Service Manual of Wheel Loader

Table of Contents
2 Engine System.............................................................................................................................................. 1

21 Key parameters of engine maintenance ............................................................... 1

22 Detection range and use steps of engine detection tools ..................................... 1

221 YN36/YN4EL engine oil pressure detection.............................................. 1

23 Flow figure on engine dismantlement and installation ........................................ 1

231 YN36/YN4EL series engine dismantlement and installation flow ............ 3

Different engine types have different installation and dismantlement orders. It is

for reference only. ..................................................................................................... 4

24 Engine failure diagnosis....................................................................................... 5

25 Engine failure diagnosis codes .......................................................................... 10

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 Service Manual of Wheel Loader

2 Engine System
21 Key parameters of engine maintenance

Bulge
Idle Intake Exhaust Engine oil
Engine Rated speed value of
speed of valve valve pressure (rated
model of engine cylinder
engine clearance clearance speed)
liner
YN36 0.3 0.4
2600r/min 800±30 - 196~490kPa
(II2893) -0.35mm -0.45mm
YN4EL
2200r/min 800±30
(IRG017)
Table 1 Key parameters of engine
This table is for reference only. Details of overall engine shall be subject to engine nameplate!

22 Detection range and use steps of engine

detection tools
221 YN36/YN4EL engine oil pressure detection
If engine oil pressure is to be detected, special pressure
detection connector and pressure gauge shall be used for
pressure measurement.

Figure 1 Engine pressure

detection position

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 Service Manual of Wheel Loader
Figure 2 Engine detection tools
44190001285 4120003068 test 4030000368 test 6430000942
GE06L1/8NPT connector hose Pressure
CFX VKA3/06LCF SMS20/M1/4-3000A gauge 1Mpa

YN36/YN4EL engine oil pressure detection steps

1) Place the loader on the maintenance location, put
the bucket on the ground, pull up the parking brake, and
shut down the engine.
2) Dismantle the engine oil pressure switch, and install
detection connector 1 and test connector 2 at the
dismantlement place.
3) Connect one end of test hose 3 to test connector 2,
and connect the other end to pressure gauge 4.
4) Start the engine, and respectively record oil
pressure of the engine when it is at idle speed and rated
speed.
5) After completing detection, dismantle the test
connector, install the engine oil pressure switch, and
wipe the exposed engine oil clean.
Reference pressure
Engine oil pressure is ≥49kPa generally when the engine
is at idle speed; engine oil pressure is 196~490kPa
generally when the engine is at rated speed.

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 Service Manual of Wheel Loader

23 Flow figure on engine dismantlement

and installation

231 YN36/YN4EL series engine

dismantlement and installation flow

Dismantlement flow Prepare

Discharge coolant
Discharge engine oil
Dismantle air prefilter
Dismantle rubber hose of expansion
tank
Dismantle engine hood
Lift cab
Dismantle radiator
Dismantle
Dismantle engine wiring harness
engine
Dismantle fuel pipeline
Dismantle accelerator wire and choke
wire
Dismantle pipe of fan heater
Dismantle hose of air compressor
Dismantle oil return pipeline of
torque converter
Disconnect transmission and torque
converter assembly
Lift off engine

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 Service Manual of Wheel Loader

Installation flow
Lift engine
Connect transmission and
torque converter assembly
Fix bolt of shock absorber
Install oil return pipeline of
torque converter
Install pipeline of air
compressor
Install pipe of fan heater
Install accelerator wire and
choke wire
Install fuel pipeline Install engine
Install engine wiring harness
Install radiator
Lift cab
Install engine hood
Install pipeline of expansion
tank
Install air prefilter
Add engine oil
Add antifreeze
Different engine types have different installation and dismantlement orders. It is for reference
only.

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 Service Manual of Wheel Loader

24 Engine failure diagnosis

Reason for
Failure type Solutions
failure
Battery power is Seriously inspect battery power, and charge or
Factor of
low replace the battery
starting
Starting motor is
system Repair or replace the starting motor
damaged
Dredge the oil-way (high pressure air blow is
There is air in
available), and fasten all connectors and carry
oil-way system
out emptying
Dredge the oil-way (high pressure air blow is
Oil-way system
available), and fasten all connectors and carry
is blocked
out emptying
Factor of Diesel filter
oil supply element is too Replace the filter element
The engine system dirty
cannot be Piston/Delivery
started valve is Repair fuel injection pump professionally
seriously worn
Low-pressure oil
transfer pump is Replace the oil transfer pump
damaged
Fuel injection
advance angle is Adjust fuel injection advance angle
misplaced
Factor of Valve clearance
Inspect and adjust valve clearance
adjustment changes
Starting fuel
capacity is too Inspect fuel injection pump professionally
little
Diesel filter or
filter screen of
oil transfer pump Clean or replace it
inlet connector is
blocked
Oil atomizer is
Engine power of insufficient Inspect and repair oil atomizer or replace
is insufficient pressure or poor matching parts of nozzle
atomization
Precise matching
parts of nozzle Adjust fuel supply quantity or inspect and repair
are of excessive matching parts of piston
wear
Air enters fuel Eliminate air in fuel system

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 Service Manual of Wheel Loader
system
Fuel injection
advance angle is Adjust it according to provisions
incorrect
Fuel supply
quantities of Adjust fuel supply quantities of various
various cylinders cylinders
are not uniform
Air filter is not
Clean or replace filter element
expedite
Liquid level of
Discharge excess lubricating oil, and keep the
lubricating oil in
liquid level in the prescribed scale on engine oil
engine oil pan is
dipstick
too high
Needle valve of
oil atomizer is
not tightly
closed or burns Clean and calibrate oil atomizer or replace
out at the open matching parts of needle valve
position, thus
making diesel
enter the oil pan
Seal ring of
piston bush of
fuel injection
pump is
Diesel
damaged (P-type
engine
Exhaust is pump), or piston
discharges
abnormal bush and pump Replace seal ring
blue
body are not
smoke
tightly sealed,
thus making fuel
flow into oil pan
along lubricating
oil passage
Valve oil seal is
damaged or
clearance
between valve Replace the faulty valve, duct and oil seal (oil
and duct exceeds seal must be replaced if dismantled; duct may
the limit, thus not be replaced if the clearance meets the
making engine requirements after the valve is replaced with a
oil get absorbed new one)
into combustion
chamber in air
inlet stroke
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 Service Manual of Wheel Loader
Sealing ring of
turbocharger is
damaged, thus
making
lubricating oil
enter Repair or replace it
combustion
chamber for
combustion
along air inlet
passage
There is
Clean oil tank and filter, and use qualified diesel
moisture in fuel
oil
system
Cylinder valve is
Replace the worn parts
Diesel worn
engine Nozzle is of
discharges poor oil injection
white and atomization,
smoke and diesel oil Calibrate oil atomizer and fuel supply advance
droplets fail to angle
be combusted in
combustion
chamber
Exhaust back
pressure is too
Reduce bends of exhaust pipe, and remove dust
high or exhaust
of muffler
pipeline is
blocked
Oil injection is
Adjust fuel injection advance angle
Diesel too late
engine Oil atomizer
discharges works poorly or Dismantle, clean and inspect it
black is damaged
smoke Diesel oil is of
poor quality or Replace diesel oil
wrong grade
Cylinder liner
and piston
Replace the worn parts
assembly are
seriously worn
Lubricating Engine oil
Engine oil
oil pressure is display device is Replace display device
pressure is
too high or abnormal
too high
too low Engine oil Select engine oil of the prescribed grade.

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 Service Manual of Wheel Loader
viscosity is too Preheating measures shall be adopted for
large starting the engine in winter.
Clearance of
pressure
lubrication parts
Adjust clearance of lubrication parts, and clean
is too small or
or replace engine oil filter
fine filter of
engine oil is
blocked
Pressure-limiting
Readjust spring force of pressure-limiting valve,
valve is
thus making the engine oil pressure fall back to
improperly
the prescribed value
adjusted
Engine oil pump
is worn or Repair engine oil pump and replace sealing
sealing gasket is gasket
damaged
Quantity of oil
Inspect oil quantity, add engine oil and clean
absorbed into oil
engine oil suction filter
pump reduces
Inspect whether lubrication pipeline ruptures or
Engine oil
not, and inspect and adjust fit clearance of
leakage rate is
bearings at the places of crankshaft and
large
camshaft according to requirements
Engine oil
Engine oil filter
pressure is
or cooler is Inspect and clean engine oil filter and cooler
too low
blocked
Engine oil
Select engine oil of proper grade according to
viscosity is too
requirements
small
Pressure-limiting
valve is Clean pressure-limiting valve, and adjust or
improperly replace spring
adjusted
Engine oil
Inspect and replace engine oil pressure sensor
pressure is too
and engine oil pressure gauge
low as displayed
Engine oil
viscosity is
Select proper lubricating oil
Lubricating improperly
oil selected
consumption Negative
is large pressure in Inspect the reason for too large negative
combustion pressure, and make an adjustment
chamber is too

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 Service Manual of Wheel Loader
large, thus
making engine
oil go up to
combustion
chamber
Tests have shown that engine oil consumption
Revolving speed
will rise significantly along with increase of
and operation
revolving speed. Operate the engine according
mode change
to provisions
Coolant is
improperly
Select proper coolant, and add it to proper liquid
selected or water
level
yield is
insufficient
Carefully put cooling fin back to the original
Water radiator is position with thin steel sheet, recover flat and
blocked straight shape of cooling fin, and then clean it
with compressed air or hydraulic giant
Water Measure temperature at the place of water
thermometer or temperature sensor with surface thermometer,
warning light is and observe whether the indication on water
of wrong thermometer conforms to the actual temperature
indication or not
Coolant
Rubber belt of fan is too loose, which will lead
temperature is
Revolving speed to slip, thus causing too low revolving speed of
high
of fan is too low, fan, and weakening air supply effect. Make an
and blades are adjustment if finding the rubber belt is too
deformed or loose; make a replacement if the rubber layer is
installed ageing or damaged, or the fibrous layer is
reversely broken. Replace fan blades in case of
deformation
Cooling water
Replace water pump
pump fails
Thermostat fails Replace thermostat
Cylinder gasket
Replace cylinder gasket
is damaged
Diesel engine is
of overloaded Reduce engine load
operation
Table 2 General engine failure diagnosis

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 Service Manual of Wheel Loader

25 Engine failure diagnosis codes

Yunnei three-stage engine is equipped with fresh air
electronic control system. Its failure diagnosis codes are
as follows:

DFP NUM Codes

Types Descriptions
(HEX) (DTC)
Bit0 0
Bit1 0
0
Bit2 0
Bit3 P0741 Error flag bit of credibility inspection of clutch
Bit0 0
Bit1 0
1
Bit2 P2519 Failure/error flag bit from can of air conditioning signal
Bit3 0
Bit0 P0123 Sampled voltage of accelerator pedal circuit 1 exceeds
upper limit
Bit1 P0122 Sampled voltage of accelerator pedal circuit 1 exceeds
2
lower limit
Bit2 0
Bit3 P2135 Doubtful error for dual-circuit accelerator pedal
Bit0 P0223 Sampled voltage of accelerator pedal circuit 2 exceeds
upper limit
Bit1 P0222 Sampled voltage of accelerator pedal circuit 2 exceeds
3
lower limit
Bit2 0
Bit3 P2135 Doubtful error for dual-circuit accelerator pedal
Bit0 P2229 Voltage value of barometric pressure sensor signal is too
large
Bit1 P2228 Voltage value of barometric pressure sensor signal is too
4
small
Bit2 0
Bit3 0
Bit0 P1218 Voltage value of barometric pressure sensor signal
exceeds upper limit through OBD inspection
5
Bit1 P1219 Voltage value of barometric pressure sensor signal
exceeds lower limit through OBD inspection

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 Service Manual of Wheel Loader

Bit0 P0108 Voltage value of intake pressure sensor signal exceeds

upper limit
Bit1 P0107 Voltage value of intake pressure sensor signal exceeds
lower limit
6
Bit2 0
Bit3 P0106 The absolute value of the difference between the intake
pressure and the atmospheric pressure is too large when
it is at idle speed
Bit0 P1220 Voltage value of intake pressure sensor signal exceeds
upper limit through OBD inspection
Bit1 P1221 Voltage value of intake pressure sensor signal exceeds
7
lower limit through OBD inspection
Bit2 0
Bit3 0
Bit0 P0504 Master and deputy brakes simultaneously exist
Bit1 P0504 Master and deputy brakes simultaneously nonexistent
8
Bit2 P0571 Brake can signal is invalid
Bit3 0
Bit0 P0118 Voltage value of water temperature sensor signal is too
large
Bit1 P0117 Voltage value of water temperature sensor signal is too
9
small
Bit2 0
Bit3 0
Bit0 P110D Voltage value of water temperature sensor signal exceeds
upper limit through OBD inspection
Bit1 P110E Voltage value of water temperature sensor signal exceeds
A
lower limit through OBD inspection
Bit2 0
Bit3 0
Bit0 P0217 Water temperature is too high
Bit1 0
B
Bit2 0
Bit3 0
Bit0 P2145 Control deviation of EGR actuator exceeds upper limit
Bit1 P2144 Control deviation of EGR actuator exceeds lower limit
C
Bit2 0
Bit3 0
Bit0 P2142 EGR actuator to high voltage level or its driver chip is of
excess temperature
D Bit1 P2141 EGR actuator short-circuits to ground
Bit2 P0487 EGR actuator is of open circuit
Bit3 P0488 EGR driver chip is of excess temperature
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 Service Manual of Wheel Loader

Bit0 P0402 Control deviation of EGR controller exceeds upper limit

E
Bit1 P0401 Control deviation of EGR controller exceeds lower limit
Bit0 P0406 Output voltage of EGR valve position sensor is too high
F
Bit1 P0405 Output voltage of EGR valve position sensor is too low
Position deviation of EGR valve position sensor at the time
Bit0 P0486
of full closing exceeds upper limit
10
Position deviation of EGR valve position sensor at the time
Bit1 P0409
of full closing exceeds lower limit
Position deviation of EGR valve position sensor at the time
Bit0 P0408
of full opening exceeds upper limit
11
Position deviation of EGR valve position sensor at the time
Bit1 P0407
of full opening exceeds lower limit
Bit0 P0113 Original value of air temperature exceeds upper limit
12
Bit1 P0112 Original value of air temperature exceeds lower limit
Original value of PWM duty ratio of air temperature
Bit0 P0111
exceeds upper limit
13
Original value of PWM duty ratio of air temperature
Bit1 P0114
exceeds lower limit
Original value of PWM cycle of air temperature exceeds
Bit0 P0110
upper limit
14
Original value of PWM cycle of air temperature exceeds
Bit1 P0110
lower limit
Bit0 P0103 Revised signal of intake flow sensor exceeds upper limit
15
Bit1 P0102 Revised signal of intake flow sensor exceeds lower limit
Bit0 P0101 Original signal of intake flow sensor exceeds upper limit
16 Bit1 P0104 Original signal of intake flow sensor exceeds lower limit
Bit2 P0100 Original signal of intake flow sensor fails
Bit0 P0183 Fuel temperature signal voltage exceeds upper limit
17
Bit1 P0182 Fuel temperature signal voltage exceeds lower limit
Bit0 P1110 Fuel temperature signal voltage exceeds upper limit
through OBD inspection
18
Bit1 P1111 Fuel temperature signal voltage exceeds lower limit
through OBD inspection
Bit0 P0692 Cooling fan relay 1 circuit short-circuits to high voltage
level or its driver chip is of excess temperature
Bit1 P0691 Cooling fan relay 1 circuit short-circuits to ground
19
Bit2 P0480 Cooling fan relay 1 circuit is of open circuit
Bit3 P0483 Driver chip of cooling fan relay 1 circuit is of excess
temperature
Bit0 P0694 Cooling fan relay 2 circuit short-circuits to high voltage
level or its driver chip is of excess temperature
1A Bit1 P0693 Cooling fan relay 2 circuit short-circuits to ground
Bit2 P0481 Cooling fan relay 2 circuit is of open circuit
Bit3 P0484 Driver chip of cooling fan relay 2 circuit is of excess
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 Service Manual of Wheel Loader
temperature
Bit0 P0382 Both preheating control output and GCU feedback signal
are 0 failure
1B
Bit1 P0380 Both preheating control output and GCU feedback signal
are 1 failure
Bit0 P1601 Preheating indicator light short-circuits to high voltage
level or its driver chip is of excess temperature
Bit1 P1602 Preheating indicator light short-circuits to ground
1C
Bit2 P1603 Preheating indicator light is of open circuit
Bit3 P1604 Driver chip of preheating indicator light is of excess
temperature
Bit0 P0384 Preheating control relay short-circuits to high voltage
level or its driver chip is of excess temperature
Bit1 P0383 Preheating control relay short-circuits to ground
1D
Bit2 P0670 Preheating control relay is of open circuit
Bit3 P0384 Driver chip of preheating control relay is of excess
temperature
Bit0 P1201 High end of pump solenoid valve short-circuits to high
1E voltage level
Bit1 P1202 High end of pump solenoid valve short-circuits to ground
Bit0 P0092 Low end of pump solenoid valve short-circuits to high
voltage level or its driver chip is of excess temperature
Bit1 P0091 Low end of pump solenoid valve short-circuits to ground
1F
Bit2 P0090 Low end of pump solenoid valve is of open circuit
Bit3 P0092 Driver of low end of pump solenoid valve is of excess
temperature
Bit0 P0098 Intake temperature signal voltage exceeds upper limit
20
Bit1 P0097 Intake temperature signal voltage exceeds lower limit
Bit0 P1005 Intake temperature signal voltage exceeds upper limit
through OBD inspection
21
Bit1 P1006 Intake temperature signal voltage exceeds lower limit
through OBD inspection
Bit0 P1500 Vehicle ignition key failure/error state
Bit1 P1500 Vehicle ignition key failure/error state
22
Bit2 P1500 Vehicle ignition key failure/error state
Bit3 P1500 Vehicle ignition key failure/error state
Bit0 P1100 Number of injection release times is larger than the
maximum allowable number of injection times for each
circulation
Bit1 P1100 Number of injection release times is larger than the
23 maximum allowable number of injection times for each
circulation
Bit2 P1100 Number of injection release times is larger than the
maximum allowable number of injection times for each
circulation
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 Service Manual of Wheel Loader
Bit3 P1100 Number of injection release times is larger than the
maximum allowable number of injection times for each
circulation
Bit0 P0254 Current of pump solenoid valve exceeds upper limit
24
Bit1 P0253 Current of solenoid valve exceeds lower limit
25 Bit0 P068A Failure of too early starting of main relay
26 Bit0 P068B Failure of too late starting of main relay
Bit0 P0193 Rail pressure sensor signal voltage exceeds upper limit
27
Bit1 P0192 Rail pressure sensor signal voltage exceeds lower limit
Bit0 P0563 Battery voltage exceeds upper limit
28
Bit1 P0562 Battery voltage exceeds lower limit
Bit0 P0503 Vehicle speed 1 signal is too large
Bit2 P0501 Vehicle speed 1 signal hardware failure
29
Bit3 P0500 Vehicle speed 1 signal is too small
Bit2 P2159 Vehicle speed 2 can signal failure
2B Bit0 P2265 Water level of oil-water separator is too high
Bit0 P0647 Air conditioning signal short-circuits to high voltage level
or its driver chip is of excess temperature
2C
Bit1 P0646 Air conditioning signal short-circuits to ground
Bit2 P0645 Air conditioning signal is of open circuit
Bit0 P0643 Sensor power supply voltage 1 exceeds upper limit
2D
Bit1 P0642 Sensor power supply voltage 1 exceeds lower limit
Bit0 P0653 Sensor power supply voltage 2 exceeds upper limit
2E
Bit1 P0652 Sensor power supply voltage 2 exceeds lower limit
Bit0 P0699 Sensor power supply voltage 3 exceeds upper limit
2F
Bit1 P0698 Sensor power supply voltage 3 exceeds lower limit
Bit0 P1609 Water temperature output pin short-circuits to power
supply or its driver chip is of excess temperature
Bit1 P160A Water temperature output pin short-circuits to ground
30
Bit2 P160B Water temperature output pin is of open circuit
Bit3 P160C Driver chip of water temperature output is of excess
temperature
Bit0 P1613 Instrument panel speed output pin short-circuits to high
voltage level or its driver chip is of excess temperature
Bit1 P1614 Instrument panel speed output pin short-circuits to ground
31
Bit2 P1615 Instrument panel speed output pin is of open circuit
Bit3 P1616 Driver chip of instrument panel speed output is of excess
temperature
Bit0 P1605 System light output pin short-circuits to high voltage level
or its driver chip is of excess temperature
32 Bit1 P1606 System light output pin short-circuits to ground
Bit2 P1607 System light output pin is of open circuit
Bit3 P1608 System light output driver chip is of excess temperature
33 Bit0 P0650 MI light output pin short-circuits to high voltage level or

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 Service Manual of Wheel Loader
its driver chip is of excess temperature
Bit1 P162C MI light output pin short-circuits to ground
Bit2 P162D MI light output pin is of open circuit
Bit3 P162E MI light output driver chip is of excess temperature
Bit0 P0262 Oil atomizer of physical No. 1 cylinder is of overcurrent
at low side
Bit1 P062D Oil atomizer of physical No. 1 cylinder is of overcurrent
34 at high side
Bit2 P0261 Current rise time of Boost of physical No. 1 cylinder is
too short
Bit3 P0201 Oil atomizer of physical No. 1 cylinder is of open circuit
Bit0 P0265 Oil atomizer of physical No. 2 cylinder is of overcurrent
at low side
Bit1 P062E Oil atomizer of physical No. 2 cylinder is of overcurrent
35 at high side
Bit2 P0264 Current rise time of Boost of physical No. 2 cylinder is
too short
Bit3 P0202 Oil atomizer of physical No. 2 cylinder is of open circuit
Bit0 P0268 Oil atomizer of physical No. 3 cylinder is of overcurrent
at low side
Bit1 P062E Oil atomizer of physical No. 3 cylinder is of overcurrent
36 at high side
Bit2 P0267 Current rise time of Boost of physical No. 3 cylinder is
too short
Bit3 P0203 Oil atomizer of physical No. 3 cylinder is of open circuit
Bit0 P0271 Oil atomizer of physical No. 4 cylinder is of overcurrent
at low side
Bit1 P062D Oil atomizer of physical No. 4 cylinder is of overcurrent
37 at high side
Bit2 P0270 Current rise time of Boost of physical No. 4 cylinder is
too short
Bit3 P0204 Oil atomizer of physical No. 4 cylinder is of open circuit
Bit0 P0335 Crankshaft sensor has no signal or sensor signal is
incredible
Bit1 P0335 Crankshaft sensor has no signal or sensor signal is
incredible
38
Bit2 P0335 Crankshaft sensor has no signal or sensor signal is
incredible
Bit3 P0335 Crankshaft sensor has no signal or sensor signal is
incredible
Bit0 P0340 Camshaft sensor has no signal or sensor signal is
incredible
39 Bit1 P0340 Camshaft sensor has no signal or sensor signal is
incredible
Bit2 P0340 Camshaft sensor has no signal or sensor signal is
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 Service Manual of Wheel Loader
incredible
Bit3 P0340 Camshaft sensor has no signal or sensor signal is
incredible
Bit0 P0016 Synchronous failure
Bit1 P0016 Synchronous failure
3A
Bit2 P0016 Synchronous failure
Bit3 P0016 Synchronous failure
Bit0 P0263 Fuel injection quantity balance correction failure of
ignition order No. 1 cylinder (physical No. 1 cylinder of
four-cylinder engine)
Bit1 P0263 Fuel injection quantity balance correction failure of
ignition order No. 1 cylinder (physical No. 1 cylinder of
four-cylinder engine)
3B
Bit2 P0263 Fuel injection quantity balance correction failure of
ignition order No. 1 cylinder (physical No. 1 cylinder of
four-cylinder engine)
Bit3 P0263 Fuel injection quantity balance correction failure of
ignition order No. 1 cylinder (physical No. 1 cylinder of
four-cylinder engine)
Bit0 P0266 Fuel injection quantity balance correction failure of
ignition order No. 2 cylinder (physical No. 3 cylinder of
four-cylinder engine)
Bit1 P0266 Fuel injection quantity balance correction failure of
ignition order No. 2 cylinder (physical No. 3 cylinder of
four-cylinder engine)
3C
Bit2 P0266 Fuel injection quantity balance correction failure of
ignition order No. 2 cylinder (physical No. 3 cylinder of
four-cylinder engine)
Bit3 P0266 Fuel injection quantity balance correction failure of
ignition order No. 2 cylinder (physical No. 3 cylinder of
four-cylinder engine)
Bit0 P0269 Fuel injection quantity balance correction failure of
ignition order No. 3 cylinder (physical No. 4 cylinder of
four-cylinder engine)
Bit1 P0269 Fuel injection quantity balance correction failure of
ignition order No. 3 cylinder (physical No. 4 cylinder of
four-cylinder engine)
3D
Bit2 P0269 Fuel injection quantity balance correction failure of
ignition order No. 3 cylinder (physical No. 4 cylinder of
four-cylinder engine)
Bit3 P0269 Fuel injection quantity balance correction failure of
ignition order No. 3 cylinder (physical No. 4 cylinder of
four-cylinder engine)
Bit0 P0272 Fuel injection quantity balance correction failure of
3E
ignition order No. 4 cylinder (physical No. 2 cylinder of

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 Service Manual of Wheel Loader
four-cylinder engine)
Bit1 P0272 Fuel injection quantity balance correction failure of
ignition order No. 4 cylinder (physical No. 2 cylinder of
four-cylinder engine)
Bit2 P0272 Fuel injection quantity balance correction failure of
ignition order No. 4 cylinder (physical No. 2 cylinder of
four-cylinder engine)
Bit3 P0272 Fuel injection quantity balance correction failure of
ignition order No. 4 cylinder (physical No. 2 cylinder of
four-cylinder engine)
Bit0 P0087 Positive deviation of rail pressure control is too large
3F
Bit1 P0088 Negative deviation of rail pressure control is too small
Bit0 P0089 Rail pressure exceeds the maximum rail pressure
41
monitoring value
Bit0 P1611 Actual fuel injection pulse width at OverRun state is too
42
large
Bit0 P1612 Deviation between the revolving speed internally
43 calculated by ECU and the revolving speed monitored is
too large
Bit0 P0490 (H-bridge) motor-drive EGR actuator short-circuits to
high voltage level or its driver chip is of excess
temperature
Bit1 P0489 (H-bridge) motor-drive EGR actuator short-circuits to
44
ground
Bit2 P0403 (H-bridge) motor-drive EGR actuator is of open circuit
Bit3 P0404 (H-bridge) EGR actuator driver chip is of excess
temperature
Bit0 P020A Oil atomizer of physical No. 1 cylinder short-circuits to
power supply
45
Bit1 0 Oil atomizer of physical No. 1 cylinder short-circuits to
ground
Bit0 P020B Oil atomizer of physical No. 2 cylinder short-circuits to
power supply
46
Bit1 0 Oil atomizer of physical No. 2 cylinder short-circuits to
ground
Bit0 P020C Oil atomizer of physical No. 3 cylinder short-circuits to
power supply
47
Bit1 0 Oil atomizer of physical No. 3 cylinder short-circuits to
ground
Bit0 P020D Oil atomizer of physical No. 4 cylinder short-circuits to
power supply
48
Bit1 0 Oil atomizer of physical No. 4 cylinder short-circuits to
ground
Bit0 P1400 Difference value between the air intake flow and the air
49
intake flow demanded exceeds upper limit (NOx exceeds
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 Service Manual of Wheel Loader
5g/(kW.h) according to HJ437 regulations)
4A Bit0 P1401 Difference value between the air intake flow and the air
intake flow demanded seriously exceeds upper limit (NOx
exceeds 7g/(kW.h) according to HJ437 regulations)
4B Bit0 P2455 Output voltage of differential pressure sensor exceeds
upper limit
Bit1 P2454 Output voltage of differential pressure sensor exceeds
lower limit
4C Bit0 P1009 Output voltage of differential pressure sensor exceeds
upper limit through OBD inspection
Bit1 P100A Output voltage of differential pressure sensor exceeds
lower limit through OBD inspection
4D Bit0 P0116 Doubtful error of excessively slow water temperature rise
Bit1 P0116 Doubtful error of excessively slow water temperature rise
Bit2 P0116 Doubtful error of excessively slow water temperature rise
Bit3 P0116 Doubtful error of excessively slow water temperature rise
4E Bit0 P006A Feedback air intake flow to theoretical air intake flow
ratio is too large, and the ratio between the two exceeds
upper limit value
Bit1 P006A Feedback air intake flow to theoretical air intake flow
ratio is too small, and the ratio between the two exceeds
lower limit value
4F Bit0 P2002 POC pressure difference exceeds upper limit
Bit1 P2003 POC pressure difference exceeds lower limit
50 Bit0 P062F ECU PWRDWN zone data checking error
Bit1 P062F ECU TRIM zone data checking error
51 Bit0 P1101 Sampled voltage of temperature sensor of air flow meter
exceeds upper limit
Bit1 P1102 Sampled voltage of temperature sensor of air flow meter
exceeds lower limit
Bit0 P1103 Voltage value of temperature sensor signal of air flow
meter exceeds upper limit through OBD inspection
52
Bit1 P1104 Voltage value of temperature sensor signal of air flow
meter exceeds lower limit through OBD inspection
Bit0 P1618 Failure light of oil-water separator short-circuits to high
voltage level or its driver chip is of excess temperature
Bit1 P1619 Failure light of oil-water separator short-circuits to ground
Bit2 P162A Failure light of oil-water separator is of open circuit
53
Bit3 P162B Driver chip of failure light of oil-water separator is of
excess temperature
Bit2 P2264 Water level sensor of oil-water separator is of electrical
failure
Bit0 P1631 Exhaust brake output short-circuits to high voltage level
55 or its driver chip is of excess temperature
Bit1 P1632 Exhaust brake output short-circuits to ground
18
 Service Manual of Wheel Loader
Bit2 P1633 Exhaust brake output is of open circuit
Bit3 P1634 Driver chip of exhaust brake output is of excess
temperature
Bit0 P1641 Fuel consumption output short-circuits to high voltage
level or its driver chip is of excess temperature
Bit1 P1642 Fuel consumption output short-circuits to ground
56
Bit2 P1643 Fuel consumption output is of open circuit
Bit3 P1644 Fuel consumption output driver chip is of excess
temperature
57 Bit0 U0100 CAN bus off
Bit0 P0562 Power supply voltage is too low
58
Bit1 P0563 Power supply voltage is too high
59 Bit0 U1008 Engine EEC1 message timeout failure
5A Bit0 U1006 Engine AMB message timeout failure
5B Bit0 U1005 Engine ET1 message timeout failure
5C Bit0 U1009 Engine EEC3 message reception timeout failure
5D Bit0 U100A Engine AT1O1 message timeout failure
Bit0 P205D Urea tank temperature sensor exceeds upper limit
5E
Bit1 P205C Urea tank temperature sensor exceeds lower limit
Bit0 P203D Urea tank liquid level sensor exceeds upper limit
5F
Bit1 P203C Urea tank liquid level sensor exceeds lower limit
Bit0 P3029 Pump temperature sensor exceeds upper limit
60
Bit1 P3029 Pump temperature sensor exceeds lower limit
Bit0 P204D Pump pressure sensor exceeds upper limit
61
Bit1 P204C Pump pressure sensor exceeds lower limit
Bit0 P042D Upstream temperature sensor exceeds upper limit value
62
Bit1 P042C Upstream temperature sensor exceeds lower limit value
63 Bit0 P3005 Metering pump short-circuits
Bit1 P3006 Metering pump is of open circuit
64 Bit0 P20A9 Air valve short-circuits
Bit1 P20A8 Air valve is of open circuit
65 Bit0 P3019 Urea tank heating water valve short-circuits
Bit1 P3016 Urea tank heating water valve is of open circuit
66 Bit0 P3036/ Pump heater short-circuits
P3050
Bit1 P3033/ Pump heater is of open circuit
P3049
67 Bit0 P3031 Suction pipe heater short-circuits
Bit1 P3028 Suction pipe heater is of open circuit
68 Bit0 P3026 Injection pipe heater short-circuits
Bit1 P3024 Injection pipe heater is of open circuit
69 Bit0 P0420 Final flag of exceeding 3.5g/kwh
Bit1 P0420 Final flag of exceeding7g/kwh
6A Bit0 P2214/ Unreasonable NOx sensor value1

19
 Service Manual of Wheel Loader
P2201
6B Bit0 P3066 Urea consumption is unreasonable
Bit0 P3039 Air pressure is too high
Bit1 P3056 Air pressure is too low
Bit0 P3010 Urea pump reversing solenoid valve short-circuits to
ground or is of open circuit
6D
Bit1 P3013 Urea pump reversing solenoid valve short-circuits to
power supply
Bit0 P3006 Pump motor is of open circuit
6E
Bit1 P3004 Pump motor short-circuits to power supply
Bit0 P204C Pump pressure sensor short-circuits to ground
6C Bit1 P204D Pump pressure sensor short-circuits to power supply or is
of open circuit
70 Bit0 P204B Internal pressure of pump is too high
Bit0 P204F Urea tank liquid level is low (12%)
71
Bit1 P203F Urea tank liquid level is too low (8%)
72 Bit0 P2200 Outlet NOX sensor message timeout
73 Bit0 P3020 System heating and thawing failure
74 Bit0 P2049 Nozzle solenoid valve short-circuits to power supply
Bit1 P2047 Nozzle solenoid valve short-circuits to ground or is of
open circuit
75 Bit0 P206A Nozzle is obstructed
76 Bit0 P3022 Urea return pipe heater short-circuits to ground or is of
open circuit
Bit1 P3023 Urea return pipe heater short-circuits to power supply
77 Bit0 P3081 Urea pump voltage buildup failure
78 Bit0 P042D Exhaust temperature sensor short-circuits to power supply
or is of open circuit
Bit1 P042C Exhaust temperature sensor short-circuits to ground
79 Bit0 P0420 Catalyst is deficient
7A Bit0 U0401 ECM message reception timeout
7B Bit0 U0078 CAN bus off
Bit0 P205D Urea tank temperature sensor exceeds upper limit
(open-circuit failure)
7C
Bit1 P205C Urea tank temperature sensor exceeds lower limit (failure
of short circuit to ground)
Bit0 P3060 Urea tank temperature sensor exceeds upper limit range
7D
Bit1 P3061 Urea tank temperature sensor exceeds lower limit range
7E Bit0 P3090 Urea tank temperature signal is incredible
7F Bit0 P209F Urea tank heating failure
Bit0 P203D Urea tank liquid level sensor exceeds upper limit
(open-circuit failure)
80
Bit1 P203C Urea tank liquid level sensor exceeds lower limit (failure
of short circuit to ground)

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 Service Manual of Wheel Loader
Bit0 P3062 Urea tank liquid level sensor exceeds upper limit range
81
Bit1 P3063 Urea tank liquid level sensor exceeds lower limit range
82 Bit0 P203F Urea level is low
83 Bit0 P2BA7 Urea level is empty
Bit0 P0428 Upstream temperature sensor of catalytic converter
exceeds upper limit (open-circuit failure)
84
Bit1 P0427 Upstream temperature sensor of catalytic converter
exceeds lower limit (failure of short circuit to ground)
Bit0 P3064 Upstream temperature sensor of catalytic converter
exceeds upper limit range
85
Bit1 P3065 Upstream temperature sensor of catalytic converter
exceeds lower limit range
Bit0 P3092 Upstream temperature signal of catalytic converter is
86
incredible
Bit0 P3091 Upstream temperature sensor of catalytic converter is
87
placed in air
Bit0 P042D Downstream temperature sensor of catalytic converter
exceeds upper limit (open-circuit failure)
88
Bit1 P042C Downstream temperature sensor of catalytic converter
exceeds lower limit (failure of short circuit to ground)
Bit0 P3066 Downstream temperature sensor of catalytic converter
exceeds upper limit range
89
Bit1 P3067 Downstream temperature sensor of catalytic converter
exceeds lower limit range
Bit0 P3094 Downstream temperature signal of catalytic converter is
8A
incredible
Bit0 P3093 Downstream temperature sensor of catalytic converter is
8B
placed in air
Bit0 P0073 Environmental temperature sensor exceeds upper limit
(open-circuit failure)
8C
Bit1 P0072 Environmental temperature sensor exceeds lower limit
(failure of short circuit to ground)
Bit0 P306A Environmental temperature sensor exceeds upper limit
range
8D
Bit1 P306B Environmental temperature sensor exceeds lower limit
range
Bit0 P0103 Intake flow sensor exceeds upper limit (open-circuit
failure)
8E
Bit1 P0102 Intake flow sensor exceeds lower limit (failure of short
circuit to ground)
Bit0 P306C Intake flow sensor exceeds upper limit range
8F
Bit1 P306D Intake flow sensor exceeds lower limit range
90 Bit0 P2BA8 Internal failure of pump
Bit0 P20A9 Failure that internal air valve coil of pump exceeds upper
91
limit (open-circuit failure)
21
 Service Manual of Wheel Loader
Bit1 P20A8 Failure that internal air valve coil of pump exceeds lower
limit (failure of short circuit to ground)
Bit0 P20AF Failure that internal temperature sensor of pump exceeds
upper limit(open-circuit failure)
92
Bit1 P20AE Failure that internal temperature sensor of pump exceeds
lower limit (failure of short circuit to ground)
Bit0 P30D2 Failure that internal temperature sensor of pump exceeds
upper limit range
93
Bit1 P30D3 Failure that internal temperature sensor of pump exceeds
lower limit range
94 Bit0 P30D4 Pump temperature signal is incredible
95 Bit0 P20A3 Failure that internal pressure switch of pump exceeds
upper limit (open-circuit failure)
96 Bit0 P20BC Failure that internal heating plate1 of pump exceeds upper
limit (open-circuit failure)
Bit1 P20BB Failure that internal heating plate1 of pump exceeds lower
limit (failure of short circuit to ground)
97 Bit0 P20C0 Failure that internal heating plate2 of pump exceeds upper
limit (open-circuit failure)
Bit1 P20BF Failure that internal heating plate2 of pump exceeds lower
limit (failure of short circuit to ground)
98 Bit0 P20B6 Internal heating failure of pump
99 Bit0 P202D Liquid inlet pipe blockage failure
9A Bit0 P20CA Air pipe blockage failure
9B Bit0 P208E Nozzle blockage failure
9C Bit0 P30F0 Liquid return pipeline blockage failure
9D Bit0 P20C2 Urea pipe heating failure
9E Bit0 P2200 Downstream NOx sensor power supply failure
9F Bit0 P2207 DownstreamNOx sensor heating exceeds upper limit
(open-circuit failure)
Bit1 P2206 Downstream NOx sensor heating exceeds lower limit
(failure of short circuit to ground)
A0 Bit0 P2201 DownstreamNOx sensor credibility
A1 Bit0 P3130 Downstream NOx sensor is placed in air
A2 Bit0 P3100 Internal failure of downstream NOx sensor
A3 Bit0 P2213 UpstreamNOx sensor power supply failure
A4 Bit0 P2220 UpstreamNOx sensor heating exceeds upper limit
(open-circuit failure)
Bit1 P2219 UpstreamNOx sensor heating exceeds lower limit (failure
of short circuit to ground)
A5 Bit0 P2214 UpstreamNOx sensor credibility
A6 Bit0 P3131 UpstreamNOx sensor is placed in air
A7 Bit0 P3103 Internal failure of upstreamNOx sensor
A8 Bit0 P3132 Concentration signal of downstream NOx sensor is

22
 Service Manual of Wheel Loader
incredible
Bit1 P3133 Concentration signal of upstream NOx sensor is
incredible
A9 Bit0 P30B0 Engine speed signal is incredible
AA Bit0 P30B1 Signal of fuel consumption per hour is incredible
AB Bit0 P0217 Coolant temperature signal is incredible
AC Bit0 P30B2 Torque signal is incredible
AD Bit0 P0501 Vehicle speed signal is incredible
AE Bit0 P0071 Environmental temperature signal is incredible
Bit1 P0106 Environmental pressure signal is incredible
AF Bit0 U1005 Engine ET1 message timeout failure
B0 Bit0 U1006 Engine AMB message timeout failure
B1 Bit0 U1007 Engine LFE message timeout failure
B2 Bit0 U1003 Engine TCO1 message timeout failure
B3 Bit0 U1004 Engine DM1 message timeout failure
B4 Bit0 U029D Downstream NOx sensorAT0G1 message timeout failure
Bit1 U029E Upstream NOx sensor AT0G1 message timeout failure
B5 Bit0 U0100 Engine EEC1 message timeout failure
B6 Bit0 P3150 EEPROM memory failure
B7 Bit0 P0228 Sampled voltage of manual accelerator pedal circuit 1
exceeds upper limit
Bit1 P0227 Sampled voltage of manual accelerator pedal circuit 1
exceeds lower limit
Bit2 0
Bit3 P2138 Doubtful error for dual-circuit manual accelerator
B8 Bit0 P2123 Sampled voltage of manual accelerator pedal circuit 2
exceeds upper limit
Bit1 P2122 Sampled voltage of manual accelerator pedal circuit 2
exceeds lower limit
Bit3 P2138 Doubtful error for dual-circuit manual accelerator
B9 Bit0 P0533 Voltage value of lubricating oil pressure sensor signal is
too large
Bit1 P0532 Voltage value of lubricating oil pressure sensor signal is
too small
Bit2 P1653 Stopping signal is incredible
BB Bit0 P0615 Electrical failure of starter control switch
Bit1 P0615 Electrical failure of starter control switch
Bit2 P0615 Electrical failure of starter control switch

23