Komatsu MOBILE CRUSHER BR380JG-3E0 Shop Manual SEN06863-04 PDF

Description

Komatsu MOBILE CRUSHER BR380JG-3E0 Shop Manual SEN06863-04 – PDF DOWNLOAD

FILE DETAILS:

Komatsu MOBILE CRUSHER BR380JG-3E0 Shop Manual SEN06863-04 – PDF DOWNLOAD

Language : English
Pages :2018
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu MOBILE CRUSHER BR380JG-3E0 Shop Manual SEN06863-04 – PDF DOWNLOAD

SERIAL NUMBERS 5203 and up

TABLE OF CONTENTS:

Komatsu MOBILE CRUSHER BR380JG-3E0 Shop Manual SEN06863-04 – PDF DOWNLOAD

SERIAL NUMBERS 5203 and up

Cover 1
00 Index and foreword 3
Index 4
Abbreviation list 18
Foreword, safety, and basic information 21
How to read the shop manual 21
Safety notice for operation 24
Precautions to prevent fire 32
Action if fire occurs 33
Precautions when disposing of waste materials 34
Actions taken to meet exhaust gas regulations 35
Precautions for DEF 36
Store DEF 37
Precautions for handling hydraulic component 38
Piping – Precautions for disconnection and connection 40
Precautions for handling electrical component 46
Precautions for handling fuel system component 48
Precautions for handling air intake system component 49
Practical use of KOMTRAX 50
Disconnection and connection of push-pull type coupler 51
Precautions for disconnecting and connecting connector 55
Procedures for disconnecting and connecting DT connectors 59
Procedures for disconnecting and connecting slide lock type connectors 60
Procedures for disconnecting and connecting connectors with pull and release type lock 61
Procedures for disconnecting and connecting connectors with push and release type lock 62
Procedures for disconnecting and connecting connectors that require rotation of housing to release and apply lock 64
How to read wire code 65
Description of terms used in maintenance standard 68
Standard tightening torque table 70
01 Specifications 77
Contents 78
Specifications 79
Specification drawing 79
Specifications 80
Weight table 83
Table of fuel, coolant and lubricants 84
10 Structure and function 87
Contents 88
Urea SCR system 89
Urea SCR system component layout drawing 89
Urea SCR system diagram 94
Urea SCR system functions 95
Urea SCR system components 104
Starting system 113
Starting system component layout drawing 113
System operating lamp system 115
Battery disconnect switch 116
Engine system 117
Engine system component layout drawing 117
Engine control system 119
Engine automatic warm-up system 122
Overheat prevention system 124
Turbocharger protection system 126
Engine system component 128
Cooling system 146
Cooling system component layout drawing 146
Control system 148
Control system component layout drawing 148
Machine monitor system 151
KOMTRAX system 152
Control system component 153
Hydraulic system 183
Hydraulic system component layout drawing 183
CLSS 184
Pump and engine combined control system 188
Pump and valve control system 192
Hydraulic system components 194
Work equipment system 254
Work equipment system component layout drawing 254
Structure of valve control 257
Grizzly feeder semi automatic control system 259
Abnormal load shutdown system 260
Crusher jaw tip adjustment system 261
Work equipment system components 263
Crusher motor 263
Travel system 275
Travel system component layout drawing 275
Travel control system diagram 279
Travel system components 281
Undercarriage and frame 301
Undercarriage layout drawing 301
Work equipment 303
Primary conveyor 303
Grizzly feeder 305
Crusher 306
Vibrator 310
20 Standard value table 311
Contents 312
Standard value table for engine 313
Standard value table for engine: BR380JG-3E0 313
Standard value table for machine 316
Standard value table for machine: BR380JG-3E0 316
Machine posture and measuring procedure drawings for performance measurement 323
30 Testing and adjusting 325
Contents 326
Precautions before work 327
Related information on testing and adjusting 328
Tools for testing and adjusting 328
Sketches for testing and adjusting tools 334
Engine and cooling system 335
Testing engine speed 335
Testing boost pressure 337
Testing exhaust gas color 339
Testing and adjusting valve clearance 342
Testing compression pressure 344
Testing blowby pressure 349
Testing engine oil pressure 351
Testing EGR valve and VGT oil pressures 352
Testing fuel pressure 354
Testing fuel discharged volume, return rate, and leakage 360
Bleeding air from fuel system 366
Testing leakage from fuel system 367
Handling cylinder cutout mode operation 369
Handling no-injection cranking operation 370
Testing fan/alternator belt 371
Testing automatic tensioner 372
Writing soot correction by ash influence to engine controller 374
Testing SCR-related functions 375
Flushing DEF tank 401
Undercarriage and frame 406
Testing and adjusting track shoe tension 406
Hydraulic system 408
Releasing remaining pressure from hydraulic system 408
Testing and adjusting oil pressure in work equipment and travel circuits 409
Testing control circuit pressure 420
Testing and adjusting pump PC control circuit pressure 422
Testing and adjusting pump LS control circuit pressure 425
Testing solenoid valve output pressure 431
Testing PPC valve outlet pressure 435
Testing oil leakage 437
Bleeding air from hydraulic circuit 438
Procedure for adjusting mirrors 442
Electrical system 444
Setting and operating machine monitor 444
Start up KOMTRAX system (Machine with gateway function controller) 516
Stop using of KOMTRAX system (Machine with gateway function controller) 522
Handling voltage circuit of engine controller 524
Handling battery disconnect switch 525
Testing diode 526
Pm Clinic 527
Pm Clinic Service 527
40 Troubleshooting 535
Contents 536
Precautions before work 547
Information related to troubleshooting 548
Points to remember when performing troubleshooting 548
Points to remember when performing troubleshooting of urea SCR system 549
How to proceed in troubleshooting 561
Check before starting troubleshooting 563
Procedure for checking electrical parts 565
Troubleshooting procedure 570
Symptom of failure and troubleshooting numbers 573
Information described in troubleshooting table 576
Troubleshooting procedure of wiring harness in pressure sensor system 578
Connector list and layout 580
Connector pin numbers and wiring table 596
T-box and T-adapter list 636
Fuse location table 642
Precautions when cleaning and replacing KDPF (KCSF and KDOC) 644
Preparation of short connectors (for troubleshooting for failure codes [CA1883] and [CA3135]) 648
Failure codes table 650
Troubleshooting by failure code (display of code) 666
Failure code [7RC1KB] Conv ON SwS/C 666
Failure code [7RC2KA] Conv OFF SwDisc 668
Failure code [7RC5KB] Feeder ON Switch S/C 669
Failure code [7RD2KA] Conv REV Sol Disc 670
Failure code [7RD2KB] Conv REV Sol S/C 671
Failure code [7RD2KY] Conv REV Sol HS/C 672
Failure code [7RE1KB] Crusher ON Sw S/C 673
Failure code [7RE2KA] Crusher OFF Sw Disc 675
Failure code [7RE6KB] Muck Conv On Sw S/C 677
Failure code [7RE7KA] Muck Conv OFF SwDisc 679
Failure code [7RE8KB] Magnetic Separator ON Sw S/C 681
Failure code [7RE9KA] Magnetic Separator OFF Sw Disc 683
Failure code [7REAKB] AccInput S/C 685
Failure code [7REDMA] Conveyor PSensor Abnormality 687
Failure code [7REEMA] Muck Conv PSensor Abnormality 689
Failure code [7RENKZ] Clearance Potentio Abnormality 691
Failure code [7REPKA] Grizzly Feeder Stop Sw Disc 693
Failure code [7RESKB] 1-touch Start Sw S/C 695
Failure code [7RETKA] 1-touch Stop Sw Disc 696
Failure code [7RF2KA] Crusher FWD EPC Disc 698
Failure code [7RF2KB] Crusher FWD EPC S/C 699
Failure code [7RF2KY] Crusher FWD EPC HS/C 700
Failure code [7RF3KA] Crusher REV EPC Disc 701
Failure code [7RF3KB] Crusher REV EPC S/C 702
Failure code [7RF3KY] Crusher REV EPC HS/C 703
Failure code [7RF4KA] Feeder FWD EPC Disc 704
Failure code [7RF4KB] Feeder FWD EPC S/C 705
Failure code [7RF4KY] Feeder FWD EPC HS/C 706
Failure code [7RFAKA] EngStop Relay Disc 707
Failure code [7RFAKB] EngStop Relay S/C 708
Failure code [7RFAKY] EngStop Relay HS/C 709
Failure code [7RFBKA] Muck Conv EPC Disc 710
Failure code [7RFBKB] Muck Conv EPC S/C 711
Failure code [7RFBKY] Muck Conv EPC HS/C 712
Failure code [7RFHKA] Conv FWD EPC Disc 713
Failure code [7RFHKB] Conv FWD EPC S/C 714
Failure code [7RFHKY] Conv FWD EPC HS/C 715
Failure code [7RFKKA] Lock Cyl Pull Sol Disc 716
Failure code [7RFKKB] Lock Cyl Pull Sol S/C 717
Failure code [7RFKKY] Lock Cyl Pull Sol HS/C 718
Failure code [7RFLKA] Acc EPC Disc 719
Failure code [7RFLKB] Acc EPC S/C 720
Failure code [7RFLKY] Acc EPC HS/C 721
Failure code [7RFMKA] Abnormal PressRelay Disc 722
Failure code [7RFMKB] Abnormal PressRelay S/C 723
Failure code [7RFMKY] Abnormal PressRelay HS/C 724
Failure code [7RFNKA] Lock Cyl Unlock Sol Disc 725
Failure code [7RFNKB] Lock Cyl Unlock Sol S/C 726
Failure code [7RFNKY] Lock Cyl Unlock Sol HS/C 727
Failure code [7RFPKA] Lock Cyl Push Relay Disc 728
Failure code [7RFPKB] Lock Cyl Push Relay S/C 729
Failure code [7RFPKY] Lock Cyl Push Relay HS/C 730
Failure code [7RGAMA] 2nd Conv PSensor Abnormality 731
Failure code [7RJAKA] Travel Lock EPC Disc 733
Failure code [7RJAKB] Travel Lock EPC S/C 735
Failure code [7RJAKY] Travel Lock EPC HS/C 737
Failure code [7RJLKA] Magnetic Separator EPC Disc 738
Failure code [7RJLKB] Magnetic Separator EPC S/C 739
Failure code [7RJLKY] Magnetic Separator EPC HS/C 740
Failure code [7RJMMW] Lock Cyl Slide 741
Failure code [7RJNMA] Vibratory Sieve PSensor Abnormality 742
Failure code [7RJPKB] Radio Control Work-mode Sw S/C 744
Failure code [7RJQKB] Radio Control Trav-mode Sw S/C 745
Failure code [7RJRKB] On Travel Signal S/C 746
Failure code [7RJSMA] M/Separator PSensor Abnormality 748
Failure code [989L00] Engine Controller Lock Caution 1 750
Failure code [989M00] Engine Controller Lock Caution 2 751
Failure code [989N00] Engine Controller Lock Caution 3 752
Failure code [A1U0N3] HC Desorb Request 1 753
Failure code [A1U0N4] HC Desorb Request 2 754
Failure code [AA10NX] Air Cleaner Clogging 755
Failure code [AB00KE] Charge Voltage Low 757
Failure code [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) 759
Failure code [AS00N3] Manual Stationary Regeneration Request (SCR) 760
Failure code [AS00R2] Warning 2 (SCR Device Abnormality) 761
Failure code [AS00R3] Inducement 1 (SCR Device Abnormality) 762
Failure code [AS00R4] Inducement 2 (SCR Device Abnormality) 763
Failure code [AS00R5] Inducement 3 (SCR Device Abnormality) 764
Failure code [AS00R6] Temporary Recovery of Inducement 765
Failure code [AS00ZK] DEF Level Low Error 5 766
Failure code [AS10KM] DEF Injector Overheat Warning 767
Failure code [AS10NR] DEF Injector High Temperature Warning 768
Failure code [AS10NT] DEF Injector Overheat Caution 769
Failure code [B@BAZG] Eng Oil Press Low 770
Failure code [B@BAZK] Eng Oil Level Low 771
Failure code [B@BCNS] Eng Water Overheat 772
Failure code [B@BCQA] Eng Water Level Low 773
Failure code [B@BCZK] Eng Water Level Low 775
Failure code [B@HANS] Hyd Oil Overheat 777
Failure code [CA115] Engine NE and Bkup Speed Sensor Error 778
Failure code [CA122] Charge Air Pressure Sensor High Error 779
Failure code [CA123] Charge Air Pressure Sensor Low Error 781
Failure code [CA131] Throttle Sensor High Error 783
Failure code [CA132] Throttle Sensor Low Error 785
Failure code [CA144] Coolant Temperature Sensor High Error 787
Failure code [CA145] Coolant Temperature Sensor Low Error 789
Failure code [CA153] Charge Air Temperature Sensor High Error 791
Failure code [CA154] Charge Air Temperature Sensor Low Error 793
Failure code [CA187] Sensor 2 Supply Voltage Low Error 795
Failure code [CA221] Ambient Pressure Sensor High Error 797
Failure code [CA222] Ambient Pressure Sensor Low Error 799
Failure code [CA227] Sensor 2 Supply Voltage High Error 801
Failure code [CA234] Engine Overspeed 802
Failure code [CA238] NE Speed Sensor Supply Voltage Error 803
Failure code [CA239] NE Speed Sensor Supply Voltage High Error 804
Failure code [CA249] Ambient Air Temp Sensor High Error 805
Failure code [CA256] Ambient Air Temp Sensor Low Error 807
Failure code [CA271] IMV/PCV1 Short Circuit Error 809
Failure code [CA272] IMV/PCV1 Open Circuit Error 811
Failure code [CA322] Injector #1 (L#1) Open Circuit or Short Circuit Error 812
Failure code [CA323] Injector #5 (L#5) Open Circuit or Short Circuit Error 814
Failure code [CA324] Injector #3 (L#3) Open Circuit or Short Circuit Error 816
Failure code [CA325] Injector #6 (L#6) Open Circuit or Short Circuit Error 818
Failure code [CA331] Injector #2 (L#2) Open Circuit or Short Circuit Error 820
Failure code [CA332] Injector #4 (L#4) Open Circuit or Short Circuit Error 822
Failure code [CA343] Engine Controller Internal Failure 824
Failure code [CA351] Injectors Drive Circuit Error 825
Failure code [CA352] Sensor 1 Supply Voltage Low Error 826
Failure code [CA356] MAF Sensor High Error 828
Failure code [CA357] MAF Sensor Low Error 830
Failure code [CA386] Sensor 1 Supply Voltage High Error 832
Failure code [CA428] Water in Fuel Sensor High Error 833
Failure code [CA429] Water in Fuel Sensor Low Error 835
Failure code [CA435] Engine Oil Pressure SW Error 837
Failure code [CA441] Battery Voltage Low Error 838
Failure code [CA442] Battery Voltage High Error 840
Failure code [CA449] Common Rail Pressure High Error 2 841
Failure code [CA451] Common Rail Pressure Sensor High Error 842
Failure code [CA452] Common Rail Pressure Sensor Low Error 844
Failure code [CA488] Charge Air Temperature High Torque Derate 846
Failure code [CA515] Common Rail Pressure Sensor Supply Voltage Low Error 847
Failure code [CA516] Common Rail Pressure Sensor Supply Voltage Low Error 849
Failure code [CA553] Common Rail Pressure High Error 1 851
Failure code [CA555] Crankcase Pressure High Error 1 852
Failure code [CA556] Crankcase Pressure High Error 2 853
Failure code [CA559] Common Rail Pressure Low Error 1 854
Failure code [CA595] Turbocharger Speed High Error 2 856
Failure code [CA687] Turbocharger Speed Low Error 857
Failure code [CA689] Engine NE Speed Sensor Error 859
Failure code [CA691] Intake Air Temperature Sensor High Error 861
Failure code [CA692] Intake Air Temperature Sensor Low Error 863
Failure code [CA697] Engine Controller Internal Temperature Sensor High Error 865
Failure code [CA698] Engine Controller Internal Temperature Sensor Low Error 866
Failure code [CA731] Engine Bkup Speed Sensor Phase Error 867
Failure code [CA778] Engine Bkup Speed Sensor Error 869
Failure code [CA1117] Engine Controller Partial Data Lost Error 873
Failure code [CA1664] KDOC Abnormality 874
Failure code [CA1669] DEF Level Sensor Voltage High Error 876
Failure code [CA1673] DEF Level Low Error 3 877
Failure code [CA1677] DEF Temperature Sensor Low Error 878
Failure code [CA1678] DEF Temperature Sensor High Error 879
Failure code [CA1682] DEF Pump Priming Error 880
Failure code [CA1683] DEF Tank Heating Valve Voltage High Error 882
Failure code [CA1684] DEF Tank Heating Valve Voltage Low Error 884
Failure code [CA1686] DEF Quality Sensor Voltage High Error 886
Failure code [CA1691] Defective Regeneration 887
Failure code [CA1694] SCR Outlet NOx Sensor In Range Error 889
Failure code [CA1695] Sensor 5 Supply Voltage High Error 891
Failure code [CA1696] Sensor 5 Supply Voltage Low Error 892
Failure code [CA1712] DEF Tank Thawing Error 894
Failure code [CA1713] DEF Tank Heater Valve Open Stuck Error 896
Failure code [CA1714] DEF Quality Sensor Out of Calibration Error 898
Failure code [CA1715] DEF Quality Sensor Internal Circuit Error 899
Failure code [CA1776] Sensor Supply Relay Voltage High Error 900
Failure code [CA1777] Sensor Supply Relay Voltage Low Error 903
Failure code [CA1843] Crankcase Pressure Sensor High Error 905
Failure code [CA1844] Crankcase Pressure Sensor Low Error 907
Failure code [CA1879] KDPF Differential Pressure Sensor High Error 909
Failure code [CA1881] KDPF Differential Pressure Sensor Low Error 911
Failure code [CA1883] KDPF Differential Pressure Sensor In Range Error 913
Failure code [CA1885] Turbo Outlet NOx Sensor Circuit Error 916
Failure code [CA1887] SCR Outlet NOx Sensor Circuit Error 918
Failure code [CA1921] KDPF Soot Accumulation High Error 1 920
Failure code [CA1922] KDPF Soot Accumulation High Error 2 923
Failure code [CA1942] Crankcase Pressure Sensor In Range Error 927
Failure code [CA1993] KDPF Differential Pressure Sensor Low Error 928
Failure code [CA2185] Throttle Sensor Supply Voltage High Error 930
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error 931
Failure code [CA2249] Common Rail Pressure Low Error 2 932
Failure code [CA2271] EGR Valve Position Sensor High Error 933
Failure code [CA2272] EGR Valve Position Sensor Low Error 935
Failure code [CA2288] Turbocharger Speed High Error 1 938
Failure code [CA2311] IMV Solenoid Error 939
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error 940
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error 942
Failure code [CA2357] EGR Valve Servo Error 943
Failure code [CA2381] VGT Position Sensor High Error 944
Failure code [CA2382] VGT Position Sensor Low Error 946
Failure code [CA2383] VGT Solenoid Open Circuit Error 949
Failure code [CA2386] VGT Solenoid Short Circuit Error 951
Failure code [CA2387] VGT Servo Error 952
Failure code [CA2555] Intake Air Heater Relay Open Circuit Error 953
Failure code [CA2556] Intake Air Heater Relay Short Circuit Error 955
Failure code [CA2637] KDOC Face Plugging 957
Failure code [CA2639] Manual Stationary Regeneration Request 959
Failure code [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error 961
Failure code [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable 966
Failure code [CA2976] DEF Pump Temperature Sensor Signal Error 968
Failure code [CA3133] KDPF Outlet Pressure Sensor High Error 970
Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error 972
Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error 974
Failure code [CA3142] SCR Temperature Sensor High Error 977
Failure code [CA3143] SCR Temperature Sensor Low Error 978
Failure code [CA3144] SCR Temperature Sensor In Range Error 979
Failure code [CA3146] SCR Outlet Temperature Sensor High Error 981
Failure code [CA3147] SCR Outlet Temperature Sensor Low Error 982
Failure code [CA3148] SCR Outlet Temperature Sensor In Range Error 983
Failure code [CA3151] SCR Catalyst Efficiency Low Error 2 985
Failure code [CA3165] SCR Outlet Temperature High Error 990
Failure code [CA3229] SCR Temperature High Error 992
Failure code [CA3231] SCR Temperature High Error – Non Regeneration 994
Failure code [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error 996
Failure code [CA3235] SCR Outlet Temperature High Error – Non Regeneration 999
Failure code [CA3239] DEF Line Heater 2 Voltage High Error1001
Failure code [CA3241] DEF Line Heater 2 Voltage Low Error1003
Failure code [CA3242] DEF Tank Heating Error1006
Failure code [CA3251] KDOC Inlet Temperature High Error1008
Failure code [CA3253] KDOC Temperature Error – Non Regeneration1010
Failure code [CA3254] KDOC Outlet Temperature High Error 11012
Failure code [CA3255] KDPF Temperature Error – Non Regeneration1014
Failure code [CA3256] KDPF Outlet Temperature High Error 11016
Failure code [CA3311] KDOC Outlet Temperature High Error 21018
Failure code [CA3312] KDPF Outlet Temperature High Error 21020
Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error1022
Failure code [CA3314] KDOC Inlet Temperature Sensor High Error1023
Failure code [CA3315] KDOC Inlet Temperature Sensor In Range Error1024
Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error1026
Failure code [CA3317] KDOC Outlet Temperature Sensor High Error1027
Failure code [CA3318] KDOC Outlet Temperature Sensor In Range Error1028
Failure code [CA3319] KDPF Outlet Temperature Sensor High Error1030
Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error1031
Failure code [CA3322] KDPF Outlet Temperature Sensor In Range Error1032
Failure code [CA3419] MAF Sensor Supply Voltage High Error1034
Failure code [CA3421] MAF Sensor Supply Voltage Low Error1036
Failure code [CA3497] DEF Level Low Error 11038
Failure code [CA3498] DEF Level Low Error 21039
Failure code [CA3543] DEF Quality Error (SCR Catalyst Efficiency Low)1040
Failure code [CA3545] SCR Outlet NOx Sensor Unstable Error1044
Failure code [CA3547] DEF Level Low Error 41046
Failure code [CA3558] DEF Pump Voltage High Error1047
Failure code [CA3559] DEF Pump Voltage Low Error1048
Failure code [CA3562] DEF LineHeater Relay 1 Voltage High Error1050
Failure code [CA3563] DEF LineHeater Relay 1 Voltage Low Error1052
Failure code [CA3567] DEF Injector Open Circuit Error or Short Circuit Error1054
Failure code [CA3568] DEF Injector Malfunction1056
Failure code [CA3571] DEF Pump Pressure Sensor High Error1058
Failure code [CA3572] DEF Pump Pressure Sensor Low Error1060
Failure code [CA3574] DEF Pump Pressure Too Low Error1062
Failure code [CA3575] DEF Pump Pressure Too High Error1064
Failure code [CA3577] DEF FCV Voltage High Error1065
Failure code [CA3578] DEF FCV Voltage Low Error1067
Failure code [CA3582] SCR Catalyst Efficiency Low Error 11069
Failure code [CA3583] SCR Outlet NOx Sensor Heater Warming up Error1074
Failure code [CA3596] DEF Pump Pressure Unstable Error1076
Failure code [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error1080
Failure code [CA3681] SCR Outlet NOx Sensor Power Voltage Error1082
Failure code [CA3682] Turbo Outlet NOx Sensor Power Voltage Error1086
Failure code [CA3713] DEF Line Heater 1 Voltage High Error1090
Failure code [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error1093
Failure code [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error1094
Failure code [CA3725] Turbo Outlet NOx Sensor Unstable Error1095
Failure code [CA3741] Rail Press Valve Trip Error1097
Failure code [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error1098
Failure code [CA3751] SCR Catalyst Degradation Error1100
Failure code [CA3755] DEF Dosing Performance Degradation Error1101
Failure code [CA3866] DEF Low Concentration Error 21103
Failure code [CA3867] DEF Low Concentration Error 11105
Failure code [CA3868] DEF Tank Sensor Datalink Timeout Error1107
Failure code [CA3899] SCR NH3 Sensor Circuit Error1110
Failure code [CA3911] SCR NH3 Sensor Datalink Timeout Error1112
Failure code [CA3912] SCR NH3 Sensor Heater Warming up Error1115
Failure code [CA3932] SCR NH3 Sensor Heater Voltage High Error1117
Failure code [CA3933] SCR NH3 Sensor Heater Voltage Low Error1119
Failure code [CA3934] SCR NH3 Sensor Power Interrupt Error1121
Failure code [CA3935] SCR NH3 Sensor Trim Resistance Error1124
Failure code [CA3936] SCR NH3 Sensor Internal Circuit Error1126
Failure code [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error1128
Failure code [CA4152] SCR Temperature Sensor Datalink Timeout Error1132
Failure code [CA4155] DEF Pump Heater Relay Voltage High Error1135
Failure code [CA4156] DEF Pump Heater Relay Voltage Low Error1137
Failure code [CA4157] DEF FCV Malfunction1139
Failure code [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error1141
Failure code [CA4159] SCR Temperature Sensor Internal Circuit Error1142
Failure code [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error1143
Failure code [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error1145
Failure code [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error1147
Failure code [CA4164] SCR Temperature Sensor ECU Voltage High Error1148
Failure code [CA4165] SCR Temperature Sensor ECU Voltage Low Error1150
Failure code [CA4166] SCR Temperature Sensor ECU High Temperature Error1152
Failure code [CA4168] DEF Pump Heater ON Stuck Error1153
Failure code [CA4169] DEF Pump Heater OFF Stuck Error1156
Failure code [CA4171] DEF Pump Thawing Error1158
Failure code [CA4249] DEF Pump Temperature Sensor 1 In Range Error1161
Failure code [CA4251] DEF Pump Temperature Sensor 2 In Range Error1163
Failure code [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error1165
Failure code [CA4261] SCR Temperature Sensor Power Interrupt Error1167
Failure code [CA4277] DEF Quality Sensor Liquid Distinction Error1169
Failure code [CA4281] SCR NH3 Sensor Stuck Response Error1171
Failure code [CA4459] DEF LineHeater Relay 2 Voltage High Error1174
Failure code [CA4461] DEF LineHeater Relay 2 Voltage Low Error1176
Failure code [CA4658] DEF Flow Low Error1178
Failure code [CA4731] DEF Temperature Sensor Transmission Data Error1180
Failure code [CA4732] DEF Level Sensor Transmission Data Error1181
Failure code [CA4739] DEF Level Sensor Internal Circuit Error1182
Failure code [CA4768] Fuel in DEF Tank Error1183
Failure code [CA4769] DEF Level Measurement Impossible1184
Failure code [CA4842] DEF High Concentration Error1186
Failure code [CA4952] System Operating Lamp Short Circuit (Engine Controller)1188
Failure code [CA5115] DEF Line Heater 1 Voltage Low Error1190
Failure code [CA5179] Engine Room Temperature Sensor High Error1193
Failure code [CA5181] Engine Room Temperature Sensor Low Error1195
Failure code [CA5383] Ash Accumulation High Error1197
Failure code [D110KB] Battery Relay Output Short Circuit1198
Failure code [D162KY] Horn Relay S/C1199
Failure code [D162KZ] Horn Relay Disc or S/C1201
Failure code [D19JKZ] Personal Code Relay Open Circuit or Short Circuit1203
Failure code [D811MC] KOMTRAX Malfunction1205
Failure code [D862KA] GNSS Antenna Open Circuit1206
Failure code [D8ALKA] System Operating Lamp Open Circuit (Gateway function controller)1207
Failure code [D8ALKB] System Operating Lamp Short Circuit (Gateway function controller)1209
Failure code [D8AQKR] CAN 2 Defective Communication (Gateway function controller)1211
Failure code [D8ARKR] CAN 1 Defective Communication (Gateway function controller)1215
Failure code [D8G1KT] Gateway Function Controller Error1219
Failure code [D8G6KT] Malfunction of Communication Terminal1220
Failure code [DA22KK] SolPower Supply Low Voltage(W/E Controller)1221
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error1223
Failure code [DA26KP] 5V Sensor 2 Power Voltage Low Error1225
Failure code [DA29KQ] Model Selection Signal Mismatch (W/E Controller)1227
Failure code [DA2LKA] System Operating Lamp Open Circuit (W/ E Controller)1228
Failure code [DA2LKB] System Operating Lamp Short Circuit (W/ E Controller)1230
Failure code [DAF0MB] Monitor ROM Abnormality1232
Failure code [DAF0MC] Monitor Malfunction1233
Failure code [DAF7KB] Fuel Refract-meter Power Supply Short Circuit1234
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor)1235
Failure code [DAFGMC] GPS Module Malfunction1236
Failure code [DAFLKA] System Operating Lamp Open Circuit (Monitor)1237
Failure code [DAFLKB] System Operating Lamp Open Circuit (Monitor)1239
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor)1241
Failure code [DAFSMC] Fuel Refract-meter Serial Communication Malfunction1244
Failure code [DB2QKR] CAN 2 Defective Communication (Engine Controller)1246
Failure code [DB2RKR] CAN 1 Defective Communication (Engine Controller)1250
Failure code [DB90MC] Malfunction (W/E Controller)1256
Failure code [DB9QKR] CAN 2 Defective Communication (W/E Con)1257
Failure code [DB9RKR] CAN 1 Defective Communication (W/E Con)1261
Failure code [DDA6KA] Engine Stop Sw Disc1265
Failure code [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit1267
Failure code [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault1269
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit1270
Failure code [DHAAMA] KDPF Differential Pressure Sensor Frozen1272
Failure code [DHACMA] KDPF Outlet Pressure Sensor Frozen1273
Failure code [DHPAMA] Front Pump Pressure Sensor Defective Function1274
Failure code [DHPBMA] Rear Pump Pressure Sensor Defective Function1276
Failure code [DUB0KY] Beacon Solid State Relay S/C1277
Failure code [DUB0KZ] Beacon SS Relay Disc or S/C1279
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit1281
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit1282
Failure code [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit1283
Failure code [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit1284
Failure code [DXE0KA] LS-EPC Solenoid Open Circuit1285
Failure code [DXE0KB] LS-EPC Solenoid Short Circuit1286
Failure code [F311KA] Centralized Warning Lamp Signal 1 Open Circuit1287
Failure code [F311KB] Centralized Warning Lamp Signal 1 Short Circuit1289
Failure code [F312KA] Centralized Warning Lamp Signal 2 Open Circuit1291
Failure code [F312KB] Centralized Warning Lamp Signal 2 Short Circuit1293
Failure code [F313KA] Communication Terminal Startup Signal Open Circuit1295
Failure code [F313KB] Communication Terminal Startup Signal Short Circuit1296
Failure code [F314KA] Software Update Signal Open Circuit1297
Failure code [F314KB] Software Update Signal Short Circuit1299
Failure code [F315KB] Engine Controller WAKE Signal Open Circuit1301
Failure code [F315KY] Engine Controller WAKE Signal Short Circuit1303
Failure code [F316KB] 3rd Party Component Startup Signal Open Circuit1305
Failure code [F316KY] 3rd Party Component Startup Signal Short Circuit1307
Failure code [F318KB] Communication Terminal Power Supply 1 Short Circuit1309
Failure code [F318KY] Communication Terminal Power Supply 1 Hot Short Circuit1310
Failure code [F31AKB] Ethernet Power Supply Short Circuit1311
Failure code [F31AKY] Ethernet Power Supply Hot Short Circuit1313
Failure code [F31BKB] 5V Sensor Power Supply Short Circuit (Gateway Controller)1315
Failure code [F31BKY] 5V Sensor Power Supply Hot Short Circuit (Gateway Controller)1317
Failure code [F31CKB] 12V Sensor Power Supply Short Circuit (Gateway Controller)1319
Failure code [F31CKY] 12V Sensor Power Supply Hot Short Circuit (Gateway Controller)1321
Failure code [F31DKB] 24V Sensor Power Supply Short Circuit (Gateway Controller)1323
Failure code [F31DKY] 24V Sensor Power Supply Hot Short Circuit (Gateway Controller)1325
Failure code [F31EKB] 24V Sensor Power Supply Booster Output Short Circuit (Gateway Controller)1327
Failure code [F31EKY] 24V Sensor Power Supply Booster Output Hot Short Circuit (Gateway Controller)1329
Troubleshooting of electrical system (E mode)1331
Information described in troubleshooting table1331
E-1 Engine does not start (Engine does not crank)1333
E-2 Manual preheating does not work1337
E-3 Automatic preheating does not work1340
E-4 Preheat monitor does not light up when preheating operation is performed1342
E-5 Machine monitor displays nothing when starting switch is turned to ON position1344
E-6 Engine oil level monitor lights up yellow when starting switch is in ON position but engine is stopped1346
E-7 Radiator coolant level monitor lights up yellow when starting switch is in ON position but engine is stopped1347
E-8 Engine coolant temperature monitor lights up white while engine is running1348
E-9 Hydraulic oil temperature monitor lights up white while engine is running1349
E-10 Air cleaner clogging monitor lights up yellow while engine is running1350
E-11 Charge level monitor lights up red while engine is running1351
E-12 Fuel level monitor lights up red while engine is running1352
E-13 Water separator monitor lights up red while engine is running1353
E-14 Engine coolant temperature monitor lights up red while engine is running1354
E-15 Engine oil pressure monitor lights up red while engine is running1355
E-16 Hydraulic oil temperature monitor lights up red while engine is running1356
E-17 Indicator of fuel gauge remains at the minimum or maximum display position1357
E-18 Indication of fuel gauge does not agree with actual fuel level1358
E-19 Indicator of engine coolant temperature gauge remains at the minimum or maximum display position1359
E-20 Indication of engine coolant temperature gauge does not agree with actual coolant temperature1360
E-21 Indicator of hydraulic oil temperature gauge remains at the minimum or maximum display position1361
E-22 Indication of hydraulic oil temperature gauge does not agree with actual oil temperature1362
E-23 Machine monitor displays nothing partially on screen1363
E-24 Function switches do not work1364
E-25 Automatic warm-up operation system does not work (in cold season)1365
E-26 When travel speed switch is operated, travel speed monitor does not change1366
E-27 Current travel speed is not changed when travel speed setting is switched1367
E-28 Alarm buzzer does not stop sounding1368
E-29 Machine monitor does not display service meter when starting switch is in OFF position1369
E-30 Machine monitor cannot be switched to service mode1370
E-31 All work equipment stop suddenly1371
E-32 Message of “Under emergency work equipment stop” is displayed red immediately after engine is started1373
E-33 Alarm buzzer does not sound while machine is traveling1375
E-34 Alarm buzzer does not stop sounding while machine is not traveling1378
E-35 Horn does not sound1380
E-36 Horn does not stop sounding1382
E-37 Operation mode does not switch between Travel, Work, and Inspection modes1384
E-38 Crusher clearance adjustment mode cannot be switched1386
E-39 Crusher rotation cannot be switched between normal and reverse rotations1387
E-40 Machine cannot travel1388
E-41 Machine cannot travel under radio control1390
E-42 Feeder cannot be turned on or off under radio control1393
E-43 One-touch start and stop of work equipment cannot be performed under radio control1396
E-44 Nothing is displayed when monitor switches are operated1399
E-45 Crusher cannot be controlled using crusher manual forward and reverse rotation switches on monitor1400
E-46 Conveyor cannot be controlled using conveyor manual forward and reverse rotation switches on monitor1401
E-47 KOMTRAX system does not operate normally1402
Troubleshooting for hydraulic and mechanical system (H mode)1403
Information described in troubleshooting table1403
H-1 All work equipment and travel system move too slow or lack power1405
H-2 Engine speed drops significantly or engine stalls1406
H-3 All work equipment and travel system do not operate1407
H-4 Unusual noise is heard from around hydraulic pump1408
H-5 Fine control performance or its practicability is poor1409
H-6 Conveyor does not operate1410
H-7 Conveyor moves too slow or lacks power1411
H-8 Crusher does not operate1412
H-9 Crusher does not rotate smoothly or lacks power1413
H-10 Feeder does not operate1414
H-11 Feed performance of feeder is poor (Vibration frequency is small)1415
H-12 Magnetic separator does not operate1416
H-13 Magnetic separator belt moves too slow1417
H-14 Muck discharge conveyor does not operate1418
H-15 Muck discharge conveyor moves too slow or lacks power1419
H-16 Primary conveyor and muck discharge conveyor do not move up and down1420
H-17 Machine deviates during traveling1421
H-18 Travel speed is too slow1422
H-19 Machine is hard to be steered or steering system lacks power1423
H-20 Track does not operate (only either side)1424
H-21 Machine cannot travel when travel switch on radio control unit is pressed1425
H-22 Crusher clearance cannot be opened nor closed1426
Troubleshooting of engine (S mode)1427
Information described in troubleshooting table (S mode)1427
S-1 Engine does not crank when starting switch is turned to “START” position1428
S-2 Engine cranks but no exhaust gas is discharged1429
S-3 Fuel is injected but engine does not start (Engine cranks but cannot start due to incomplete combustion)1430
S-4 Engine startability is poor1431
S-5 Engine pickup is poor1433
S-6 Running engine stops1435
S-7 Engine rotation is unstable1437
S-8 Engine output is insufficient (Engine lacks power)1438
S-9 KDPF is clogged early1440
S-10 Engine oil consumption is excessive1442
S-11 Engine oil is contaminated early1443
S-12 Fuel consumption is excessive1444
S-13 Oil gets mixed in coolant (Or coolant blows back and reduces)1445
S-14 Engine oil pressure drops1446
S-15 Fuel gets mixed in engine oil1447
S-16 Water gets mixed in engine oil (Engine oil becomes cloudy)1448
S-17 Coolant temperature rises too high (Coolant overheats)1449
S-18 Unusual noise is heard1450
S-19 Vibrations are too large1451
S-20 Air cannot be bled from fuel circuit1452
S-21 Active regeneration is performed too frequently1453
S-22 Active regeneration duration is too long1454
S-23 White smoke is exhausted during active regeneration1455
S-24 DEF consumption is excessive1456
S-25 Abnormal (irritating) odor is smelled1457
S-26 Foreign material gets mixed in DEF (DEF level increases)1458
50 Disassembly and assembly1459
Contents1460
Precautions before work1462
Related information on disassembly and assembly1463
How to read this manual1463
Coating materials list1464
Special tools list1468
Sketches of special tools1477
Engine and cooling system1481
Removal and installation of supply pump assembly1481
Removal and installation of injector assembly1486
Removal and installation of cylinder head assembly1496
Removal and installation of EGR valve assembly1521
Removal and installation of EGR cooler assembly1524
Removal and installation of starting motor assembly1533
Removal and installation of alternator belt1539
Removal and installation of radiator assembly1543
Removal and installation of hydraulic oil cooler assembly1548
Removal and installation of aftercooler assembly1554
Removal and installation of engine and main pump assembly1557
Removal and installation of engine front oil seal1581
Removal and installation of engine rear oil seal1587
Removal and installation of fuel cooler assembly1591
Removal and installation of engine hood assembly1593
Removal and installation of fuel tank assembly1600
Removal and installation of DEF tank assembly1609
Removal and installation of DEF tank sensor flange assembly1621
Removal and installation of DEF tank sensor1623
Removal and installation of DEF tank strainer1629
Removal and installation of DEF tank filler port filter1630
Removal and installation of KDPF assembly1634
Disassembly and assembly of KDPF assembly1638
Removal and installation of SCR assembly1645
Removal and installation of KDPF and SCR assembly1649
Removal and installation of bracket for KDPF and SCR assembly1660
Removal and installation of KCCV assembly1673
Removal and installation of DEF mixing tube1675
Removal and installation of DEF injector1684
Removal and installation of DEF pump assembly1690
Removal and installation of DEF hose1696
Removal and installation of air cleaner assembly1711
Power train1718
Removal and installation of travel motor, final drive assembly1718
Disassembly and assembly of final drive assembly1720
Undercarriage and frame1731
Separation and connection of track shoe assembly1731
Removal and installation of sprocket1735
Removal and installation of idler and idler cushion assembly1737
Disassembly and assembly of idler assembly1739
Disassembly and assembly of idler cushion assembly1744
Disassembly and assembly of track roller assembly1747
Disassembly and assembly of carrier roller assembly1751
Hydraulic system1755
Removal and installation of hydraulic tank assembly1755
Removal and installation of main pump assembly1763
Removal and installation of control valve assembly1769
Removal and installation of crusher motor assembly1783
Removal and installation of lock cylinder assembly1787
Disassembly and assembly of lock cylinder assembly1794
Removal and installation of primary conveyor motor1798
Removal and installation of grizzly feeder motor assembly1801
Removal and installation of magnetic separator motor assembly1803
Work equipment1806
Removal and installation of cheek plate1806
Removal and installation of fixed jaw plate1813
Removal and installation of swing jaw plate1818
Removal and installation of toggle plate1823
Removal and installation of fixed link1832
Removal and installation of swing jaw assembly1835
Removal and installation of V-sieve and balance weight1840
Removal and installation of crusher assembly1849
Removal and installation of primary conveyor assembly1857
Removal and installation of belt1862
Replacement of primary conveyor head pulley frame1864
Removal and installation of crusher main bearing1874
Removal and installation of crusher motor and V-sieve1880
Removal and installation of potentiometer1886
Removal and installation of engine front cover1888
Electrical system1894
Removal and installation of engine controller assembly1894
Removal and installation of work equipment controller assembly1898
Removal and installation of machine monitor assembly1900
Removal and installation of pump swash plate sensor1903
Removal and installation of mass air flow and temperature sensor1905
Removal and installation of KCCV crankcase pressure sensor1907
Removal and installation of SCR temperature sensor1909
Removal and installation of Gateway function controller assembly1914
60 Maintenance standard1921
Contents1922
Engine and cooling system1923
Maintenance standard for engine mount1923
Maintenance standard for cooling system1925
Power train1927
Maintenance standard for final drive1927
Maintenance standard for sprocket1929
Undercarriage and frame1931
Maintenance standard for track frame and idler cushion1931
Maintenance standard for idler1933
Maintenance standard for track roller1935
Maintenance standard for carrier roller1937
Maintenance standard for track shoe1938
Maintenance standard for triple grouser shoe1941
Hydraulic system1942
Maintenance standard for hydraulic tank1942
Maintenance standard for main pump1943
Maintenance standard for LS-EPC valve1945
Maintenance standard for PC-EPC valve1946
Maintenance standard for control valve1947
Maintenance standard for crusher motor1958
Maintenance standard for solenoid valve1960
Maintenance standard for EPC valve1961
Maintenance standard for travel motor1963
Maintenance standard for travel PPC valve1966
Work equipment1969
Maintenance standard for primary conveyor1969
Maintenance standard for vibrator1971
Maintenance standard for conveyor lift cylinder1972
Maintenance standard for muck discharge conveyor lift cylinder1973
Maintenance standard for lock cylinder1974
90 Circuit diagrams1975
Contents1976
Hydraulic circuit diagram1977
Symbols used on hydraulic circuit diagram1977
Hydraulic circuit diagram (1/2)1981
Hydraulic circuit diagram (2/2)1981
Electrical circuit diagram1985
Symbols used on electrical circuit diagram1985
Electrical circuit diagram (1/9)1989
Electrical circuit diagram (2/9)1991
Electrical circuit diagram (3/9)1993
Electrical circuit diagram (4/9)1995
Electrical circuit diagram (5/9)1997
Electrical circuit diagram (6/9)1999
Electrical circuit diagram (7/9)2001
Electrical circuit diagram (8/9)2003
Electrical circuit diagram (9/9)2005
INDEX2007

S.M 29/12/24