PC78US-8 Troubleshooting by Failure Code PDF

SEN04809-00
PC78US-8 15001 and up
40 Troubleshooting
301 Troubleshooting by failure code, Part 1
40
Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3

Failure code [989M00] Engine controller lock caution 2 ................................................................................. 4
Failure code [989N00] Engine controller lock caution 3.................................................................................. 5
Failure code [AB00KE] Charge voltage low .................................................................................................... 6
Failure code [B@BAZG] Eng oil press. low .................................................................................................... 8
Failure code [B@BCNS] Eng coolant overheat .............................................................................................. 9
Failure code [B@HANS] Hydr oil overheat ..................................................................................................... 9
Failure code [CA111] ECM critical internal failure ......................................................................................... 10
Failure code [CA115] Eng. Ne and Bkup speed sensor error .......................................................................13
Failure code [CA122] Charge air press sensor high error ............................................................................ 14
Failure code [CA123] Charge air press sensor low error.............................................................................. 16
Failure code [CA131] Throttle sensor high error........................................................................................... 18
Failure code [CA132] Throttle sensor low error ............................................................................................ 20
Failure code [CA144] Coolant temp. sensor high error................................................................................. 22
Failure code [CA145] Coolant temp. sensor low error .................................................................................. 24
Failure code [CA153] Charge air temp. sensor high error ............................................................................ 26
Failure code [CA154] Charge air temp. sensor low error.............................................................................. 28
Failure code [CA187] Sensor sup. 2 volt. low error ...................................................................................... 29
Failure code [CA221] Ambient air press. sensor high error .......................................................................... 30
Failure code [CA222] Ambient air press. sensor low error ........................................................................... 32
Failure code [CA227] Sensor sup. 2 volt. high error ..................................................................................... 33
Failure code [CA234] Eng. overspeed .......................................................................................................... 34
Failure code [CA238] Ne speed sensor sup. volt. error ................................................................................ 36
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Failure code [CA271] IMV/PCV1 short error ................................................................................................. 38

Failure code [CA272] IMV/PCV1 open error ................................................................................................. 39
Failure code [CA322] Injector #1 (L #1) system open/short error ................................................................. 40
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Failure code [989L00] Engine controller lock caution 1 1
User code Failure code Engine controller lock caution 1

Trouble
— 989L00 (Machine monitor system)
Contents of
• Engine controller lock is detected (Factor 1).
trouble
Action of • None in particular.
machine monitor • If cause of failure disappears, system resets itself.
Problem that
appears on • Engine cannot be started.
machine
• If this failure code is displayed after machine monitor is replaced, user password must be changed
Related
to one before replacement.
information
• Method of reproducing failure code: Turn starting switch ON.
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Replacement of machine
1 This trouble may be caused by replacement of machine monitor.
state monitor
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Failure code [989M00] Engine controller lock caution 2 1

Trouble
— 989M00 (Machine monitor system)
Contents of
trouble
Problem that
appears on • Engine cannot be started.
machine
• If this failure code is displayed after machine monitor is replaced, user password must be changed
Related
to one before replacement.
information
Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Replacement of machine
1 This trouble may be caused by replacement of machine monitor.
and standard monitor
value in normal If this failure code is displayed while machine monitor is not
state 2 Defective machine monitor replaced, machine monitor may be defective. (Since trouble is in
system, troubleshooting cannot be carried out.)
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Failure code [989N00] Engine controller lock caution 3 1

Trouble
— 989N00 (Machine monitor system)
Contents of
trouble
Action of • Tries automatic resetting.
Problem that
appears on
machine
Related • Method of reproducing failure code: Failure code is not reproduced since system is reset automati-
information cally.

and standard If this failure code is displayed repeatedly, engine controller may be
value in normal 1 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
state carried out.)
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Failure code [AB00KE] Charge voltage low 1
User code Failure code Charge voltage low

Trouble
— AB00KE (Machine monitor system)
Contents of
• While engine is running, signal circuit of alternator detected low charge voltage (below 7.8 V).
trouble
Action of • Displays charge level monitor on machine monitor.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • If machine is operated as it is, battery may not be charged.
machine
Related • Signal voltage of alternator can be checked with monitoring function. (Code: 04300 Charge voltage)
information • Method of reproducing failure code: Start engine.

Prepare with starting switch OFF, then start engine and carry
Defective alternator out troubleshooting.
1
(when system is normal) M22 (male) Engine speed Voltage
(1) – chassis ground Min. medium speed 27.5 – 29.5 V
Disconnection in wiring har- Prepare with starting switch OFF, then carry out troubleshoot-
ness ing without turning starting switch ON.
2 (Disconnection in wiring or
defective contact in connec- Wiring harness between CM01 (female) (11) Resis-
Possible causes Max. 1
tor) – J06 – AR (female) (1) tance
and standard
value in normal Prepare with starting switch OFF, then carry out troubleshoot-
state Ground fault in wiring har- ing without turning starting switch ON.
ness
3 Wiring harness between CM01 (female) (11)
(Short circuit with GND cir- Resis-
cuit) – J06 – AR (female) (1) and circuit branch Min. 1M
tance
end and chassis ground
Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
4 Defective machine monitor CM01 Engine speed Voltage
Between (11) –
Operation Min. 7.8 V
chassis ground
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Related circuit diagram
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Failure code [B@BAZG] Eng oil press. low 1
User code Failure code Engine oil pressure low

Trouble
— B@BAZG (Engine controller system)
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (sensor contact opened).
Action of • Displays engine oil pressure monitor on machine monitor.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon-
Related
itor.
information
• Method of reproducing failure code: Start engine.

Possible causes Lowering of engine oil pres-
Engine oil pressure may be low. Check it and remove cause if it is
and standard 1 sure (when system is nor-
low.
value in normal mal)
state Defective engine oil pressure If cause 1 is not detected, engine oil pressure switch system may
2
switch system be defective. Carry out troubleshooting for failure code [CA435].
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Failure code [B@BCNS] Eng coolant overheat 1
User code Failure code Engine coolant overheat

Trouble
— B@BCNS (Engine controller system)
Contents of • While engine was running, signal circuit of engine coolant temperature sensor detected overheating
trouble of engine coolant (above about 102°C).
Action of • Displays engine coolant temperature monitor with red on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.
Related
• Engine coolant temperature can be checked with monitoring function.
information
(Code: 04107 Engine coolant temperature)

Overheating of engine
Possible causes Engine coolant may be overheating. Check it and remove cause if
1 coolant (when system is nor-
and standard it is overheating.
mal)
value in normal
state If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
[CA144] and [CA145].
Failure code [B@HANS] Hydr oil overheat 1
User code Failure code Hydraulic oil overheat

Trouble
— B@HANS (Pump controller system)
Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of
trouble hydraulic oil (above about 102°C).
Action of • Displays hydraulic oil temperature monitor with red on machine monitor.
Problem that
appears on • If machine is operated as it is, engine may be seized.
machine
• Hydraulic oil temperature sensor signal is input to engine controller and then transmitted to machine
monitor.
Related
• Hydraulic oil temperature can be checked with monitoring function.
information
(Code: 04401 Hydraulic oil temperature)

Possible causes Overheating of hydraulic oil Hydraulic oil may be overheating. Check it and remove cause if it
1
and standard (when system is normal) is overheating.
value in normal If cause 1 is not detected, hydraulic oil temperature gauge system
state Defective hydraulic oil tem-
2 may be defective. Carry out troubleshooting for "E-9 Hydraulic oil
perature gauge system
temperature gauge does not indicate normally" in E-mode.
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Failure code [CA111] ECM critical internal failure 1
User code Failure code ECM critical internal failure

Trouble
E10 CA111 (Engine controller system)
Contents of
• Abnormality occurred in controller.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine runs normally but it may stop during operation or may not be able to start.
machine
Related
information

Check fuse or circuit breaker on machine side directly for defect.
1 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
Prepare with starting switch OFF, then carry out troubleshoot-
Defective power supply cut- ing without turning starting switch ON.
2
out relay Wiring harness between CE02 (female) (55) Resis- 185 –
– (32) tance 265
ing without turning starting switch ON.
Wiring harness between CE02 (female) (55) Resis-
Max. 1
– R23 (1) tance
Possible causes Wiring harness between CE02 (female) (55) Resis-
Max. 1
and standard – R24 (1) tance
value in normal Wiring harness between CE02 (female) (32) Resis-
state Max. 1
– R23 (2) tance
Disconnection in wiring Wiring harness between CE02 (female) (32) Resis-
harness Max. 1
– R24 (2) tance
defective contact in connec- Wiring harness between CE03 (female) (1) Resis-
Max. 1
tor) – T12 tance
Max. 1
– R23 (5) tance
Max. 1
– R24 (5) tance
Wiring harness between R23 (female) (3) – Resis-
Max. 1
battery (+) tance
Max. 1
battery (+) tance
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Min. 1 M
– R23 (1) and chassis ground tance
Min. 1 M
Min. 1 M
Ground fault in wiring har-
Possible causes 4 ness (Short circuit with GND Min. 1 M
and standard circuit)
value in normal Min. 1 M
state
Min. 1 M
Min. 1 M
battery (+) and chassis ground tance
Min. 1 M
Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
5 Defective engine controller
CE03 Voltage
Between (3) – (1) 20 – 30 V
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Failure code [CA115] Eng. Ne and Bkup speed sensor error 1
User code Failure code Eng. Ne and Bkup speed sensor error
Trouble
Contents of
• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
controller
Problem that
• Engine cannot be started (if engine has been stopped).
appears on
• Engine stops (if engine has been running).
machine
Related
information
Causes Standard value in normal state/Remarks on troubleshooting

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sen-
2 Carry out troubleshooting for failure code [CA778].
sor system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, indicator ring of crank pulley, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, indicator ring of camshaft, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for defec-
5
connection) tive connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
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Failure code [CA122] Charge air press sensor high error 1
User code Failure code Charge air press sensor high error
Trouble
Contents of
• High voltage was detected in charge (boost) pressure sensor circuit.
trouble
Action of
• Fixes charge (boost) pressure (400 kPa {4.08 kg/cm 2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine drops.
machine
• Signal voltage of charge (boost) pressure sensor can be checked with monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage).
information

Defective sensor power sup- If failure code [CA227] is indicated, carry out troubleshooting for it
1
ply system first.
Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
Defective charge (boost) PTIM Voltage
2 pressure sensor Between (3) – (1) Power supply 4.75 – 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Possible causes ing without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
value in normal ness Max. 1
(19) – PTIM (female) (1) tance
state 3 (Disconnection in wiring or
defective contact in connec- Wiring harness between ENG1 (female) Resis-
Max. 1
tor) (36) – PTIM (female) (2) tance
Wiring harness between ENG1 (female) Resis-
Max. 1
Ground fault in wiring har- Wiring harness between ENG1 (female) Resis-
Min. 1 M
ness (19) – PTIM (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between ENG1 (female) Resis-
cuit) Min. 1 M
(36) – PTIM (female) (2) and chassis ground tance
Min. 1 M
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Wiring harness between ENG1 (female)
(19) – PTIM (female) (1) and wiring harness Resis-
Min. 1 M
between ENG1 (female) (36) – PTIM tance
Short circuit in wiring har- (female) (2)
ness Wiring harness between ENG1 (female)
Possible causes 5
(With another wiring har- (19) – PTIM (female) (1) and wiring harness Resis-
and standard ness) Min. 1 M
value in normal (female) (4)
state
(36) – PTIM (female) (2) and wiring harness Resis-
Min. 1 M
(female) (4)
and carry out troubleshooting.
ENG1 Voltage
Between (36) – (48) Power supply 4.75 – 5.25 V
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Failure code [CA123] Charge air press sensor low error 1
User code Failure code Charge air press sensor low error
Trouble
Contents of
• Low voltage was detected in charge (boost) pressure sensor circuit.
trouble
Action of
• Fixes charge pressure (101 kPa {1.02 kg/cm 2}) and continues operation.
controller
Problem that
appears on • Acceleration performance of engine drops.
machine
• Signal voltage of charge (boost) pressure sensor can be checked with monitoring function.
Related
(Code: 36501 Boost pressure sensor voltage).
information

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
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Failure code [CA131] Throttle sensor high error 1
User code Failure code Throttle sensor high error

Trouble
Contents of
• High voltage was detected in fuel control dial circuit.
trouble
Action of • Sets throttle angle with signal other than fuel control dial signal and continues operation.
controller (depending on each model)
Problem that
appears on • Engine speed cannot be controlled with fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related
(Code: 03000 Fuel control dial voltage)
information

1
ply system first.
Defective fuel control dial P20 (male) Resistance

2
(Internal trouble) Between (1) – (3) 4.0 – 6.0 k
Between (2) – (1) 0.25 – 5.0 k
Between (2) – (3) 0.25 – 5.0 k
Disconnection in wiring har- Wiring harness between CE02 (female) (27) Resis-
ness Max. 1
– P20 (female) (1) tance
Possible causes defective contact in connec- Wiring harness between CE02 (female) (35) Resis-
Max. 1
and standard tor) – P20 (female) (2) tance
value in normal Wiring harness between CE02 (female) (28) Resis-
state Max. 1
Ground fault in wiring har- Wiring harness between CE02 (female) (27) Resis-
Min. 1 M
ness – P20 (female) (1) and chassis ground tance
4
(Short circuit with GND cir- Wiring harness between CE02 (female) (35) Resis-
cuit) Min. 1 M
– P20 (female) (2) and chassis ground tance
Min. 1 M
5 Defective engine controller CE02 Voltage
Between (35) – (28) Signal 0.5 – 4.5 V
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Failure code [CA132] Throttle sensor low error 1
User code Failure code Throttle sensor low error

Trouble
Contents of
• Low voltage was detected in fuel control dial circuit.
trouble
Action of • Sets throttle angle with signal other than fuel control dial signal and continues operation.
controller (depending on each model)
Problem that
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related
(Code: 03000 Fuel control dial voltage)
information

and standard
state
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Failure code [CA144] Coolant temp. sensor high error 1
User code Failure code Coolant temp. sensor high error

Trouble
Contents of
• High voltage was detected in coolant temperature sensor circuit.
trouble
Action of
• Fixes coolant temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related
(Code: 04105 Engine coolant temperature sensor voltage)
information

TWTR (male) Coolant temperature Resistance
Defective coolant tempera- 0°C 30 – 37 k
1 ture sensor
25°C 9.3 – 10.7 k
(Internal trouble)
Between (A) – (B) 50°C 3.2 – 3.8 k
80°C 1.0 – 1.3 k
95°C 700 – 800
Disconnection in wiring har- ing without turning starting switch ON.
ness
2 (Disconnection in wiring or Max. 1
Possible causes (47) – TWTR (female) (A) tance
defective contact in connec-
and standard tor) Wiring harness between ENG1 (female) Resis-
value in normal Max. 1
(49) – TWTR (female) (B) tance
state
Ground fault in wiring har- ing without turning starting switch ON.
ness
3 Wiring harness between ENG1 (female)
cuit) (49) – TWTR (female) (B) and chassis Min. 1 M
tance
ground
ENG1 (female) Coolant temperature Resistance
0°C 30 – 37 k
25°C 9.3 – 10.7 k
Between (47) – (49) 50°C 3.2 – 3.8 k
80°C 1.0 – 1.3 k
95°C 700 – 800
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Failure code [CA145] Coolant temp. sensor low error 1
User code Failure code Coolant temp. sensor low error

Trouble
Contents of
• Low voltage was detected in coolant temperature sensor circuit.
trouble
Action of
• Fixes coolant temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of coolant temperature sensor can be checked with monitoring function.
Related
(Code: 04105 Engine coolant temperature sensor voltage)
information

and standard
state
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Failure code [CA153] Charge air temp. sensor high error 1
User code Failure code Charge air temp. sensor high error
Trouble
Contents of
• High voltage was detected in charge (boost) temperature sensor circuit.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (70°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of charge (boost) temperature sensor can be checked with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information

Intake air
PTIM (male) Resistance
temperature
Defective charge (boost) 0°C 29 – 36 k
1 temperature sensor
25°C 9 – 11 k
(Internal trouble) Between (2) – (1)
40°C 4.9 – 5.8 k
100°C 600 – 700
Between (2) –
All range Min. 1 M
chassis ground
Disconnection in wiring ing without turning starting switch ON.
Possible causes harness
and standard 2 (Disconnection in wiring or Max. 1
value in normal defective contact in connec-
state tor) Wiring harness between ENG1 (female) Resis-
Max. 1
Ground fault in wiring har- Prepare with starting switch OFF, then carry out troubleshoot-
3
cuit) Min. 1 M
Intake air
ENG1 (female) Resistance
temperature
4 Defective engine controller 0°C 29 – 36 k
25°C 9 – 11 k
Between (11) – (48)
40°C 4.9 – 5.8 k
100°C 600 – 700
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Failure code [CA154] Charge air temp. sensor low error 1
User code Failure code Charge air temp. sensor low error
Trouble
Contents of
• Low voltage was detected in charge (boost) temperature sensor circuit.
trouble
Action of
• Fixes charge (boost) temperature (intake air temperature) (46°C) and continues operation.
controller
Problem that
appears on
machine
• Signal voltage of charge (boost) temperature sensor can be checked with monitoring function.
Related
(Code: 18501 Boost temperature sensor voltage)
information

and standard
state
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Failure code [CA187] Sensor sup. 2 volt. low error 1
User code Failure code Sensor sup. 2 volt. low error

Trouble
Contents of
• Low voltage was detected in sensor power supply 2 (5 V) circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
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Failure code [CA221] Ambient air press. sensor high error 1
User code Failure code Ambient air press. sensor high error
Trouble
Contents of
• High voltage was detected in ambient pressure sensor circuit.
trouble
Action of • Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm 2}) and continues opera-
controller tion.
Problem that
appears on • Output drops.
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information

1
ply system first.
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) – (1) Signal 0.3 – 4.7 V
Possible causes Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
and standard ness Max. 1
(36) – PAMB (female) (3) tance
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between ENG1 (female) Resis-
Max. 1
tor) (20) – PAMB (female) (2) tance
Max. 1
(48) – PAMB (female) (1) tance
Resis-
(36) – PAMB (female) (3) and chassis Min. 1 M
Ground fault in wiring har- tance
ground
ness
cuit) (20) – PAMB (female) (2) and chassis Min. 1 M
tance
ground
Resis-
(48) – PAMB (female) (1) and chassis Min. 1 M
tance
ground
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(36) – PAMB (female) (3) and wiring har- Resis-
Min. 1 M
ness between ENG1 (female) (20) – PAMB tance
Short circuit in wiring har- (female) (2)
5
(With another wiring har- (36) – PAMB (female) (3) and wiring har- Resis-
Possible causes Min. 1 M
ness) ness between ENG1 (female) (48) – PAMB tance
and standard
value in normal (female) (1)
state Wiring harness between ENG1 (female)
(20) – PAMB (female) (2) and wiring har- Resis-
Min. 1 M
ness between ENG1 (female) (48) – PAMB tance
(female) (1)
6 Defective engine controller ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (20) – (48) 0.3 – 4.7 V
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Failure code [CA222] Ambient air press. sensor low error 1
User code Failure code Ambient air press. sensor low error
Trouble
Contents of
• Low voltage was detected in ambient pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default value (52.44 kPa {0.53 kg/cm 2}) and continues operation.
controller
Problem that
machine
• Signal voltage of ambient pressure sensor can be checked with monitoring function.
Related
(Code: 37401 Ambient pressure sensor voltage)
information

and standard
state
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Failure code [CA227] Sensor sup. 2 volt. high error 1
User code Failure code Sensor sup. 2 volt. high error

Trouble
Contents of
• High voltage was detected in sensor power supply 2 (5 V) circuit.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Possible causes Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 1 Defective engine controller
state CE02 Voltage
Between (26) – (22) 4.75 – 5.25 V
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Failure code [CA234] Eng. overspeed 1
User code Failure code Eng. overspeed

Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed is above operating range.
trouble
Action of
• Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
• Engine speed can be checked with monitoring function.
Related
(Code: 01002 Engine speed)
information
• Method of reproducing failure code: Run engine at high idle.

Possible causes 1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
and standard 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
value in normal
If causes 1 and 2 are not detected, engine controller may be defec-
state
out.)
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Failure code [CA238] Ne speed sensor sup. volt. error 1
User code Failure code Ne speed sensor sup. volt. error

Trouble
Contents of
• Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
• Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
• Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1 failure code disap-
(Internal trouble)
pears when a device Ne speed sensor NE connector
is disconnected, that
device has a defect
in it.
ness (Disconnection in wiring Wiring harness between ENG1 (female) Resis-
2 Max. 1
or defective contact in con- (26) – NE (female) (3) tance
nector) Wiring harness between ENG1 (female) Resis-
Possible causes
Max. 1
and standard (44) – NE (female) (2) tance
state ing without turning starting switch ON.
3 ness (Short circuit with GND Min. 1 M
(26) – NE (female) (3) and chassis ground tance
circuit)
Min. 1 M
Short circuit in wiring har- ing without turning starting switch ON.
4 ness (with another wiring Wiring harness between ENG1 (female)
harness) Resis-
(26) – NE (female) (3) and between ENG1 Min. 1 M
tance
(female) (44) – NE (female) (2)
ENG1 Voltage
Between (26) – (44) 4.75 – 5.25 V
40-301 36 PC78US-8
SEN04809-00
PC78US-8 40-301 37
SEN04809-00
Failure code [CA271] IMV/PCV1 short error 1
User code Failure code IMV/PCV1 short error

Trouble
Contents of
• There is short circuit in IMV circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump IMV PREG (male) Resistance
1
(Internal trouble) Between (1) – (2) 2.3 – 5.3
Between (1), (2) – chassis
Min. 1 M
ground
ness Wiring harness between ENG1 (female) Resis-
2 Min. 1 M
(Short circuit with GND cir- (10) – PREG (female) (1) tance
Possible causes cuit) Wiring harness between ENG1 (female) Resis-
and standard Min. 1 M
(14) – PREG (female) (2) tance
value in normal
state Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between ENG1 (female) (10)
3 Voltage Max. 1 V
24V circuit) in wiring harness – PREG (female) (1) and chassis ground
Wiring harness between ENG1 (female) (14)
Voltage Max. 1 V
– PREG (female) (2) and chassis ground
Between (10) – (14) 2.3 – 5.3
Min. 1 M
ground
40-301 38 PC78US-8
SEN04809-00
Failure code [CA272] IMV/PCV1 open error 1
User code Failure code IMV/PCV1 open error

Trouble
Contents of
• There is disconnection in IMV circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump IMV PREG (male) Resistance
1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3
Min. 1 M
ground
ness
Possible causes defective contact in connec-
tor) Wiring harness between ENG1 (female) Resis-
and standard Max. 1
value in normal
state Prepare with starting switch OFF, then carry out troubleshoot-
ness Wiring harness between ENG1 (female) (10) Resis-
3 Min. 1 M
(Short circuit with GND cir- – PREG (female) (1) and chassis ground tance
cuit) Wiring harness between ENG1 (female) (14) Resis-
Min. 1 M
– PREG (female) (2) and chassis ground tance
Between (10) – (14) 2.3 – 5.3
Between (10) (14) – chassis
Min. 1 M
ground
PC78US-8 40-301 39
SEN04809-00
Failure code [CA322] Injector #1 (L #1) system open/short error 1
User code Failure code Injector #1 (L #1) system open/short error

Trouble
Contents of
• There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
controller
Problem that
• Output drops.
appears on
• Rotation is unstable.
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
(Internal trouble) Between (1) – (2) 0.4 – 1.1
Min. 1 M
ground
ness
(57) – CN1 (female) (2) tance
tor) Wiring harness between ENG1 (female) Resis-
and standard
ness Wiring harness between ENG1 (female) Resis-
3 Min. 1 M
(Short circuit with GND cir- (57) – CN1 (female) (2) and chassis ground tance
cuit) Wiring harness between ENG1 (female) Resis-
Min. 1 M
(53) – CN1 (female) (1) and chassis ground tance
Defective injector or wiring If another failure code for injector abnormality is displayed, carry
4
harness of another cylinder out troubleshooting for it.
Between (57) – (53) 0.4 – 1.1
Min. 1 M
ground
40-301 40 PC78US-8
SEN04809-00
PC78US-8 40-301 41
SEN04809-00

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

Defective injector #3 (Inter- CN3 (male) Resistance
1
nal trouble) Between (1) – (2) 0.4 – 1.1
Min. 1 M
ground
2 Max. 1
or defective contact in con- (55) – CN3 (female) (2) tance
and standard
circuit)
Min. 1 M
4
Between (55) – (59) 0.4 – 1.1
Min. 1 M
ground
40-301 42 PC78US-8
SEN04809-00
PC78US-8 40-301 43
SEN04809-00

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 M
ground
2 Max. 1
and standard
circuit)
Min. 1 M
4
Between (45) – (58) 0.4 – 1.1
Min. 1 M
ground
40-301 44 PC78US-8
SEN04809-00
PC78US-8 40-301 45
SEN04809-00

Trouble
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 M
ground
2 Max. 1
and standard
circuit)
Min. 1 M
4
Between (56) – (51) 0.4 – 1.1
Min. 1 M
ground
40-301 46 PC78US-8
SEN04809-00
PC78US-8 40-301 47
SEN04809-00
PC78US-8 Hydraulic excavator

Form No. SEN04809-00
©2008 KOMATSU
All Rights Reserved
Printed in Japan 10-08 (01)
40-301 48
SEN04810-00
40 Troubleshooting
40
Failure code [CA351] Inj. drive circuit error..................................................................................................... 3

Failure code [CA352] Sensor sup. 1 volt. low error ........................................................................................ 6
Failure code [CA386] Sensor sup. 1 volt. high error ....................................................................................... 8
Failure code [CA435] Abnormality in engine oil pressure switch .................................................................. 10
Failure code [CA441] Battery voltage low error .............................................................................................11
Failure code [CA442] Battery voltage high error ........................................................................................... 12
Failure code [CA449] Rail press. very high error .......................................................................................... 13
Failure code [CA451] Rail press. sensor high error ...................................................................................... 14
Failure code [CA452] Rail press. sensor low error ....................................................................................... 16
Failure code [CA488] Chg air temp high torque derate ................................................................................ 17
Failure code [CA553] Rail press. high error.................................................................................................. 18
Failure code [CA559] Rail press. low error ................................................................................................... 19
Failure code [CA689] Eng. Ne speed sensor error ....................................................................................... 22
Failure code [CA731] Eng. Bkup speed sensor phase error......................................................................... 24
Failure code [CA757] All persistent data lost error ....................................................................................... 25
Failure code [CA778] Eng. Bkup speed sensor error ................................................................................... 26
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 28
Failure code [CA2185] Throttle sens. sup. volt. high error............................................................................ 30
Failure code [CA2186] Throttle sens. sup. volt. low error ............................................................................. 32
Failure code [CA2249] Rail press. very low error ......................................................................................... 32
Failure code [CA2311] Abnormality in IMV solenoid ..................................................................................... 33
Failure code [D110KB] Battery relay drive short ........................................................................................... 34
Failure code [D19JKZ] Personal code relay abnormality .............................................................................. 36
PC78US-8 40-302 1
SEN04810-00
Failure code [D862KA] GPS antenna discon ................................................................................................ 38

Failure code [DA22KK] Pump solenoid power low error ............................................................................... 40
Failure code [DA25KP] 5V sensor 1 power abnormality ............................................................................... 42
Failure code [DA26KP] 5V sensor 2 power abnormality ............................................................................... 44
Failure code [DA29KQ] Model selection abnormality.................................................................................... 46
40-302 2 PC78US-8
SEN04810-00
Failure code [CA351] Inj. drive circuit error 1
User code Failure code Inj. drive circuit error

Trouble
Contents of
• Abnormality occurred in injector drive circuit.
trouble
Action of
• Limits output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

If another failure code (code of abnormality in injector system) is
1 Defective related system
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on machine side directly for defect.
2 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
Defective power supply cut- ing without turning starting switch ON.
3
out relay Wiring harness between CE02 (female) (55) Resis- 185 –
– (32) tance 265
Max. 1
Possible causes – R23 (1) tance
and standard Wiring harness between CE02 (female) (55) Resis-
Max. 1
value in normal – R24 (1) tance
state Wiring harness between CE02 (female) (32) Resis-
Max. 1
– R23 (2) tance
Disconnection in wiring Wiring harness between CE02 (female) (32) Resis-
harness Max. 1
– R24 (2) tance
defective contact in connec- Wiring harness between CE03 (female) (1) Resis-
Max. 1
tor) – T15 tance
Max. 1
– R23 (5) tance
Max. 1
– R24 (5) tance
Max. 1
battery (+) tance
Max. 1
battery (+) tance
PC78US-8 40-302 3
SEN04810-00

Min. 1 M
Min. 1 M
Min. 1 M
Possible causes 5 ness (Short circuit with GND Min. 1 M
and standard circuit)
value in normal Min. 1 M
state
Min. 1 M
Min. 1 M
Min. 1 M
Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
CE03 Voltage
Between (3) – (1) 20 – 30 V
40-302 4 PC78US-8
SEN04810-00
PC78US-8 40-302 5
SEN04810-00
Failure code [CA352] Sensor sup. 1 volt. low error 1
User code Failure code Sensor sup. 1 volt. low error

Trouble
Contents of
• Low voltage was detected in sensor power supply 1 (5 V) circuit.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm 2}) and continues opera-
Action of
tion.
controller
• Fixes charge pressure sensor value (400 kPa {4.08 kg/cm 2}) and continues operation.
Problem that
machine
Related
information

and standard
state
40-302 6 PC78US-8
SEN04810-00
PC78US-8 40-302 7
SEN04810-00
Failure code [CA386] Sensor sup. 1 volt. high error 1
User code Failure code Sensor sup. 1 volt. high error

Trouble
Contents of
• High voltage was detected in sensor power supply 1 (5 V) circuit.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm 2}) and continues opera-
Action of
tion.
controller
• Fixes charge pressure sensor value (400 kPa {4.08 kg/cm 2}) and continues operation.
Problem that
machine
Related
information

1 Defective related system If another failure code is indicated, carry out troubleshooting for it.
Bkup speed sensor CAM connector
Disconnect devices
at right in order. If Atmospheric
Defective sensor (Internal PAMB connector
2 failure code disap- pressure sensor
trouble)
pears when a device Charge pressure
is disconnected, that PTIM connector
sensor
device has a defect
Common rail
in it. PFUEL connector
pressure sensor
ness
(36) – each sensor (female) tance
Possible causes tor) Wiring harness between ENG1 (female) Resis-
Max. 1
and standard (48) – each sensor (female) tance
Ground fault in wiring har- Wiring harness between ENG1 (female)
Resis-
ness (36) – each sensor (female) and chassis Min. 1 M
4 tance
(Short circuit with GND cir- ground
cuit) Wiring harness between ENG1 (female)
Resis-
(48) – each sensor (female) and chassis Min. 1 M
tance
ground
5
(With another wiring har- (36) – each sensor (female) and Resis-
ness) Min. 1 M
wiring harness between ENG1 (female) (48) tance
– each sensor (female)
ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
40-302 8 PC78US-8
SEN04810-00
PC78US-8 40-302 9
SEN04810-00
Failure code [CA435] Abnormality in engine oil pressure switch 1
User code Failure code Abnormality in engine oil pressure switch

Trouble
Contents of
• Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
controller
Problem that
• Engine oil pressure switch-based engine protection function does not function.
appears
• Engine oil pressure monitor does not display normally.
on machine
Related
• Method of reproducing failure code: Turn starting switch or start engine.
information

Defective engine oil pressure ing without turning starting switch ON.
1
switch POIL (male) Resistance
Between (1) – chassis ground Max. 1
Disconnection in wiring har- Prepare with starting switch OFF, then carry out troubleshoot-
Possible Max. 1
tor) (32) – POIL (female) (1) tance
causes and
standard value Prepare with starting switch OFF, then carry out troubleshoot-
in normal state ing without turning starting switch ON.
Short circuit in wiring harness Wiring harness among all pins between
3
(With another wiring harness) ENG1 (female) (32) – ENG1 (female) Resis-
Min. 1 M
(With all connectors of wiring harness dis- tance
connected)
Between (32) – chassis ground Max. 1
40-302 10 PC78US-8
SEN04810-00
Failure code [CA441] Battery voltage low error 1
User code Failure code Battery voltage low error

Trouble
Contents of
• Low voltage was detected in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
PC78US-8 40-302 11
SEN04810-00
Failure code [CA442] Battery voltage high error 1
User code Failure code Battery voltage high error

Trouble
Contents of
• High voltage was detected in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
40-302 12 PC78US-8
SEN04810-00
Failure code [CA449] Rail press. very high error 1
User code Failure code Rail press. very high error

Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
• Common rail pressure can be checked with monitoring function.
Related
(Code: 36400 Common rail pressure)
information

and standard
state
PC78US-8 40-302 13
SEN04810-00
Failure code [CA451] Rail press. sensor high error 1
User code Failure code Rail press. sensor high error

Trouble
Contents of
• High voltage was detected in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

Defective sensor power sup- If failure code [CA352] or [CA386] is indicated, carry out trouble-
1
ply system shooting for it first.
PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal trouble) Between (2) – (1) Signal 0.25 – 4.6 V
Possible causes Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
and standard ness Max. 1
(36) – PFUEL (female) (3) tance
value in normal 3 (Disconnection in wiring or
state defective contact in connec- Wiring harness between ENG1 (female) Resis-
Max. 1
tor) (29) – PFUEL (female) (2) tance
Max. 1
(48) – PFUEL (female) (1) tance
Resis-
(36) – PFUEL (female) (3) and chassis Min.1 M
Ground fault in wiring har- tance
ground
ness
cuit) (29) – PFUEL (female) (2) and chassis Min.1 M
tance
ground
Resis-
(48) – PFUEL (female) (1) and chassis Min.1 M
tance
ground
40-302 14 PC78US-8
SEN04810-00

(36) – PFUEL (female) (3) and Resis-
Min.1 M
Short circuit in wiring har- – PFUEL (female) (2)
5
(With another wiring har- (36) – PFUEL (female) (3) and Resis-
Possible causes Min.1 M
ness) wiring harness between ENG1 (female) (48) tance
and standard
value in normal – PFUEL (female) (1)
state Wiring harness between ENG1 (female)
(29) – PFUEL (female) (2) and Resis-
Min.1 M
– PFUEL (female) (1)
6 Defective engine controller ENG1 Voltage
Between (36) – (48) 4.75 – 5.25 V
Between (29) – (48) 0.25 – 4.6 V
PC78US-8 40-302 15
SEN04810-00
Failure code [CA452] Rail press. sensor low error 1
User code Failure code Rail press. sensor low error

Trouble
Contents of
• Low voltage was detected in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
Related
(Code: 36401 Common rail pressure sensor voltage)
information

and standard
state
40-302 16 PC78US-8
SEN04810-00
Failure code [CA488] Chg air temp high torque derate 1
User code Failure code Charge air temperature high torque derate
Trouble
Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature
trouble limit.
Action of
• Limits output and continues operation.
controller
Problem that
appears on • Engine output lowers.
machine
Related • Boost temperature can be checked with monitoring function. (Code: 18500 Boost temperature)
information • Method of reproducing failure code: Start engine.

Cooling performance of aftercooler may be low. Check following
points directly.
Lowering of cooling perfor-
1 • Looseness and breakage of fan belt.
Possible causes mance of aftercooler
• Insufficiency of cooling air
and standard • Clogging of aftercooler fins
value in normal
state Abnormal rise of turbo- Outlet temperature of turbocharger may be abnormally high.
2
charger outlet temperature Check related parts directly.
out.)
PC78US-8 40-302 17
SEN04810-00
Failure code [CA553] Rail press. high error 1
User code Failure code Rail press. high error

Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
controller
Problem that
machine
Related
information

2 Use of improper fuel Check fuel used directly (for high viscosity).
Defective electrical system of Common rail pressure sensor may have electric trouble. Carry out
3
Possible causes common rail pressure sensor troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal 4 of common rail pressure sen- Check mechanical system of common rail pressure sensor directly.
state sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
40-302 18 PC78US-8
SEN04810-00
Failure code [CA559] Rail press. low error 1
User code Failure code Rail press. low error

Trouble
Contents of
• Supply pump does not feed fuel (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

2 Use of improper fuel Check fuel used directly (for high viscosity).
3 Clogging of fuel filter If a fuel filter is clogged, replace it.
For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure cir- "Testing fuel pressure".
4
cuit device Pressure in fuel low-pressure
-49 – 0 kPa
circuit
{-0.5 – 0 kg/cm2}
(At high idle or rated load)
Defective electrical system of Supply pump IMV may have electric trouble. Carry out trouble-
5
supply pump IMV shooting for following failure codes [CA271], [CA272].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
6
sure sensor ness for damage.
Possible causes
and standard For testing of leakage from pressure limiter, see Testing and
value in normal adjusting, "Testing leakage from pressure limiter and return
state rate from injector".
7 Defective pressure limiter
Leakage from pressure limiter Max. 20 cc/min (*)
*: A limit value is the value mentioned above, but a standard
value in normalcy is "0 cc/min. (no leak)".
For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Speed at rated operation Return (Spill) limit from injector
8 Defective injector 1,600 rpm 190 cc/min

1,700 rpm 200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>
Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed“.
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Clogging of fuel filter
PC78US-8 40-302 19
SEN04810-00
Check sheet for no-pressure feed
Model Work No.

Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 1,150 + 50

0
*1 Engine speed High idle rpm 2,050 ± 50
Equivalent to rating rpm 1,950
Low idle % 0
*2 Throttle opening degree
High idle % 100
*3 Fuel injection command Equivalent to rating mm3 — — —
4 Common rail pressure
*4 Equivalent to rating MPa
command
Common rail fuel
*5 Equivalent to rating MPa
pressure
Low idle CA — — —
Fuel injection timing
*6 High idle CA — — —
command
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Engine coolant
*8 Low idle °C — — —
temperature
*9 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
5 No. 1 cylinder Low idle rpm — — —
No. 2 cylinder Low idle rpm — — —
*10
C. Check of fuel circuit pressure Standard value

Checking condition Unit Measured value Good NG
(Reference value)
MPa -49 – 0 kPa
6 Fuel low-pressure circuit pressure High idle or rated load
{kg/cm2} {-0.5 – 0 kg/cm2}
D. Check of strainers and filters Good NG

7 Visual check of fuel filter
E. Check of leakage and return rate Standard value

Checking condition Unit Measured value Good NG
(Reference value)
8 Leakage through pressure limiter Equivalent to rating cc/min Max. 20 (*)
Equivalent to rating 1,600 rpm cc/min 190
Equivalent to rating 1,700 rpm cc/min 200 Speed:
9 Return rate from injector Equivalent to rating 1,800 rpm cc/min 210
Equivalent to rating 1,900 rpm cc/min 220 Return rate:
Equivalent to rating 2,000 rpm cc/min 230
40-302 20 PC78US-8
SEN04810-00
*1 – *10:
See Testing and adjusting, "Special functions of machine monitor", Monitoring items table.
*: A limit value is the value mentioned above, but a standard value in normalcy is "0 cc/min. (no leak)".
Rating or equivalent:
Relieve the circuit under the following condition.
1) Engine: Full throttle
2) Mode: P
3) Boom: Raise
PC78US-8 40-302 21
SEN04810-00
Failure code [CA689] Eng. Ne speed sensor error 1
User code Failure code Eng. Ne speed sensor error

Trouble
Contents of
• Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
• Operates with signals of Bkup speed sensor.
controller
Problem that
• Running engine stops (when Bkup speed sensor is also abnormal).
appears on
machine • Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Related
information

1
ply system first.
Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
ness Max. 1
(26) – NE (female) (3) tance
Max. 1
tor) (44) – NE (female) (2) tance
Max. 1
(42) – NE (female) (1) tance
Min.1 M
ness (26) – NE (female) (3) and chassis ground tance
3
cuit) Min.1 M
Possible causes Wiring harness between ENG1 (female) Resis-
Min.1 M
and standard (42) – NE (female) (1) and chassis ground tance
value in normal
state
(26) – NE (female) (3) and Resis-
Min.1 M
Short circuit in wiring har- – NE (female) (2)
4
(With another wiring har- (26) – NE (female) (3) and Resis-
ness) Min.1 M
– NE (female) (1)
(44) – NE (female) (2) and Resis-
Min.1 M
– NE (female) (1)
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (crankshaft pulley)
part directly for defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
40-302 22 PC78US-8
SEN04810-00

and standard If causes 1 – 6 are not detected, engine controller may be defec-
value in normal 7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
state out.)
PC78US-8 40-302 23
SEN04810-00
Failure code [CA731] Eng. Bkup speed sensor phase error 1
User code Failure code Eng. Bkup speed sensor phase error
Trouble
Contents of
• Engine Bkup speed sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signals of engine Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for failure code [CA698].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
40-302 24 PC78US-8
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Failure code [CA757] All persistent data lost error 1
User code Failure code All persistent data lost error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
PC78US-8 40-302 25
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Failure code [CA778] Eng. Bkup speed sensor error 1
User code Failure code Eng. Bkup speed sensor error

Trouble
Contents of
• Abnormality occurred in engine Bkup speed sensor circuit.
trouble
Action of
• Operates with signals of Ne speed sensor.
controller
Problem that
• Running engine stops (when Ne speed sensor is also abnormal).
appears on
machine • Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information

Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
ply system shooting for it first.
Disconnection in wiring har- Wiring harness between ENG1 (female) Resis-
ness Max. 1
(36) – CAM (female) (3) tance
Max. 1
tor) (48) – CAM (female) (2) tance
Max. 1
(37) – CAM (female) (1) tance
Min.1 M
ness (36) – CAM (female) (3) and chassis ground tance
3
cuit) Min.1 M
(48) – CAM (female) (2) and chassis ground tance
Possible causes Wiring harness between ENG1 (female) Resis-
Min.1 M
and standard (37) – CAM (female) (1) and chassis ground tance
Resis-
(36) – CAM (female) (3) and between ENG1 Min.1 M
Short circuit in wiring har- tance
(female) (48) – CAM (female) (2)
ness
(With another wiring har- Resis-
ness) (36) – CAM (female) (3) and between ENG1 Min.1 M
tance
Resis-
(48) – CAM (female) (2) and between ENG1 Min.1 M
tance
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot be
speed sensor
carried out.)
out.)
40-302 26 PC78US-8
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PC78US-8 40-302 27
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Failure code [CA1633] KOMNET datalink timeout error 1
User code Failure code KOMNET datalink timeout error

Trouble
E0E CA1633 (Engine controller system)
Contents of • Engine controller detected communication error in KOMNET communication circuit between pump
trouble controller and machine monitor.
Action of • Continues operation in default mode.
Problem that
• Information may not transmitted normally by KOMNET communication and machine may not oper-
appears on
ate normally. (Trouble phenomenon depends on failed section.)
machine
Related
information

Disconnection in wiring har- Wiring harness between CM02 (female) (8),
Resis-
ness (Disconnection in wiring (9) – C01 (female) (45), – CE02 (female) Max. 1
1 tance
or defective contact in con- (1), – K02 (female) (A)
nector) Wiring harness between CM02 (female)
Resis-
(10) – C01 (female) (64), – CE02 (female) Max. 1
tance
(21), – K02 (female) (B)
Wiring harness between CM02 (female) (8),
(9) – C01 (female) (45), – CE02 (female) Resis-
Ground fault in wiring har- Min. 1 M
(1), – K02 (female) (A), – N08 (male) (3) and tance
2 ness (Short circuit with GND
chassis ground
circuit)
Wiring harness between CM02 (female)
Possible causes (10) – C01 (female) (64), – CE02 (female) Resis-
Min. 1 M
and standard (21), – K02 (female) (B), – N08 (male) (10) tance
value in normal and chassis ground
(9) – C01 (female) (45), – CE02 (female) Max.
Hot short (Short circuit with Voltage
(1), – K02 (female) (A), – N08 (male) (3) and 5.5 V
3 24 V circuit) in wiring har-
chassis ground
ness
(10) – C01 (female) (64), – CE02 (female) Max.
Voltage
(21), – K02 (female) (B), – N08 (male) (10) 5.5 V
and chassis ground
Defective CAN terminal ing without turning starting switch ON.
4 resistance (Internal short cir-
K02 (male) Resistance
cuit or disconnection)
Between (A) – (B) 120 ± 12
out.)
40-302 28 PC78US-8
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PC78US-8 40-302 29
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Failure code [CA2185] Throttle sens. sup. volt. high error 1
User code Failure code Throttle Sens. sup. volt. high error
Trouble
Contents of
• High voltage was detected in throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
machine
Related
information

Disconnect devices
Defective fuel control dial at right in order. If
1 failure code disap-
(Internal trouble)
pears when a device Fuel control dial P20 connector
is disconnected, that
device has a defect
in it.
ness (Disconnection in wiring Wiring harness between CE02 (female) (27) Resis-
2 Max. 1
or defective contact in con- – P20 (female) (1) tance
nector) Wiring harness between CE02 (female) (28) Resis-
Possible causes
Max. 1
and standard – P20 (female) (3) tance
3 ness (Short circuit with GND Min.1 M
circuit)
Min.1 M
4 ness (with another wiring Wiring harness between CE02 (female) (27)
harness) Resis-
– P20 (female) (1) and between CE02 Min.1 M
tance
(female) (28) – P20 (female) (3)
CE02 Voltage
Between (27) – (28) 4.75 – 5.25 V
40-302 30 PC78US-8
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PC78US-8 40-302 31
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Failure code [CA2186] Throttle sens. sup. volt. low error 1
User code Failure code Throttle sens. sup. volt. low error
Trouble
Contents of
• Low voltage was detected in throttle sensor power supply (5 V) circuit.
trouble
Action of • Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
machine
Related
information

and standard
state
Failure code [CA2249] Rail press. very low error 1
User code Failure code Rail press. very low error

Trouble
Contents of
• Supply pump does not feed fuel (level 2).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
40-302 32 PC78US-8
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Failure code [CA2311] Abnormality in IMV solenoid 1
User code Failure code Abnormality in IMV solenoid

Trouble
Contents of
• Resistance in supply pump actuator is abnormally high or low.
trouble
Action of
controller
Problem that
appears • Engine output drops.
on machine
Related
information

Defective supply pump PREG (male) Resistance
2
actuator
Between (1) – (2) Max. 1
Between (2) – chassis ground Min. 1 M
ness
Possible 3 (Disconnection in wiring or Max. 1
causes and defective contact in connec-
standard value tor) Wiring harness between ENG1 (female) Resis-
Max. 1
in normal state (14) – PREG (female) (2) tance
Ground fault in wiring harness
4
(Short circuit with GND circuit) Wiring harness between ENG1 (female) Resis-
(14) – PREG (female) (2) and chassis Min.1 M
tance
ground
5 Defective engine controller ENG1 (female) Resistance
Between (10) – (14) Max. 1
PC78US-8 40-302 33
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Failure code [D110KB] Battery relay drive short 1
User code Failure code Battery relay drive short

Trouble
— D110KB (Pump controller system)
Contents of
• Abnormal current flowed at output to battery relay drive circuit.
trouble
Action of • Turns output to battery relay drive circuit OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Engine does not stop.
machine
Related
information

Battery relay Resistance
Defective battery relay
1 Between BR (terminal BR) –
(Internal defect) There is continuity
RE (terminal E)
Between BR (terminal BR) –
Min. 1 M
chassis ground
Possible causes
and standard Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ness
state 2 Wiring harness between C02 (female) (108)
cuit) – D01 – J01 – R02 (terminal BR) and chas- Min. 1 M
tance
sis ground
Turn starting switch
3 Defective pump controller C02 (female) Voltage
OFF.
Between (108) – 20 – 30 V
ON OFF
chassis ground (4 – 7 sec.)
40-302 34 PC78US-8
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PC78US-8 40-302 35
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Failure code [D19JKZ] Personal code relay abnormality 1
User code Failure code Personal code relay abnormality

Trouble
E01 D19JKZ (KOMTRAX system in machine monitor)
Contents of
• Disconnection or short circuit was detected in personal code relay circuit.
trouble
• None in particular (when disconnection is detected).
• Turns output to personal code relay OFF (when short circuit is detected).
Action of
• If cause of failure disappears, system resets itself (when disconnection is detected).
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF
(when disconnection is detected).
Problem that
appears on
machine
• This failure code is displayed only when engine lock function is effective.
Related
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble cannot be
information
reproduced on machine (Short circuit).

1 Defective fuse No. 3 If fuse is broken, circuit probably has ground fault (See cause 4).
ing without turning starting switch ON. (Troubleshooting for
relay unit)
R07 (male) Resistance
Defective personal code Between (1) – (2) (300 – 600 )
2 relay (Internal disconnection Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting. (Troubleshooting by replace-
ment)
Replace personal code relay (R07) with another relay and perform
reproducing operation. If "E" of failure code goes off at this time,
Possible causes replaced relay is defective.
and standard Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
Disconnection in wiring har-
state
ness (Disconnection in wiring Wiring harness between F01 (3) – R07 Resis-
3 Max. 1
or defective contact in con- (female) (1) tance
nector) Wiring harness between R07 (female) (2) – Resis-
Max. 1
CM01 (female) (6) tance
Wiring harness between F01 (3) – R07 Resis-
(female) (1) and chassis ground tance
circuit)
Min. 1 M
CM01 (female) (6) and chassis ground tance
If causes 1 – 4 are not detected, machine monitor (KOMTRAX)
Defective machine monitor
5 may be defective. (Since trouble is in system, troubleshooting can-
(KOMTRAX section)
not be carried out.)
40-302 36 PC78US-8
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PC78US-8 40-302 37
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Failure code [D862KA] GPS antenna discon 1
User code Failure code GPS antenna disconnection

Trouble
— D862KA (KOMTRAX system in machine monitor)
Contents of
• Disconnection was detected in GPS antenna circuit.
trouble
Problem that
appears on • GPS cannot measure position.
machine
Related
information

and standard Possible causes are defective GPS antenna, disconnection or
value in normal Defective GPS antenna or
1 short circuit in antenna cable, and defective connection of antenna
state antenna cable
cable connector (GPS).
Configuration drawing
40-302 38 PC78US-8
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PC78US-8 40-302 39
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Failure code [DA22KK] Pump solenoid power low error 1
User code Failure code Lowering of solenoid power supply voltage

Trouble
E0E DA22KK (Pump controller system)
Contents of
• Solenoid power supply voltage of controller is below 20 V.
trouble
• While this failure code is displayed, detection of failure codes (disconnection/short circuit) of all the
Action of
solenoid systems is stopped.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Since no solenoid valve is driven normally, machine does not operate normally.
machine
Related
information

1 Defective fuse F01 If fuse is broken, circuit probably has ground fault. (See Cause 3.)
Disconnection in wiring har- Wiring harness between C02 (female) (116), Resis-
Max. 1
ness (Disconnection in wiring (118), (121) – F01-2 tance
2
or defective contact in con- Wiring harness between F01-1A – F02 Resis-
nector) Max. 1
(male) (2) tance
Wiring harness between F02 (male) (1) – Resis-
Max. 1
RM tance
Possible causes Prepare with starting switch OFF, then carry out troubleshoot-
and standard ing without turning starting switch ON.
value in normal Wiring harness between C02 (female) (116), Resis-
state Min. 1 M
Ground fault in wiring har- (118), (121) – F01-2 and chassis ground tance
3 ness (Short circuit with GND Wiring harness between F01-1A – F02
circuit) Resis-
(male) (2), – circuit branch end and chassis Min. 1 M
tance
ground
Wiring harness between F02 (male) (1) – Resis-
Min. 1 M
RM and chassis ground tance
4 Defective pump controller C01 (female), C02 (female) Voltage
Between C02 (116), (118),
20 – 30 V
(121) – C01 (2), (5)
40-302 40 PC78US-8
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PC78US-8 40-302 41
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Failure code [DA25KP] 5V sensor 1 power abnormality 1
(North America specification)

User code Failure code
Trouble 5V sensor power supply output 1 abnormality
— DA25KP
Contents of
• Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
trouble
Action of • Turns output of 5 V sensor power supply output 1 OFF.
Problem that
appears on
machine
Related
information

circuit) Wiring harness between C01 (female) (8) – Resis-
Possible causes Min. 1 M
A08 (female) (1) and chassis ground tance
and standard
value in normal Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with and carry out troubleshooting.
state 2 24 V circuit) in wiring har-
ness Wiring harness between C01 (female) (8) –
Voltage Max. 1 V
A08 (female) (1) and chassis ground
If causes 1 – 2 are not detected, pump controller may be defective.
3 Defective pump controller
(Since trouble is in system, troubleshooting cannot be carried out.)
40-302 42 PC78US-8
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(North America specification)
PC78US-8 40-302 43
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Failure code [DA26KP] 5V sensor 2 power abnormality 1
User code Failure code 5V sensor power supply output 2 abnormality

Trouble
— DA26KP (For pump control)
Contents of
• Voltage of 5 V sensor power supply output 2 circuit is below 2.5 V or above 6.0 V.
trouble
Action of • Turns output of 5 V sensor power supply output 2 OFF.
Problem that • Automatic gear shifting function does not work (pump pressure sensor system).
appears on • Auto-decelerator keeps working and is not reset or fine control performance of work equipment is
machine lowered (PPC pressure sensor system).
Related
information

Disconnect connector with starting switch OFF, then turn start-
ing switch ON and carry out troubleshooting.
Swing right PPC
P07
pressure sensor
Disconnect sensors at right in
Defective pressure sensor order and carry out operation to Swing left PPC
1 P08
(Internal short circuit) reproduce trouble. If "E" of failure pressure sensor
code goes off when a sensor is Pump pressure
disconnected, that sensor is P25
sensor
defective.
Travel PPC pressure
P26
sensor
Between C01 (female) (36) – P07 (female)
Resis-
(2) wiring harness and ground Min. 1 M
tance
[Swing right PPC pressure sensor system]
Ground fault in wiring har- Resis-
2 ness (Short circuit with GND tance
[Swing left PPC pressure sensor]
Possible causes circuit)
and standard Between C01 (female) (9) – P25 (female)
Resis-
value in normal (3) wiring harness and ground Min. 1 M
tance
state [Pump pressure sensor system]
Resis-
tance
[Travel PPC pressure sensor system]
(2) wiring harness and ground Voltage Max. 1 V
[Swing right PPC pressure sensor system]
Hot short (Short circuit with
[Swing left PPC pressure sensor]
ness
[Pump pressure sensor system]
[Travel PPC pressure sensor system]
40-302 44 PC78US-8
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PC78US-8 40-302 45
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Failure code [DA29KQ] Model selection abnormality 1
User code Failure code Model selection abnormality

Trouble
— DA29KQ (Pump controller system)
Contents of
• Model code signal for model which is not registered in controller is input.
trouble
Action of • Changes input model code to code of default model (PC78US) and continues control.
Problem that
appears on • Since control is carried out on assumption that model is PC78US, no particular problem occurs.
machine
• Model code of pump controller can be checked with monitoring function.
(Code: 00200 Controller model code)
Related
• Condition of model selection signal can be checked with monitoring function.
information
(Code: 02209 Switch input 6)

Defective model selection ing without turning starting switch ON.
1 connector (Internal discon-
C01 (female) Resistance
nection or short circuit)
Between (40), (76) – (81) Min. 1
ness (Disconnection in wiring Wiring harness between C01 (female) (40) Resis-
2 Max. 1
or defective contact in con- – C01 (female) (76) tance
Possible causes nector) Wiring harness between C01 (female) (40) Resis-
Max. 1
and standard – C01 (female) (81) tance
Wiring harness between C01 (female) (40) Resis-
– C01 (female) (76) and chassis ground tance
circuit)
Min. 1 M
– C01 (female) (81) and chassis ground tance
4 Defective pump controller C01 (female) Resistance
Between (40), (76), (81) –
Min. 1 M
chassis ground
40-302 46 PC78US-8
SEN04810-00
PC78US-8 40-302 47
SEN04810-00

©2008 KOMATSU
All Rights Reserved
40-302 48
SEN04811-00
40 Troubleshooting
40
Failure code [DA2RMC] CAN discon (Pump controller detected)................................................................... 2

Failure code [DAFGMC] GPS module error.................................................................................................... 4
Failure code [DAFRMC] CAN discon (Monitor detected)................................................................................ 6
Failure code [DGH2KB] Hydr oil sensor short ................................................................................................ 8
Failure code [DHPAMA] Pump press sensor abnormality............................................................................. 10
Failure code [DHS5KX] Travel PPC press sensor abnormality .................................................................... 12
Failure code [DHSAMA] Swing right PPC press sensor abnormality ........................................................... 14
Failure code [DHSBMA] Swing left PPC press sensor abnormality.............................................................. 16
Failure code [DHX1MA] Overload sensor abnormality (Analog)................................................................... 18
Failure code [DV20KB] Travel alarm S/C...................................................................................................... 19
Failure code [DW43KA] Travel speed sol discon.......................................................................................... 20
Failure code [DW43KB] Travel speed sol short ............................................................................................ 21
Failure code [DW45KA] Swing brake sol discon........................................................................................... 22
Failure code [DW45KB] Swing brake sol short ............................................................................................. 24
Failure code [DWJ0KA] Merge-divider sol discon......................................................................................... 26
Failure code [DWJ0KB] Merge-divider sol short ........................................................................................... 27
PC78US-8 40-303 1
SEN04811-00
Failure code [DA2RMC] CAN discon (Pump controller detected) 1
User code Failure code CAN disconnection (Pump controller detected)

Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine
trouble monitor and engine controller.
Action of • Continues operation with information of CAN communication just before detection of error.
Problem that
• Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed section.)
machine
Related
information

Resis-
1 tance
Resis-
tance
(21), – K02 (female) (B)
(9) – C01 (female) (45), – CE02 (female) Min. 1 M
(1), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female)
and standard Resis-
value in normal tance
(21), – K02 (female) (B), – N08 (male) (10)
state
Hot short (Short circuit with Max.
(9) – C01 (female) (45), – CE02 (female) Voltage
3 24 V circuit) in wiring har- 5.5 V
(1), – K02 (female) (A), – N08 (male) (3)
ness
Max.
5.5 V
(21), – K02 (female) (B), – N08 (male) (10)
Between (A) – (B) 120 ± 12
40-303 2 PC78US-8
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PC78US-8 40-303 3
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Failure code [DAFGMC] GPS module error 1
User code Failure code GPS module operation error

Trouble
— DAFGMC (KOMTRAX system in machine monitor)
Contents of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX communication
trouble MODEM in 50 seconds after KOMTRAX is started.
Problem that
appears on
machine
Related • Method of reproducing failure code: Turn starting switch ON (At least 50 seconds after starting
information switch is turned ON).

and standard
value in normal GPS module of machine monitor may be defective. (Since trouble
1 Defective machine monitor
state is in system, troubleshooting cannot be carried out.)
40-303 4 PC78US-8
SEN04811-00
PC78US-8 40-303 5
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Failure code [DAFRMC] CAN discon (Monitor detected) 1
User code Failure code CAN disconnection (Monitor detected)

Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of
• If cause of failure disappears, system resets itself.
machine monitor
Problem that
• Information may not be transmitted normally by CAN communication and machine may not operate
appears on
normally. (Trouble phenomenon depends on failed section.)
machine
Related
information

Resis-
1 tance
Resis-
tance
(21), – K02 (female) (B)
(1), – K02 (female) (A), – N08 (male) (3)
circuit)
Possible causes Wiring harness between CM02 (female)
Resis-
and standard (10) – C01 (female) (64), – CE02 (female) Min. 1 M
tance
value in normal (21), – K02 (female) (B), – N08 (male) (10)
Hot short (Short circuit with Max.
3 24 V circuit) in wiring har- 5.5 V
(1), – K02 (female) (A), – N08 (male) (3)
ness
Max.
5.5 V
(21), – K02 (female) (B), – N08 (male) (10)
Between (A) – (B) 120 ± 12
If causes 1 – 4 are not detected, machine monitor may be defec-
5 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-303 6 PC78US-8
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PC78US-8 40-303 7
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Failure code [DGH2KB] Hydr oil sensor short 1
User code Failure code Hydraulic oil temperature sensor short

Trouble
— DGH2KB (Pump controller system)
Contents of
• Ground fault was detected in hydraulic oil temperature sensor circuit.
trouble
Action of • Controls pump in normal mode (as when hydraulic oil temperature is 20°C to below 95°C).
controller (Overheat prevention function does not work.)
Problem that
• While hydraulic oil temperature rises normally, hydraulic oil temperature gauge does not move from
appears on
top of white range (bottom of green range).
machine
• Signal voltage of hydraulic oil temperature sensor can be checked with monitoring function.
Related
(Code: 04402 Hydraulic oil temperature sensor voltage)
information

Defective hydraulic oil tem-
1 perature sensor (Internal dis- P22 (male) Resistance
connection or short circuit) Between (1) – (2) 3.5 – 90 k
Possible causes
and standard Ground fault in wiring har- ing without turning starting switch ON.
value in normal 2 ness (Short circuit with GND
state circuit) Wiring harness between C01 (female) (29) Resis-
Min. 1 M
Between (29) – (46) 3.5 – 90 k
40-303 8 PC78US-8
SEN04811-00
PC78US-8 40-303 9
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Failure code [DHPAMA] Pump press sensor abnormality 1
User code Failure code Pump pressure sensor abnormality

Trouble
— DHPAMA (Pump controller system)
Contents of
• Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.4 V.
trouble
Action of • Fixes pump pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic gear shifting function does not work.
appears on
• Straight travel performance or steering performance lowers.
machine
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
Related will be broken. Accordingly, take extreme care when checking.
information • Pump pressure can be checked with monitoring function. (Code: 01100 Pump pressure)
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective 5 V sensor power If failure code [DA25KP] is also displayed, carry out trouble-
1
supply 1 system shooting for it first.
or start engine and carry out troubleshooting in each case.
P25 Voltage
Defective pump pressure
2 Between (3) – (1) Power supply 4.5 – 5.5 V
sensor (Internal defect)
Between (2) – (1) Signal 0.3 – 4.5 V
If voltage is abnormal, check failure code. (If "E" of failure code
goes off at this time, pump pressure sensor is defective.)
Possible causes Disconnection in wiring har- Wiring harness between C01 (female) (18) Resis-
and standard Max. 1
ness (Disconnection in wiring – P25 (female) (1) tance
value in normal 3
or defective contact in con- Wiring harness between C01 (female) (49) Resis-
state nector) Max. 1
Wiring harness between C01 (female) (9) – Resis-
Max. 1
J07 – P25 (female) (3) tance
circuit) Wiring harness between C01 (female) (49) Resis-
Min. 1 M
ness Wiring harness between C01 (female) (49)
Voltage Max. 1 V
– P25 (female) (2)
40-303 10 PC78US-8
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PC78US-8 40-303 11
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Failure code [DHS5KX] Travel PPC press sensor abnormality 1
User code Failure code Travel PPC pressure sensor abnormality

Trouble
E20 DHS5KX (Pump controller system)
Contents of
• Signal voltage of travel PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes travel PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
• Automatic decelerator cannot be reset.
appears on
• Travel right forward performance lowers.
machine
will be broken. Accordingly, take extreme care when checking.
Related
• Travel PPC pressure can be checked with monitoring function.
information
(Code: 07101 Travel PPC pressure)

Defective 5 V sensor power If failure code [DA25KP] is also displayed, carry out troubleshoot-
1
supply 1 system ing for it first.
P26 Voltage
Defective travel PPC pres-
2 Between (2) – (1) Signal 0.3 – 4.5 V
sure sensor (Internal defect)
If voltage is abnormal, replace travel PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, travel PPC pressure sensor is defec-
tive.)
and standard Disconnection in wiring har- Wiring harness between C01 (female) (18) Resis-
state 3
nector) Max. 1
Max. 1
Min. 1 M
Voltage Max. 1 V
– P26 (female) (2)
40-303 12 PC78US-8
SEN04811-00
PC78US-8 40-303 13
SEN04811-00
Failure code [DHSAMA] Swing right PPC press sensor abnormality 1
User code Failure code Swing right PPC pressure sensor abnormality
Trouble
E20 DHSAMA (Pump controller system)
Contents of
• Signal voltage of swing right PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing right PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
• Swing right performance lowers.
machine
Related
• Swing right PPC pressure can be checked with monitoring function.
information
(Code: 09002 Swing right PPC pressure)

1
P07 Voltage
Defective swing right PPC Between (3) – (1) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal Between (2) – (1) Signal 0.3 – 4.5 V
defect)
If voltage is abnormal, replace swing right PPC pressure sensor
with another PPC pressure sensor and check failure code. (If "E" of
failure code goes off at this time, swing right PPC pressure sensor
is defective.)
state 3
nector) Max. 1
Max. 1
Min. 1 M
Voltage Max. 1 V
– P07 (female) (2)
40-303 14 PC78US-8
SEN04811-00
PC78US-8 40-303 15
SEN04811-00
Failure code [DHSBMA] Swing left PPC press sensor abnormality 1
User code Failure code Swing left PPC pressure sensor abnormality
Trouble
E20 DHSBMA (Pump controller system)
Contents of
• Signal voltage of swing left PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
trouble
Action of • Fixes swing left PPC pressure at 0 MPa {0 kg/cm2} and continues control.
Problem that
appears on
• Swing left performance lowers.
machine
Related
• Swing left PPC pressure can be checked with monitoring function.
information
(Code: 09001 Swing left PPC pressure)

1
P08 Voltage
Defective swing left PPC Between (3) – (1) Power supply 4.5 – 5.5 V
2 pressure sensor (Internal Between (2) – (1) Signal 0.3 – 4.5 V
defect)
If voltage is abnormal, replace swing left PPC pressure sensor with
another PPC pressure sensor and check failure code. (If "E" of fail-
ure code goes off at this time, swing left PPC pressure sensor is
defective.)
state 3
nector) Max. 1
Max. 1
Min. 1 M
Voltage Max. 1 V
– P08 (female) (2)
40-303 16 PC78US-8
SEN04811-00
PC78US-8 40-303 17
SEN04811-00
Failure code [DHX1MA] Overload sensor abnormality (Analog) 1
User code Failure code Overload sensor abnormality (Analog)

Trouble
— DHX1MA (Pump controller system)
Contents of
• Monitor which is not set to be displayed (Overload alarm monitor) is displayed.
trouble
Problem that
appears on
machine
Related
Method of reproducing failure code: Turn starting switch ON.
information

and standard
value in normal Pump controller may be defective. (Since trouble is in system, trou-
state bleshooting cannot be carried out.)
40-303 18 PC78US-8
SEN04811-00
Failure code [DV20KB] Travel alarm S/C 1
User code Failure code Travel alarm S/C

Trouble
— DV20KB (Pump controller system)
Contents of
• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
trouble
• Power to the travel alarm circuit is switched OFF.
Action of
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Problem that
appears on • The travel alarm does not sound.
machine
Related • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code: 03701 Controller output 2)

Turn the engine starting switch OFF for the preparations, and
keep the engine running during the troubleshooting.
M14 (female) Travel lever Voltage
Travel alarm defective
1 Neutral Max. 1 V
(Internal defect) Between (1) and (2)
Operated 20 – 30 V
If the above voltage is normal but the travel alarm does not oper-
Possible causes ate, the travel alarm is defective.
and standard Turn the engine starting switch OFF for the preparations, and
value in normal Grounding fault of wiring har- hold it in the OFF position during the troubleshooting.
state ness
2 Between wiring harness between C02
(Contact with grounding cir- Resis-
cuit) (female) (107) and M14 (female) (1) and Min. 1 M
tance
chassis ground
Turn the engine starting switch OFF for the preparations, and
keep the engine running during the troubleshooting.
3 Pump controller defective C02 Travel lever Voltage
Between (107) – Neutral Max. 1 V
chassis ground Operated 20 – 30 V
PC78US-8 40-303 19
SEN04811-00
Failure code [DW43KA] Travel speed sol discon 1
User code Failure code Travel speed solenoid system disconnection

Trouble
— DW43KA (Pump controller system)
Contents of
• When output to travel speed shifting solenoid was turned ON, disconnection was detected in circuit.
trouble
Action of • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about
appears on
Middle).
machine
• Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related
(Code: 02300 Solenoid 1)
information
• Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever.

Defective travel speed shifting without turning starting switch ON.
1 ing solenoid (Internal discon-
V02 (male) Resistance
nection)
Between (1) – (2) 20 – 60
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between C02 (female) (87) Resis-
value in normal 2 Max. 1
or defective contact in con- – V02 (female) (2) tance
state nector) Wiring harness between C02 (female) (115), Resis-
Max. 1
(117), (120) – V02 (female) (1) tance
Between (87) – (115), (117),
20 – 60
(120)
40-303 20 PC78US-8
SEN04811-00
Failure code [DW43KB] Travel speed sol short 1
User code Failure code Travel speed solenoid system short

Trouble
— DW43KB (Pump controller system)
Contents of
• When output to travel speed shifting solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to travel speed shifting solenoid OFF.
Problem that
• Speed is low at High travel speed position (Machine monitor is set to High but actual speed is about
appears on
Middle).
machine
• Operating condition of travel speed shifting solenoid can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Start engine + Set travel speed to High + Operate travel lever.

Defective travel speed shift-
1 ing solenoid (Internal discon- V02 (male) Resistance
nection) Between (1) – (2) 20 – 60
state Min. 1 M
– V02 (female) (2) tance
Between (87) – (115), (117),
20 – 60
(120)
PC78US-8 40-303 21
SEN04811-00
Failure code [DW45KA] Swing brake sol discon 1
User code Failure code Swing holding brake solenoid system disconnection
Trouble
E03 DW45KA (Pump controller system)
Contents of • When output to swing holding brake solenoid was turned OFF, disconnection was detected in cir-
trouble cuit.
Action of • None in particular. (Since no current flows, solenoid does not operate.)
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related • Keep swing lock switch in OFF position and swing holding brake release switch in release position
information during troubleshooting.
• Operating condition of swing holding brake solenoid can be checked with monitoring function.

Defective swing holding ing without turning starting switch ON.
1 brake solenoid (Internal dis-
connection)
Between (1) – (2) 20 – 60
Defective assembled-type ing without turning starting switch ON.
2 diode D01 (Internal discon-
D01 (male) Digital circuit tester Continuity
nection)
Between (7) – (3) Diode mode There is continuity
value in normal Wiring harness between C02 (female) (101) Resis-
Disconnection in wiring har- Max. 1
state – D01 (female) (7) tance
ness (Disconnection in wiring
3
or defective contact in con- Wiring harness between D01 (female) (3) – Resis-
nector) Max. 1
J04 – V03 (female) (3) tance
Wiring harness between C02 (female) (115), Resis-
Max. 1
(117), (120) – V03 (female) (1) tance
4 Defective pump controller C02 (female) Disconnect D01 and Resistance

connect pins (3) and
Between (101) – (7) on female side 20 – 60
(115), (117), (120) directly.
40-303 22 PC78US-8
SEN04811-00
PC78US-8 40-303 23
SEN04811-00
Failure code [DW45KB] Swing brake sol short 1
User code Failure code Swing holding brake solenoid system short
Trouble
E03 DW45KB (Pump controller system)
Contents of
• When output to swing holding brake solenoid was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to swing holding brake solenoid OFF.
Problem that
appears on • Machine cannot swing (Swing holding brake is not reset).
machine
• If solenoid and wiring harness are normal, operator can swing machine by setting swing holding
brake release switch in release position (Swing holding brake does not work, however, when
machine stops).
Related
• Keep swing holding brake release switch in release position during troubleshooting.
information
• Operating condition of swing holding brake solenoid can be checked with monitoring function.
• Method of reproducing failure code: Start engine + Swing with left work equipment control lever.

Defective swing holding
1 brake solenoid (Internal short V03 (male) Resistance
circuit or ground fault) Between (1) – (2) 20 – 60
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard ness (Disconnection in wiring
2
value in normal or defective contact in con- Wiring harness between C02 (female) (101) Resis-
nector) – D01 – J04 – V03 (female) (2), – S25 Min. 1 M
state tance
(female) (14)
3 Defective pump controller Disconnect D01 and
Between (101) –
connect pins (3) and 20 – 60
(115), (117), (120)
(7) on female side
Between (101) – directly. Min. 1 M
chassis ground
40-303 24 PC78US-8
SEN04811-00
PC78US-8 40-303 25
SEN04811-00
Failure code [DWJ0KA] Merge-divider sol discon 1
User code Failure code Merge-divider solenoid disconnection

Trouble
— DWJ0KA (Pump controller system)
Contents of
• When merge-divider EPC solenoid was driven, disconnection was detected in circuit.
trouble
Action of • None in particular (Since no current flows, solenoid does not operate).
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related
information

Defective merge-divider EPC ing without turning starting switch ON.
1 solenoid (Internal disconnec-
tion)
Between (1) – (2) 7 – 14
Max. 1
(117), (120) – V04 (female) (1) tance
Between (110) – (115), (117),
7 – 14
(120)
40-303 26 PC78US-8
SEN04811-00
Failure code [DWJ0KB] Merge-divider sol short 1
User code Failure code Merge-divider solenoid short

Trouble
— DWJ0KB (Pump controller system)
Contents of
• When merge-divider EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to merge-divider EPC solenoid OFF.
Problem that
appears on • Single operation speed of work equipment and swing is high in lifting mode (L).
machine
Related
information

Defective merge-divider EPC
1 solenoid (Internal short cir- V04 (male) Resistance
cuit or ground fault) Between (1) – (2) 7 – 14
state Min. 1 M
Between (110) – (115), (117),
7 – 14
(120)
PC78US-8 40-303 27
SEN04811-00

©2008 KOMATSU
All Rights Reserved
40-303 28
SEN04812-00
40 Troubleshooting
40
Failure code [DXA8KA] PC-EPC sol discon ................................................................................................... 2

Failure code [DXA8KB] PC-EPC sol short ...................................................................................................... 4
Failure code [DXE4KA] Service current EPC discon ...................................................................................... 6
Failure code [DXE4KB] Service current EPC short ........................................................................................ 7
Failure code [DY20KA] Wiper working abnormality ........................................................................................ 8
Failure code [DY20MA] Wiper parking abnormality ...................................................................................... 10
Failure code [DY2CKA] Washer drive discon ............................................................................................... 12
Failure code [DY2CKB] Washer drive short.................................................................................................. 14
Failure code [DY2DKB] Wiper drive (for) short ............................................................................................. 16
Failure code [DY2EKB] Wiper drive (rev) short ............................................................................................ 18
PC78US-8 40-304 1
SEN04812-00
Failure code [DXA8KA] PC-EPC sol discon 1
User code Failure code PC-EPC solenoid system disconnection

Trouble
E02 DXA8KA (Pump controller system)
Contents of
• When PC-EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Drive current of PC-EPC solenoid can be checked with monitoring function.
Related
(Code: 01300 PC-EPC solenoid current)
information

Defective PC-EPC solenoid ing without turning starting switch ON.
1
(Internal disconnection) V11 (male) Resistance
Between (1) – (2) 7 – 14
Emergency pump
S25 (male) Resistance
Defective emergency pump drive switch
2 drive switch (Internal discon- Normal Max. 1
nection) Between (3) – (2)
Emergency Min. 1 M
Normal Max. 1
Between (6) – (5)
Possible causes Emergency Min. 1 M
and standard
value in normal
state
Max. 1
Disconnection in wiring har- – S25 (female) (3) tance
ness (Disconnection in wiring Wiring harness between S25 (female) (2) – Resis-
3 Max. 1
or defective contact in con- V11 (female) (1) tance
nector) Wiring harness between C02 (female) (115), Resis-
Max. 1
(117), (120) – S25 (female) (6) tance
Wiring harness between S25 (female) (5) – Resis-
Max. 1
V11 (female) (2) tance
Between (96) – (115), (117),
7 – 14
(120)
40-304 2 PC78US-8
SEN04812-00
PC78US-8 40-304 3
SEN04812-00
Failure code [DXA8KB] PC-EPC sol short 1
User code Failure code PC-EPC solenoid system short

Trouble
E02 DXA8KB (Pump controller system)
Contents of
• When PC-EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to PC-EPC solenoid OFF.
Problem that
appears on • If pump load increases, engine speed lowers largely and engine may stall.
machine
• Drive current of PC-EPC solenoid can be checked with monitoring function.
Related
(Code: 01300 PC-EPC solenoid current)
information

Defective PC-EPC solenoid
1 (Internal short circuit or V11 (male) Resistance
ground fault) Between (1) – (2) 7 – 14
Defective emergency pump Emergency pump
S25 (male) Resistance
2 drive switch (Internal short drive switch
circuit or ground fault) Between (2), (3) – (4) Min. 1 M
Possible causes
Between (2), (3) – Normal
and standard Min. 1 M
value in normal chassis ground
state Prepare with starting switch OFF, then carry out troubleshoot-
3 ness (Contact with GND cir- Min. 1 M
– S25 (female) (3) tance
cuit)
Wiring harness between S25 (female) (5) – Resis-
Min. 1 M
V11 (female) (2) tance
Between (96) – (115), (117),
7 – 14
(120)
40-304 4 PC78US-8
SEN04812-00
PC78US-8 40-304 5
SEN04812-00
Failure code [DXE4KA] Service current EPC discon 1
User code Failure code Service current EPC solenoid disconnection

Trouble
— DXE4KA (Pump controller system)
Contents of
• When service EPC solenoid was driven, disconnection was detected in circuit.
trouble
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 Service solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defective service EPC sole- ing without turning starting switch ON.
1
noid (Internal disconnection) V30 (male) Resistance
Between (1) – (2) 7 – 14
Max. 1
(117), (120) – V30 (female) (2) tance
Between (97) – (115), (117),
7 – 14
(120)
40-304 6 PC78US-8
SEN04812-00
Failure code [DXE4KB] Service current EPC short 1
User code Failure code Service current EPC solenoid short

Trouble
— DXE4KB (Pump controller system)
Contents of
• When service EPC solenoid was driven, short circuit was detected in circuit.
trouble
Action of • Turns output to service EPC solenoid OFF.
Problem that
appears on • Attachment does not operate.
machine
• Drive current of service EPC solenoid can be checked with monitoring function.
Related
(Code: 01700 Service EPC solenoid current)
information
• Method of reproducing failure code: Turn starting switch ON + Set in attachment mode (ATT).

Defective service EPC sole-
1 noid (Internal short circuit or V30 (male) Resistance
state Min. 1 M
Between (97) – (115), (117),
7 – 14
(120)
PC78US-8 40-304 7
SEN04812-00
Failure code [DY20KA] Wiper working abnormality 1
User code Failure code Wiper working abnormality

Trouble
— DY20KA (Pump controller system)
Contents of
• When windshield wiper works, W signal of working ends is not input.
trouble
Action of • Turns working output to wiper motor OFF.
Problem that
appears on • Wiper motor does not work.
machine
• Condition of W contact signal of wiper working area can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT or ON.

M05 (female) Wiper blade Resistance
Defective wiper motor (Inter-
1 Operating range top Max. 1
nal disconnection)
Between (6) – (5) Other than operating
Min. 1 M
range top
Between (1) – (3) All range Max. 20
Disconnection in wiring har- – M05 (male) (6) tance
and standard
value in normal ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resis-
2 Max. 1
state or defective contact in con- J01 – chassis ground (T09) tance
nector) Wiring harness between C02 (female) (114) Resis-
Max. 1
– M05 (male) (1) tance
Max. 1
C01 (female) Wiper blade Resistance
3 Defective pump controller Operating range top Max. 1
Between (56) – chas-
sis ground Other than operating
Min. 1 M
range top
40-304 8 PC78US-8
SEN04812-00
PC78US-8 40-304 9
SEN04812-00
Failure code [DY20MA] Wiper parking abnormality 1
User code Failure code Wiper parking abnormality

Trouble
— DY20MA (Pump controller system)
Contents of
• When windshield wiper is stored, P signal of storage area is not input.
trouble
Action of • Turns storage output to wiper motor OFF.
Problem that
appears on • Wiper is not stored.
machine
• Condition of P contact signal of wiper storage area can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Turn starting switch ON + Set wiper switch to INT/ON to OFF.

M05 (female) Wiper blade Resistance
Storage area Max. 1
Between (4) – (5)
Defective wiper motor (Inter- Working area Min. 1 M
1
nal disconnection) Between (1) – (3) All range Max. 20
Max. 1
Max. 1
and standard
value in normal Wiring harness between C01 (female) (75) Resis-
Max. 1
state Disconnection in wiring har- – M05 (male) (4) tance
ness (Disconnection in wiring Wiring harness between M05 (female) (5) – Resis-
2 Max. 1
or defective contact in con- J01 – chassis ground (T09) tance
nector) Wiring harness between C02 (female) (114) Resis-
Max. 1
Max. 1
C01 (female) Wiper blade Resistance
Between (75) – chas- Storage area Max. 1
sis ground Working area Min. 1 M
40-304 10 PC78US-8
SEN04812-00
PC78US-8 40-304 11
SEN04812-00
Failure code [DY2CKA] Washer drive discon 1
User code Failure code Window washer drive system disconnection

Trouble
— DY2CKA (Pump controller system)
Contents of • When output to window washer drive system was turned OFF (when ground circuit was connected),
trouble disconnection was detected in circuit.
Action of • None in particular (Since no current flows, washer motor does not operate).
Problem that
appears on • Window washer does not operate.
machine
Related
information

1 Defective fuse No. 4 If fuse is broken, circuit probably has ground fault. (See cause 5.)
Defective washer motor M06 (male) Resistance
2 (Internal short circuit or
Min. 1 M
ground
Defective assembled-type ing without turning starting switch ON.
3 diode D02 (Internal short cir-
D02 (female) Continuity (Resistance)
cuit)
Between (3) – (7) No continuity (Min. 1 M )
Disconnection in wiring har-
value in normal
ness (Disconnection in wiring Wiring harness between F01 (4) – J05 – Resis-
state 4 Max. 1
or defective contact in con- M06 (female) (1) tance
nector) Wiring harness between C01 (female) (3) – Resis-
Max. 1
J01 – M06 (female) (2) tance
Wiring harness between F01 (4) – J05 – Resis-
M06 (female) (1), – D02 (female) (3) tance
circuit)
Min. 1 M
J01 – M06 (female) (2), – D02 (female) (7) tance
C01 (female) Voltage
Between (3) – chassis ground 20 – 30 V
40-304 12 PC78US-8
SEN04812-00
PC78US-8 40-304 13
SEN04812-00
Failure code [DY2CKB] Washer drive short 1
User code Failure code Window washer drive system short

Trouble
— DY2CKB (Pump controller system)
Contents of • When output to window washer drive system was turned ON (ground circuit was disconnected),
trouble short circuit was detected in circuit.
Action of • Turns output to washer motor OFF.
Problem that
appears on • Window washer does not operate.
machine
Related
• Method of reproducing failure code: Turn starting switch ON + Turn washer switch ON.
information

Defective washer motor ing without turning starting switch ON.
1
(Internal short circuit) M06 (male) Resistance
Possible causes Between (1) – (2) 5 – 20
and standard Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short (Short circuit with and carry out troubleshooting.
state 2 24 V circuit) in wiring har-
ness Wiring harness between C01 (female) (3) –
Voltage Max. 1 V
J01 – M6 (female) (2), – D02 (female) (7)
If causes 1 and 2 are not detected, pump controller may be defec-
3 Defective pump controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-304 14 PC78US-8
SEN04812-00
PC78US-8 40-304 15
SEN04812-00
Failure code [DY2DKB] Wiper drive (for) short 1
User code Failure code Wiper motor drive forward system short
Trouble
— DY2DKB (Pump controller system)
Contents of
• When output to wiper motor drive forward side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive forward side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
information

1 nal short circuit or ground M05 (female) Resistance
fault) Between (3) – (1) There is continuity
Possible causes
and standard Between (3) – chassis ground Min. 1 M
Min. 1 M
out.)
40-304 16 PC78US-8
SEN04812-00
PC78US-8 40-304 17
SEN04812-00
Failure code [DY2EKB] Wiper drive (rev) short 1
User code Failure code Wiper motor drive reverse system short
Trouble
— DY2EKB (Pump controller system)
Contents of
• When output to wiper motor drive reverse side was turned ON, short circuit was detected in circuit.
trouble
Action of • Turns output to wiper motor drive reverse side OFF.
Problem that
appears on • Windshield wiper does not operate.
machine
Related
information

1 nal short circuit or ground M05 (female) Continuity/Resistance
fault) Between (1) – (3) There is continuity
Possible causes
and standard Between (1) – chassis ground Min. 1 M
Min. 1 M
out.)
40-304 18 PC78US-8
SEN04812-00
PC78US-8 40-304 19
SEN04812-00

©2008 KOMATSU
All Rights Reserved
40-304 20

PC78US-8 Troubleshooting by Failure Code PDF

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SEN04809-00

PC78US-8 15001 and up

Failure code [989L00] Engine controller lock caution 1 .................................................................................. 3

Failure code [CA271] IMV/PCV1 short error ................................................................................................. 38

Failure code [989L00] Engine controller lock caution 1 1

User code Failure code Engine controller lock caution 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [989M00] Engine controller lock caution 2 1

User code Failure code Engine controller lock caution 2

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [989N00] Engine controller lock caution 3 1

User code Failure code Engine controller lock caution 3

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [AB00KE] Charge voltage low 1

User code Failure code Charge voltage low

Cause Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

Failure code [B@BAZG] Eng oil press. low 1

User code Failure code Engine oil pressure low

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@BCNS] Eng coolant overheat 1

User code Failure code Engine coolant overheat

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [B@HANS] Hydr oil overheat 1

User code Failure code Hydraulic oil overheat

Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA111] ECM critical internal failure 1

User code Failure code ECM critical internal failure

Cause Standard value in normal state/Remarks on troubleshooting

Cause Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

Failure code [CA115] Eng. Ne and Bkup speed sensor error 1

Causes Standard value in normal state/Remarks on troubleshooting

Failure code [CA122] Charge air press sensor high error 1

Causes Standard value in normal state/Remarks on troubleshooting

Causes Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

Failure code [CA123] Charge air press sensor low error 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA131] Throttle sensor high error 1

User code Failure code Throttle sensor high error

Causes Standard value in normal state/Remarks on troubleshooting

Defective fuel control dial P20 (male) Resistance

Related circuit diagram

Failure code [CA132] Throttle sensor low error 1

User code Failure code Throttle sensor low error

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA144] Coolant temp. sensor high error 1

User code Failure code Coolant temp. sensor high error

Cause Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

Failure code [CA145] Coolant temp. sensor low error 1

User code Failure code Coolant temp. sensor low error

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA153] Charge air temp. sensor high error 1

Cause Standard value in normal state/Remarks on troubleshooting

Related circuit diagram

Failure code [CA154] Charge air temp. sensor low error 1

Possible causes Cause Standard value in normal state/Remarks on troubleshooting

Failure code [CA187] Sensor sup. 2 volt. low error 1

User code Failure code Sensor sup. 2 volt. low error

Possible causes Causes Standard value in normal state/Remarks on troubleshooting

Failure code [CA221] Ambient air press. sensor high error 1