boom cylinders 130 x 2

Adjust cylinder 210
Arm cylinder 143
Bucket cylinder 97
Boom foot pin 30
1st Boom / 2nd Boom pin 27
Boom cylinder pins foot 6x2

foot 14
Adjust cylinder pins
head 19
Arm cylinder pins 7x2
Boom/Arm pivot pin 13
Bucket Linkage and pins 115
PW168-11E1 VENBM75000 01-11

Fuel, Coolant, Lubricant Specification
Fuel, Coolant, Lubricant

For details of notes (Note 1, Note 2...) in the table, see the Oper-
ation and Maintenance Manual.
Ambient Temperature
Recommended
Reservoir Fluid Type
Komatsu Fluids
Min Max
Engine oil for KDPF used in cold terrain EOS5W30-LA (KES) -25°C 35°C
(Oil Change interval 250 hours)
(Note 1) EOS5W40-LA (KES) -25°C 40°C
Engine oil pan
Engine oil for KDPF (Oil Change inter- EO10W30-LA (KES) -20°C 40°C
val 500 hours) EO15W40-LA (KES) -15°C 50°C
Swing machinery case PTO Engine oil SAE 30 (KES) -20°C 40°C
gear case Power train oil (Note 2) TO 30 (KES) -30°C 50°C
Bio-oil B046-G4 (KES) -20°C 30°C
Hydraulic system Hydraulic oil HO 46-HM (KES) -20°C 50°C
Power train oil TO 10 (KES) -20°C 50°C
Hyper grease (Note 3) G2-T, G2-TE (KES) -20°C 50°C

Grease fitting
Lithium EP grease G2-LI (KES) -20°C 50°C
EN 590 Grade D -10°C 50°C

Diesel fuel (EN590)
EN 590 Class 2 -30°C 20°C
Fuel tank
Fuel, HVO
EN15940 -22°C 50°C
(Bio-based paraffin diesel) (Note 4)
Non-Amine Engine Coolant (AF- NAC)

Cooling system AF-NAC (KES) -30°C 50°C
(Note 5)
Axles
Multi oil Shell Spirax S4 TXM -30°C 40°C
Hubs
Transmission + clutch Power train oil TO 30 (KES) -30°C 50°C
DEF tank DEF tank (Note 6) DEF (KES) -30°C 50°C
Air conditioner Refrigerant R134a (HFC134A) - -
Remark
• We recommend Komatsu genuine oil which has been spe-
cifically formulated and approved for use in engine and hy-
draulic work equipment applications.
• Only use high quality oils which meet internationally recog-

nized specifications.
01-12 PW168-11E1 VENBM75000

Specification Fuel, Coolant, Lubricant
Capacity (litre)
Reservoir
Specified Refill
Engine oil pan 20 18
Swing machinery case 5.5 -
PTO gear case 0.75
Hydraulic system 195 95
Fuel tank 267
Cooling system 22 18
Axle width (m)
Front axles 2.5 9.5 9.5
2.75 10.4 10.4
2.5 17.4 17.4

Rear axles + rear hubs
2.75 17.8 17.8
Front hubs 2.5 2.5
Transmission + clutch 3 3
DEF Tank 57.7 -
Air conditioner 850 ± 50g
PW168-11E1 VENBM75000 01-13

Fuel, Coolant, Lubricant Specification
Thank you for watching!
Blank for technical reason
01-14 PW168-11E1 VENBM75000

Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000

Uploaded by

Copyright:

Available Formats

Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Komatsu PW168-11E1 H68051-UP Shop Manual VENBM75000

Uploaded by

Copyright:

Available Formats

Shop Manual VENBM75000

Komatsu PW168-11E1 Excavator Shop Manual VENBM75000 PDF

• Materials and specifications are subject to change without notice.

• PW168-11E1 mount the SAA4D107E-5 engine.

PW168-11E1 VENBM75000 TOC-1

Automatic Idle Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61

TOC-2 PW168-11E1 VENBM75000

Ambient Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350

PW168-11E1 VENBM75000 TOC-3

Examine DEF Tank Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-66

TOC-4 PW168-11E1 VENBM75000

Failure Code [879EMC] – Ventilation Damper Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144

PW168-11E1 VENBM75000 TOC-5

Failure Code [CA428] – Water In Fuel Sensor High Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228

TOC-6 PW168-11E1 VENBM75000

PW168-11E1 VENBM75000 TOC-7

Failure Code [CA3568] – DEF Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-435

TOC-8 PW168-11E1 VENBM75000

PW168-11E1 VENBM75000 TOC-9

Failure Code [DAF0MB] – Monitor ROM Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-676

TOC-10 PW168-11E1 VENBM75000

PW168-11E1 VENBM75000 TOC-11

Failure Code [DW4AKB] – SUSLock Sol Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-892

TOC-12 PW168-11E1 VENBM75000

Failure Code [DXA8KB] – Pump PC-EPC Solenoid Short Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1002

PW168-11E1 VENBM75000 TOC-13

Troubleshooting of Central Lubrication System (CLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1113

TOC-14 PW168-11E1 VENBM75000

Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40

PW168-11E1 VENBM75000 TOC-15

How to Connect Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-78

TOC-16 PW168-11E1 VENBM75000

11-0 ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-56

PW168-11E1 VENBM75000 TOC-17

Pin Location List W3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-112

TOC-18 PW168-11E1 VENBM75000

List of Abbreviations Used in the Text

Purpose of use (major

A lever is used to perform the steering operations instead

A device that can be fixed onto the standard ma- chine in

When the retarder is not being used, this valve bypasses

A regulator valve which is installed to KCCV ventilator. It is

PW168-11E1 VENBM75000 00-1

Purpose of use (major

Electronic control device uses the signals from the sensors

Proportional electromagnetic valve that gradually increases

Electronically Con- This system ensures smooth high-speed travel by absorb-

Electronic control device uses the signals from the sensors

This function recirculates part of exhaust gas to combustion

This system allows data (filter, oil replacement interval, mal-

Electromagnetic Pro- This mechanism allows actuators to be operated in propor-

Communication Global Navigation Satellite System: This system uses sat-

This function uses a combination of hydraulic motor and

This function uses a combination of hydraulic pump and

00-2 PW168-11E1 VENBM75000

Purpose of use (major

This valve is installed at inlet port of pump, and it adjusts

This valve is installed at inlet port of pump, and it adjusts

This mechanism separates oil in blowby gas and returns it

Komatsu Catalyzed This filter captures soot in exhaust gas.