Service manual Komatsu BR380JG-3 5001 & Up | SEN06703-05

Komatsu BR380JG-3 5001 & Up SEN06703-05 (Preview)

COVER
00 Index and foreword
– Index
– Abbreviations
– Foreword, safety, and basic information
— How to read the shop manual
— Safety notice for operation
— Precautions to prevent fire
— Action if fire occurs
— Precautions when disposing of waste materials
— Exhaust gas regulations – Actions taken
— Precautions about AdBlue®
— AdBlue/DEF – Store
— Precautions for handling hydraulic component
— Piping – Precautions for disconnection and connection
— Precautions for handling electrical component
— Precautions for handling fuel system component
— Precautions for handling air intake system component
— Practical use of KOMTRAX
— Disconnection and connection of push-pull type coupler
— Precautions for disconnecting and connecting connector
— Procedures for disconnecting and connecting DT connectors
— Procedures for disconnecting and connecting slide lock type connectors
— Procedures for disconnecting and connecting connectors with pull and release type lock
— Procedures for disconnecting and connecting connectors with push and release type lock
— Procedures for disconnecting and connecting connectors that require rotation of housing to release and apply lock
— How to read wire code
— Description of terms used in maintenance standard
— Standard tightening torque table
01 Specifications
– Contents
– Abbreviations
– Specifications
— Specification drawing
— Specifications
— Weight table
— Table of fuel, coolant and lubricants
10 Structure and function
– Contents
– Abbreviations
– Urea SCR system
— Urea SCR system component layout drawing
— Urea SCR system diagram
— Urea SCR system functions
— Urea SCR system components
– Starting system
— Starting system component layout drawing
— System operating lamp system
— Battery disconnect switch
– Engine system
— Engine system component layout drawing
— Engine control system
— Engine automatic warm-up system
— Overheat prevention system
— Turbocharger protection system
— Engine system component
– Cooling system
— Cooling system component layout drawing
– Control system
— Control system component layout drawing
— Machine monitor system
— KOMTRAX system
— Control system component
– Hydraulic system
— Hydraulic system component layout drawing
— CLSS
— Pump and engine combined control system
— Pump and valve control system
— Hydraulic system components
– Work equipment system
— Work equipment system component layout drawing
— Structure of valve control
— Grizzly feeder semi automatic control system
— Abnormal load shutdown system
— Crusher jaw tip adjustment system
— Work equipment system components
— Crusher motor
– Travel system
— Travel system component layout drawing
— Travel control system diagram
— Travel system components
– Undercarriage and frame
— Undercarriage layout drawing
– Work equipment
— Primary conveyor
— Grizzly feeder
— Crusher
— Vibrator
20 Standard value table
– Contents
– Abbreviations
– Standard value table for engine
— Standard value table for engine: BR380JG-3
– Standard value table for machine
— Standard value table for machine: BR380JG-3
— Machine posture and measuring procedure drawings for performance measurement
30 Testing and adjusting
– Contents
– Abbreviations
– Related information on testing and adjusting
— Tools for testing and adjusting
— Sketches for testing and adjusting tools
– Engine and cooling system
— Testing engine speed
— Testing boost pressure
— Testing exhaust gas color
— Testing and adjusting valve clearance
— Testing compression pressure
— Testing blowby pressure
— Testing engine oil pressure
— Testing EGR valve and VGT oil pressures
— Testing fuel pressure
— Testing fuel discharged volume, return rate, and leakage
— Bleeding air from fuel system
— Testing leakage from fuel system
— Handling cylinder cutout mode operation
— Handling no-injection cranking operation
— Test fan belt and alternator belt
— Test automatic tensioner
— Writing soot correction by ash influence to engine controller
— Testing SCR-related functions
— Flushing AdBlue/DEF tank
— Clean AdBlue/DEF pump
– Undercarriage and frame
— Testing and adjusting track shoe tension
– Hydraulic system
— Releasing remaining pressure from hydraulic system
— Testing and adjusting oil pressure in work equipment and travel circuits
— Testing control circuit pressure
— Testing and adjusting pump PC control circuit pressure
— Testing and adjusting pump LS control circuit pressure
— Testing solenoid valve output pressure
— Testing PPC valve outlet pressure
— Testing oil leakage
— Bleeding air from hydraulic circuit
— Procedure for adjusting mirrors
– Electrical system
— Setting and operating machine monitor
— Procedure for starting up KOMTRAX terminal
— Handling voltage circuit of engine controller
— Handling battery disconnect switch
— Testing diode
– Pm Clinic
— Pm Clinic Service
40 Troubleshooting
– Contents
– Abbreviations
– Information related to troubleshooting
— Points to remember when performing troubleshooting
— Points to remember when performing troubleshooting of urea SCR system
— How to proceed in troubleshooting
— Check before starting troubleshooting
— Procedure for checking electrical parts
— Troubleshooting procedure
— Symptom of failure and troubleshooting numbers
— Information described in troubleshooting table
— Troubleshooting procedure of wiring harness in pressure sensor system
— Connector list and layout
— Connector pin numbers and wiring table
— T-box and T-adapter list
— Fuse location table
— Precautions when cleaning and replacing KDPF (KCSF and KDOC)
— Preparation of short connectors (for troubleshooting for failure codes [CA1883] and [CA3135])
— Failure codes table
– Troubleshooting by failure code (display of code)
— Failure code [7RC1KB] Conv. ON Sw.S/C
— Failure code [7RC2KA] Conv. OFF Sw.Disc.
— Failure code [7RC5KB] Feeder ON Switch S/C
— Failure code [7RD2KA] Conv. REV Sol. Disc.
— Failure code [7RD2KB] Conv. REV Sol. S/C
— Failure code [7RD2KY] Conv. REV Sol. H.S/C
— Failure code [7RE1KB] Crusher ON Sw. S/C
— Failure code [7RE2KA] Crusher OFF Sw. Disc.
— Failure code [7RE6KB] Muck Conv. On Sw. S/C
— Failure code [7RE7KA] Muck Conv. OFF Sw.Disc.
— Failure code [7RE8KB] Magnetic Separator ON Sw. S/C
— Failure code [7RE9KA] Magnetic Separator OFF Sw. Disc.
— Failure code [7REAKB] Acc.Input1 S/C
— Failure code [7REDMA] Conveyor P.Sensor Abnormality
— Failure code [7REEMA] Muck Conv. P.Sensor Abnormality
— Failure code [7RENKZ] Clearance Potentio Abnormality
— Failure code [7REPKA] Grizzly Feeder Stop Sw. Disc.
— Failure code [7RESKB] 1-touch Start Sw. S/C
— Failure code [7RETKA] 1-touch Stop Sw. Disc.
— Failure code [7RF2KA] Crusher FWD EPC Disc.
— Failure code [7RF2KB] Crusher FWD EPC S/C
— Failure code [7RF2KY] Crusher FWD EPC H.S/C
— Failure code [7RF3KA] Crusher REV EPC Disc.
— Failure code [7RF3KB] Crusher REV EPC S/C
— Failure code [7RF3KY] Crusher REV EPC H.S/C
— Failure code [7RF4KA] Feeder FWD EPC Disc.
— Failure code [7RF4KB] Feeder FWD EPC S/C
— Failure code [7RF4KY] Feeder FWD EPC H.S/C
— Failure code [7RFAKA] Eng.Stop Relay Disc.
— Failure code [7RFAKB] Eng.Stop Relay S/C
— Failure code [7RFAKY] Eng.Stop Relay H.S/C
— Failure code [7RFBKA] Muck Conv. EPC Disc.
— Failure code [7RFBKB] Muck Conv. EPC S/C
— Failure code [7RFBKY] Muck Conv. EPC H.S/C
— Failure code [7RFHKB] Conv. FWD EPC S/C
— Failure code [7RFHKY] Conv. FWD EPC H.S/C
— Failure code [7RFKKA] Lock Cyl. Pull Sol. Disc.
— Failure code [7RFKKB] Lock Cyl. Pull Sol. S/C
— Failure code [7RFKKY] Lock Cyl. Pull Sol. H.S/C
— Failure code [7RFLKA] Acc. EPC Disc.
— Failure code [7RFLKB] Acc. EPC S/C
— Failure code [7RFLKY] Acc. EPC H.S/C
— Failure code [7RFMKA] Abnormal Press.Relay Disc.
— Failure code [7RFMKB] Abnormal Press.Relay S/C
— Failure code [7RFMKY] Abnormal Press.Relay H.S/C
— Failure code [7RFNKA] Lock Cyl. Unlock Sol. Disc.
— Failure code [7RFNKB] Lock Cyl. Unlock Sol. S/C
— Failure code [7RFNKY] Lock Cyl. Unlock Sol. H.S/C
— Failure code [7RFPKA] Lock Cyl. Push Relay Disc.
— Failure code [7RFPKB] Lock Cyl. Push Relay S/C
— Failure code [7RFPKY] Lock Cyl. Push Relay H.S/C
— Failure code [7RGAMA] 2nd Conv. P.Sensor Abnormality
— Failure code [7RJAKA] Travel Lock EPC Disc.
— Failure code [7RJAKB] Travel Lock EPC S/C
— Failure code [7RJAKY] Travel Lock EPC H.S/C
— Failure code [7RJLKA] Magnetic Separator EPC Disc.
— Failure code [7RJLKB] Magnetic Separator EPC S/C
— Failure code [7RJLKY] Magnetic Separator EPC H.S/C
— Failure code [7RJMMW] Lock Cyl. Slide
— Failure code [7RJNMA] Vibratory Sieve P.Sensor Abnormality
— Failure code [7RJPKB] Radio Control Work-mode Sw. S/C
— Failure code [7RJQKB] Radio Control Trav.-mode Sw. S/C
— Failure code [7RJRKB] On Travel Signal S/C
— Failure code [7RJSMA] M/Separator P.Sensor Abnormality
— Failure code [989L00] Engine Controller Lock Caution 1
— Failure code [989M00] Engine Controller Lock Caution 2
— Failure code [989N00] Engine Controller Lock Caution 3
— Failure code [A1U0N3] HC Desorb Request 1
— Failure code [A1U0N4] HC Desorb Request 2
— Failure code [A900FR] Abrupt Engine Stop by Auto Idling Stop 3
— Failure code [A900N6] Abrupt Engine Stop by Auto Idling Stop 1
— Failure code [A900NY] Abrupt Engine Stop by Auto Idling Stop 2
— Failure code [AA10NX] Air Cleaner Clogging
— Failure code [AB00KE] Charge Voltage Low
— Failure code [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)
— Failure code [AS00N3] Manual Stationary Regeneration Request (SCR)
— Failure code [AS00R2] Warning 2 (SCR Device Abnormality)
— Failure code [AS00R3] Inducement 1 (SCR Device Abnormality)
— Failure code [AS00R4] Inducement 2 (SCR Device Abnormality)
— Failure code [AS00R5] Inducement 3 (SCR Device Abnormality)
— Failure code [AS00R6] Temporary Recovery of Inducement
— Failure code [AS00ZK] AdBlue/DEF Level Low Error 5
— Failure code [AS10KM] AdBlue/DEF Injector Overheat Warning
— Failure code [AS10NR] AdBlue/DEF Injector High Temperature Warning
— Failure code [AS10NT] AdBlue/DEF Injector Overheat Caution
— Failure code [B@BAZG] Eng Oil Press Low
— Failure code [B@BAZK] Eng Oil Level Low
— Failure code [B@BCNS] Eng Water Overheat
— Failure code [B@BCQA] Radiator Water Level Low
— Failure code [B@BCZK] Eng Water Level Low
— Failure code [B@HANS] Hyd Oil Overheat
— Failure code [CA115] Engine NE and Bkup Speed Sensor Error
— Failure code [CA122] Charge Air Pressure Sensor High Error
— Failure code [CA123] Charge Air Pressure Sensor Low Error
— Failure code [CA131] Throttle Sensor High Error
— Failure code [CA132] Throttle Sensor Low Error
— Failure code [CA144] Coolant Temperature Sensor High Error
— Failure code [CA145] Coolant Temperature Sensor Low Error
— Failure code [CA153] Charge Air Temperature Sensor High Error
— Failure code [CA154] Charge Air Temperature Sensor Low Error
— Failure code [CA187] Sensor 2 Supply Voltage Low Error
— Failure code [CA221] Ambient Pressure Sensor High Error
— Failure code [CA222] Ambient Pressure Sensor Low Error
— Failure code [CA227] Sensor 2 Supply Voltage High Error
— Failure code [CA234] Engine Overspeed
— Failure code [CA238] NE Speed Sensor Supply Voltage Error
— Failure code [CA239] NE Speed Sensor Supply Voltage High Error
— Failure code [CA249] Ambient Air Temp Sensor High Error
— Failure code [CA256] Ambient Air Temp Sensor Low Error
— Failure code [CA271] IMV/PCV1 Short Circuit Error
— Failure code [CA272] IMV/PCV1 Open Circuit Error
— Failure code [CA322] Injector #1 (L#1) Open Circuit or Short Circuit Error
— Failure code [CA323] Injector #5 (L#5) Open Circuit or Short Circuit Error
— Failure code [CA324] Injector #3 (L#3) Open Circuit or Short Circuit Error
— Failure code [CA325] Injector #6 (L#6) Open Circuit or Short Circuit Error
— Failure code [CA331] Injector #2 (L#2) Open Circuit or Short Circuit Error
— Failure code [CA332] Injector #4 (L#4) Open Circuit or Short Circuit Error
— Failure code [CA343] Engine Controller Internal Failure
— Failure code [CA351] Injectors Drive Circuit Error
— Failure code [CA352] Sensor 1 Supply Voltage Low Error
— Failure code [CA356] MAF Sensor High Error
— Failure code [CA357] MAF Sensor Low Error
— Failure code [CA386] Sensor 1 Supply Voltage High Error
— Failure code [CA428] Water in Fuel Sensor High Error
— Failure code [CA429] Water in Fuel Sensor Low Error
— Failure code [CA435] Engine Oil Pressure SW Error
— Failure code [CA441] Battery Voltage Low Error
— Failure code [CA442] Battery Voltage High Error
— Failure code [CA449] Common Rail Pressure High Error 2
— Failure code [CA451] Common Rail Pressure Sensor High Error
— Failure code [CA452] Common Rail Pressure Sensor Low Error
— Failure code [CA488] Charge Air Temperature High Torque Derate
— Failure code [CA515] Common Rail Pressure Sensor Supply Voltage Low Error
— Failure code [CA516] Common Rail Pressure Sensor Supply Voltage Low Error
— Failure code [CA553] Common Rail Pressure High Error 1
— Failure code [CA555] Crankcase Pressure High Error 1
— Failure code [CA556] Crankcase Pressure High Error 2
— Failure code [CA559] Common Rail Pressure Low Error 1
— Failure code [CA595] Turbocharger Speed High Error 2
— Failure code [CA687] Turbocharger Speed Low Error
— Failure code [CA689] Engine NE Speed Sensor Error
— Failure code [CA691] Intake Air Temperature Sensor High Error
— Failure code [CA692] Intake Air Temperature Sensor Low Error
— Failure code [CA697] Engine Controller Internal Temperature Sensor High Error
— Failure code [CA698] Engine Controller Internal Temperature Sensor Low Error
— Failure code [CA731] Engine Bkup Speed Sensor Phase Error
— Failure code [CA778] Engine Bkup Speed Sensor Error
— Failure code [CA1117] Engine Controller Partial Data Lost Error
— Failure code [CA1664] KDOC Abnormality
— Failure code [CA1669] AdBlue/DEF Level Sensor Voltage High Error
— Failure code [CA1673] AdBlue/DEF Level Low Error 3
— Failure code [CA1677] AdBlue/DEF Temperature Sensor Low Error
— Failure code [CA1678] AdBlue/DEF Temperature Sensor High Error
— Failure code [CA1682] AdBlue/DEF Pump Priming Error
— Failure code [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error
— Failure code [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error
— Failure code [CA1686] AdBlue/DEF Quality Sensor Voltage High Error
— Failure code [CA1691] Defective Regeneration
— Failure code [CA1694] SCR Outlet NOx Sensor In Range Error
— Failure code [CA1695] Sensor 5 Supply Voltage High Error
— Failure code [CA1696] Sensor 5 Supply Voltage Low Error
— Failure code [CA1712] AdBlue/DEF Tank Thawing Error
— Failure code [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error
— Failure code [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error
— Failure code [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error
— Failure code [CA1776] Sensor Supply Relay Voltage High Error
— Failure code [CA1777] Sensor Supply Relay Voltage Low Error
— Failure code [CA1843] Crankcase Pressure Sensor High Error
— Failure code [CA1844] Crankcase Pressure Sensor Low Error
— Failure code [CA1879] KDPF Differential Pressure Sensor High Error
— Failure code [CA1881] KDPF Differential Pressure Sensor Low Error
— Failure code [CA1883] KDPF Differential Pressure Sensor In Range Error
— Failure code [CA1885] Turbo Outlet NOx Sensor Circuit Error
— Failure code [CA1887] SCR Outlet NOx Sensor Circuit Error
— Failure code [CA1921] KDPF Soot Accumulation High Error 1
— Failure code [CA1922] KDPF Soot Accumulation High Error 2
— Failure code [CA1942] Crankcase Pressure Sensor In Range Error
— Failure code [CA1993] KDPF Differential Pressure Sensor Low Error
— Failure code [CA2185] Throttle Sensor Supply Voltage High Error
— Failure code [CA2186] Throttle Sensor Supply Voltage Low Error
— Failure code [CA2249] Common Rail Pressure Low Error 2
— Failure code [CA2271] EGR Valve Position Sensor High Error
— Failure code [CA2272] EGR Valve Position Sensor Low Error
— Failure code [CA2288] Turbocharger Speed High Error 1
— Failure code [CA2311] IMV Solenoid Error
— Failure code [CA2349] EGR Valve Solenoid Open Circuit Error
— Failure code [CA2353] EGR Valve Solenoid Short Circuit Error
— Failure code [CA2357] EGR Valve Servo Error
— Failure code [CA2381] VGT Position Sensor High Error
— Failure code [CA2382] VGT Position Sensor Low Error
— Failure code [CA2383] VGT Solenoid Open Circuit Error
— Failure code [CA2386] VGT Solenoid Short Circuit Error
— Failure code [CA2387] VGT Servo Error
— Failure code [CA2555] Intake Air Heater Relay Open Circuit Error
— Failure code [CA2556] Intake Air Heater Relay Short Circuit Error
— Failure code [CA2637] KDOC Face Plugging
— Failure code [CA2639] Manual Stationary Regeneration Request
— Failure code [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error
— Failure code [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable
— Failure code [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error
— Failure code [CA3133] KDPF Outlet Pressure Sensor High Error
— Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error
— Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error
— Failure code [CA3142] SCR Temperature Sensor High Error
— Failure code [CA3143] SCR Temperature Sensor Low Error
— Failure code [CA3144] SCR Temperature Sensor In Range Error
— Failure code [CA3146] SCR Outlet Temperature Sensor High Error
— Failure code [CA3147] SCR Outlet Temperature Sensor Low Error
— Failure code [CA3148] SCR Outlet Temperature Sensor In Range Error
— Failure code [CA3151] SCR Catalyst Efficiency Low Error 2
— Failure code [CA3165] SCR Outlet Temperature High Error
— Failure code [CA3229] SCR Temperature High Error
— Failure code [CA3231] SCR Temperature High Error – Non Regeneration
— Failure code [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error
— Failure code [CA3235] SCR Outlet Temperature High Error – Non Regeneration
— Failure code [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error
— Failure code [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error
— Failure code [CA3242] AdBlue/DEF Tank Heating Error
— Failure code [CA3251] KDOC Inlet Temperature High Error
— Failure code [CA3253] KDOC Temperature Error – Non Regeneration
— Failure code [CA3254] KDOC Outlet Temperature High Error 1
— Failure code [CA3255] KDPF Temperature Error – Non Regeneration
— Failure code [CA3256] KDPF Outlet Temperature High Error 1
— Failure code [CA3311] KDOC Outlet Temperature High Error 2
— Failure code [CA3312] KDPF Outlet Temperature High Error 2
— Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error
— Failure code [CA3314] KDOC Inlet Temperature Sensor High Error
— Failure code [CA3315] KDOC Inlet Temperature Sensor In Range Error
— Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error
— Failure code [CA3317] KDOC Outlet Temperature Sensor High Error
— Failure code [CA3318] KDOC Outlet Temperature Sensor In Range Error
— Failure code [CA3319] KDPF Outlet Temperature Sensor High Error
— Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error
— Failure code [CA3322] KDPF Outlet Temperature Sensor In Range Error
— Failure code [CA3419] MAF Sensor Supply Voltage High Error
— Failure code [CA3421] MAF Sensor Supply Voltage Low Error
— Failure code [CA3497] AdBlue/DEF Level Low Error 1
— Failure code [CA3498] AdBlue/DEF Level Low Error 2
— Failure code [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)
— Failure code [CA3545] SCR Outlet NOx Sensor Unstable Error
— Failure code [CA3547] AdBlue/DEF Level Low Error 4
— Failure code [CA3558] AdBlue/DEF Pump Voltage High Error
— Failure code [CA3559] AdBlue/DEF Pump Voltage Low Error
— Failure code [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error
— Failure code [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error
— Failure code [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
— Failure code [CA3568] AdBlue/DEF Injector Malfunction
— Failure code [CA3571] AdBlue/DEF Pump Pressure Sensor High Error
— Failure code [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error
— Failure code [CA3574] AdBlue/DEF Pump Pressure Too Low Error
— Failure code [CA3575] AdBlue/DEF Pump Pressure Too High Error
— Failure code [CA3577] AdBlue/DEF FCV Voltage High Error
— Failure code [CA3578] AdBlue/DEF FCV Voltage Low Error
— Failure code [CA3582] SCR Catalyst Efficiency Low Error 1
— Failure code [CA3583] SCR Outlet NOx Sensor Heater Warming up Error
— Failure code [CA3596] AdBlue/DEF Pump Pressure Unstable Error
— Failure code [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error
— Failure code [CA3681] SCR Outlet NOx Sensor Power Voltage Error
— Failure code [CA3682] Turbo Outlet NOx Sensor Power Voltage Error
— Failure code [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error
— Failure code [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error
— Failure code [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error
— Failure code [CA3725] Turbo Outlet NOx Sensor Unstable Error
— Failure code [CA3741] Rail Press Valve Trip Error
— Failure code [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error
— Failure code [CA3751] SCR Catalyst Degradation Error
— Failure code [CA3755] AdBlue/DEF Dosing Performance Degradation Error
— Failure code [CA3866] AdBlue/DEF Low Concentration Error 2
— Failure code [CA3867] AdBlue/DEF Low Concentration Error 1
— Failure code [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error
— Failure code [CA3899] SCR NH3 Sensor Circuit Error
— Failure code [CA3911] SCR NH3 Sensor Datalink Timeout Error
— Failure code [CA3912] SCR NH3 Sensor Heater Warming up Error
— Failure code [CA3932] SCR NH3 Sensor Heater Voltage High Error
— Failure code [CA3933] SCR NH3 Sensor Heater Voltage Low Error
— Failure code [CA3934] SCR NH3 Sensor Power Interrupt Error
— Failure code [CA3935] SCR NH3 Sensor Trim Resistance Error
— Failure code [CA3936] SCR NH3 Sensor Internal Circuit Error
— Failure code [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error
— Failure code [CA4152] SCR Temperature Sensor Datalink Timeout Error
— Failure code [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error
— Failure code [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error
— Failure code [CA4157] AdBlue/DEF FCV Malfunction
— Failure code [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error
— Failure code [CA4159] SCR Temperature Sensor Internal Circuit Error
— Failure code [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error
— Failure code [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error
— Failure code [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error
— Failure code [CA4164] SCR Temperature Sensor ECU Voltage High Error
— Failure code [CA4165] SCR Temperature Sensor ECU Voltage Low Error
— Failure code [CA4166] SCR Temperature Sensor ECU High Temperature Error
— Failure code [CA4168] AdBlue/DEF Pump Heater ON Stuck Error
— Failure code [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error
— Failure code [CA4171] AdBlue/DEF Pump Thawing Error
— Failure code [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error
— Failure code [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error
— Failure code [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error
— Failure code [CA4261] SCR Temperature Sensor Power Interrupt Error
— Failure code [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Error
— Failure code [CA4281] SCR NH3 Sensor Stuck Response Error
— Failure code [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error
— Failure code [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error
— Failure code [CA4658] AdBlue/DEF Flow Low Error
— Failure code [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error
— Failure code [CA4732] AdBlue/DEF Level Sensor Transmission Data Error
— Failure code [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error
— Failure code [CA4768] Fuel in AdBlue/DEF Tank Error
— Failure code [CA4769] AdBlue/DEF Level Measurement Impossible
— Failure code [CA4842] AdBlue/DEF High Concentration Error
— Failure code [CA4952] System Operating Lamp Short Circuit (Engine Controller)
— Failure code [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error
— Failure code [CA5179] Engine Room Temperature Sensor High Error
— Failure code [CA5181] Engine Room Temperature Sensor Low Error
— Failure code [CA5383] Ash Accumulation High Error
— Failure code [D110KB] Battery Relay Output Short Circuit
— Failure code [D162KY] Horn Relay S/C
— Failure code [D162KZ] Horn Relay Disc. or S/C
— Failure code [D19JKZ] Personal Code Relay Open Circuit or Short Circuit
— Failure code [D811MC] KOMTRAX Malfunction
— Failure code [D862KA] GPS Antenna Open Circuit
— Failure code [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)
— Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)
— Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX)
— Failure code [DA22KK] Sol.Power Supply Low Voltage(W/E Controller)
— Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error
— Failure code [DA26KP] 5V Sensor 2 Power Voltage Low Error
— Failure code [DA29KQ] Model Selection Signal Mismatch (W/E Controller)
— Failure code [DA2LKA] System Operating Lamp Open Circuit (W/ E Controller)
— Failure code [DA2LKB] System Operating Lamp Short Circuit (W/ E Controller)
— Failure code [DAF0MB] Monitor ROM Abnormality
— Failure code [DAF0MC] Monitor Malfunction
— Failure code [DAF7KB] Fuel Refract-meter Power Supply Short Circuit
— Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor)
— Failure code [DAFGMC] GPS Module Malfunction
— Failure code [DAFLKA] System Operating Lamp Open Circuit (Monitor)
— Failure code [DAFLKB] System Operating Lamp Open Circuit (Monitor)
— Failure code [DAFQKR] CAN 2 Defective Communication (Monitor)
— Failure code [DAFSMC] Fuel Refract-meter Serial Communication Malfunction
— Failure code [DB2QKR] CAN 2 Defective Communication (Engine Controller)
— Failure code [DB2RKR] CAN 1 Defective Communication (Engine Controller)
— Failure code [DB90MC] Malfunction (W/E Controller)
— Failure code [DB9QKR] CAN 2 Defective Communication (W/E Con)
— Failure code [DB9RKR] CAN 1 Defective Communication (W/E Con)
— Failure code [DDA6KA] Engine Stop Sw. Disc.
— Failure code [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit
— Failure code [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault
— Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
— Failure code [DHAAMA] KDPF Differential Pressure Sensor Frozen
— Failure code [DHACMA] KDPF Outlet Pressure Sensor Frozen
— Failure code [DHPAMA] Front Pump Pressure Sensor Defective Function
— Failure code [DHPBMA] Rear Pump Pressure Sensor Defective Function
— Failure code [DUB0KY] Beacon Solid State Relay S/C
— Failure code [DUB0KZ] Beacon S.S. Relay Disc. or S/C
— Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit
— Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit
— Failure code [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit
— Failure code [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit
— Failure code [DXE0KA] LS-EPC Solenoid Open Circuit
— Failure code [DXE0KB] LS-EPC Solenoid Short Circuit
– Troubleshooting of electrical system (E mode)
— Information described in troubleshooting table
— E-1 Engine does not start. (Engine does not crank.)
— E-2 Manual preheating does not work.
— E-3 Automatic preheating does not work.
— E-4 Preheat monitor does not light up when preheating operation is performed.
— E-5 Machine monitor displays nothing when starting switch is turned to ON position.
— E-6 Engine oil level monitor lights up yellow when starting switch is in ON position but engine is stopped.
— E-7 Radiator coolant level monitor lights up yellow when starting switch is in ON position but engine is stopped.
— E-8 Engine coolant temperature monitor lights up white while engine is running.
— E-9 Hydraulic oil temperature monitor lights up white while engine is running.
— E-10 Air cleaner clogging monitor lights up yellow while engine is running.
— E-11 Charge level monitor lights up red while engine is running.
— E-12 Fuel level monitor lights up red while engine is running.
— E-13 Water separator monitor lights up red while engine is running.
— E-14 Engine coolant temperature monitor lights up red while engine is running.
— E-15 Engine oil pressure monitor lights up red while engine is running.
— E-16 Hydraulic oil temperature monitor lights up red while engine is running.
— E-17 Indicator of fuel gauge remains at the minimum or maximum display position.
— E-18 Indication of fuel gauge does not agree with actual fuel level.
— E-19 Indicator of engine coolant temperature gauge remains at the minimum or maximum display position.
— E-20 Indication of engine coolant temperature gauge does not agree with actual coolant temperature.
— E-21 Indicator of hydraulic oil temperature gauge remains at the minimum or maximum display position.
— E-22 Indication of hydraulic oil temperature gauge does not agree with actual oil temperature.
— E-23 Machine monitor displays nothing partially on screen.
— E-24 Function switches do not work.
— E-25 Automatic warm-up operation system does not work (in cold season).
— E-26 Travel speed monitor does not light up or go off when travel speed switch is operated.
— E-27 Current travel speed is not changed when travel speed setting is switched. (Engine speed does not change)
— E-28 Alarm buzzer does not stop sounding.
— E-29 Machine monitor does not display service meter when starting switch is in OFF position.
— E-30 Machine monitor cannot be switched to service mode.
— E-31 All work equipment stop suddenly.
— E-32 Message of “Under emergency stop” is displayed red immediately after engine is started.
— E-33 Alarm buzzer does not sound while machine is traveling.
— E-34 Alarm buzzer does not stop sounding while machine is not traveling.
— E-35 Horn does not sound.
— E-36 Horn does not stop sounding.
— E-37 Operation mode does not switch between Travel, Work, and Inspection modes.
— E-38 Crusher clearance adjustment mode cannot be switched.
— E-39 Crusher rotation cannot be switched between normal and reverse rotations.
— E-40 Machine cannot travel.
— E-41 Machine cannot travel under radio control.
— E-42 Feeder cannot be turned on or off under radio control.
— E-43 One-touch start and stop of work equipment cannot be performed under radio control.
— E-44 Nothing is displayed when monitor switches are operated.
— E-45 Crusher cannot be controlled using crusher manual forward and reverse rotation switches on monitor.
— E-46 Conveyor cannot be controlled using conveyor manual forward and reverse rotation switches on monitor.
— E-47 KOMTRAX system does not operate normally.
– Troubleshooting for hydraulic and mechanical system (H mode)
— Information described in troubleshooting table
— H-1 All work equipment and travel system move too slow or lack power.
— H-2 Engine speed drops significantly or engine stalls.
— H-3 All work equipment and travel system do not operate.
— H-4 Unusual noise is heard from around hydraulic pump.
— H-5 Fine control performance or its practicability is poor.
— H-6 Conveyor does not operate.
— H-7 Conveyor moves too slow or lacks power.
— H-8 Crusher does not operate.
— H-9 Crusher does not rotate smoothly or lacks power.
— H-10 Feeder does not operate.
— H-11 Feed performance of feeder is poor. (Vibration frequency is small.)
— H-12 Magnetic separator does not operate.
— H-13 Magnetic separator belt moves too slow.
— H-14 Muck discharge conveyor does not operate.
— H-15 Muck discharge conveyor moves too slow or lacks power.
— H-16 Primary conveyor and muck discharge conveyor do not move up and down.
— H-17 Machine deviates during traveling.
— H-18 Travel speed is too slow.
— H-19 Machine is hard to be steered or steering system lacks power.
— H-20 Track does not operate (only either side)
— H-21 Machine cannot travel when travel switch on radio control unit is pressed.
— H-22 Crusher clearance cannot be opened nor closed.
– Troubleshooting of engine (S mode)
— Information described in troubleshooting table (S mode)
— S-1 Engine does not crank when starting switch is turned to “START” position.
— S-2 Engine cranks but no exhaust gas is discharged.
— S-3 Fuel is injected but engine does not start. (Engine cranks but cannot start due to incomplete combustion.)
— S-4 Engine startability is poor.
— S-5 Engine pickup is poor.
— S-6 Running engine stops.
— S-7 Engine rotation is unstable.
— S-8 Engine output is insufficient. (Engine lacks power.)
— S-9 KDPF is clogged early.
— S-10 Engine oil consumption is excessive.
— S-11 Engine oil is contaminated early.
— S-12 Fuel consumption is excessive.
— S-13 Oil gets mixed in coolant. (Or coolant blows back and reduces.)
— S-14 Engine oil pressure drops.
— S-15 Fuel gets mixed in engine oil.
— S-16 Water gets mixed in engine oil. (Engine oil becomes cloudy.)
— S-17 Coolant temperature rises too high. (Coolant overheats.)
— S-18 Unusual noise is heard.
— S-19 Vibrations are too large.
— S-20 Air cannot be bled from fuel circuit.
— S-21 Active regeneration is performed too frequently.
— S-22 Active regeneration duration is too long.
— S-23 White smoke is exhausted during active regeneration.
— S-24 AdBlue/DEF consumption is excessive.
— S-25 Abnormal (irritating) odor is smelled.
— S-26 Foreign material gets mixed in AdBlue/DEF. (AdBlue/DEF level increases.)
50 Disassembly and assembly
– Contents
– Abbreviations
– Related information on disassembly and assembly
— How to read this manual
— Coating materials list
— Special tools list
— Sketches of special tools
– Engine and cooling system
— Removal and installation of supply pump assembly
— Removal and installation of injector assembly
— Removal and installation of cylinder head assembly
— Removal and installation of EGR valve assembly
— Removal and installation of EGR cooler assembly
— Removal and installation of starting motor assembly
— Removal and installation of alternator belt
— Removal and installation of radiator assembly
— Removal and installation of hydraulic oil cooler assembly
— Removal and installation of aftercooler assembly
— Removal and installation of engine and main pump assembly
— Removal and installation of engine front oil seal
— Removal and installation of engine rear oil seal
— Removal and installation of fuel cooler assembly
— Removal and installation of engine hood assembly
— Removal and installation of fuel tank assembly
— Removal and installation of AdBlue/DEF tank assembly
— Removal and installation of AdBlue/DEF tank sensor flange assembly
— Removal and installation of AdBlue/DEF tank sensor
— Removal and installation of AdBlue/DEF tank strainer
— Removal and installation of AdBlue/DEF tank filler port filter
— Removal and installation of KDPF assembly
— Disassembly and assembly of KDPF assembly
— Removal and installation of SCR assembly
— Removal and installation of KDPF and SCR assembly
— Removal and installation of bracket for KDPF and SCR assembly
— Removal and installation of KCCV assembly
— Removal and installation of AdBlue/DEF mixing tube
— Removal and installation of AdBlue/DEF injector
— Removal and installation of AdBlue/DEF pump assembly
— Removal and installation of AdBlue/DEF hose
— Removal and installation of air cleaner assembly
– Power train
— Removal and installation of travel motor, final drive assembly
— Disassembly and assembly of final drive assembly
– Undercarriage and frame
— Separation and connection of track shoe assembly
— Removal and installation of sprocket
— Removal and installation of idler and idler cushion assembly
— Disassembly and assembly of idler assembly
— Disassembly and assembly of idler cushion assembly
— Disassembly and assembly of track roller assembly
— Disassembly and assembly of carrier roller assembly
– Hydraulic system
— Removal and installation of hydraulic tank assembly
— Removal and installation of main pump assembly
— Removal and installation of control valve assembly
— Removal and installation of crusher motor assembly
— Removal and installation of lock cylinder assembly
— Disassembly and assembly of lock cylinder assembly
— Removal and installation of primary conveyor motor
— Removal and installation of grizzly feeder motor assembly
— Removal and installation of magnetic separator motor assembly
– Work equipment
— Removal and installation of cheek plate
— Removal and installation of fixed jaw plate
— Removal and installation of swing jaw plate
— Removal and installation of toggle plate
— Removal and installation of fixed link
— Removal and installation of swing jaw assembly
— Removal and installation of V-sieve and balance weight
— Removal and installation of crusher assembly
— Removal and installation of primary conveyor assembly
— Removal and installation of belt
— Replacement of primary conveyor head pulley frame
— Removal and installation of crusher main bearing
— Removal and installation of crusher motor and V-sieve
— Removal and installation of potentiometer
— Removal and installation of engine front cover
– Electrical system
— Removal and installation of engine controller assembly
— Removal and installation of work equipment controller assembly
— Removal and installation of machine monitor assembly
— Removal and installation of pump swash plate sensor
— Removal and installation of mass air flow and temperature sensor
— Removal and installation of KCCV crankcase pressure sensor
— Removal and installation of SCR temperature sensor
— Removal and installation of KOMTRAX terminal assembly
60 Maintenance standard
– Contents
– Abbreviations
– Engine and cooling system
— Maintenance standard for engine mount
— Maintenance standard for cooling system
– Power train
— Maintenance standard for final drive
— Maintenance standard for sprocket
– Undercarriage and frame
— Maintenance standard for track frame and idler cushion
— Maintenance standard for idler
— Maintenance standard for track roller
— Maintenance standard for carrier roller
— Maintenance standard for track shoe
— Maintenance standard for triple grouser shoe
– Hydraulic system
— Maintenance standard for hydraulic tank
— Maintenance standard for main pump
— Maintenance standard for LS-EPC valve
— Maintenance standard for PC-EPC valve
— Maintenance standard for control valve
— Maintenance standard for crusher motor
— Maintenance standard for solenoid valve
— Maintenance standard for EPC valve
— Maintenance standard for travel motor
— Maintenance standard for travel PPC valve
– Work equipment
— Maintenance standard for primary conveyor
— Maintenance standard for vibrator
— Maintenance standard for conveyor lift cylinder
— Maintenance standard for muck discharge conveyor lift cylinder
— Maintenance standard for lock cylinder
90 Circuit diagrams
– Contents
– Abbreviations
– Hydraulic circuit diagram
— Symbols used on hydraulic circuit diagram
— Hydraulic circuit diagram (1/2)
— Hydraulic circuit diagram (2/2)
– Electrical circuit diagram
— Symbols used on electrical circuit diagram
— Electrical circuit diagram (1/8)
— Electrical circuit diagram (2/8)
— Electrical circuit diagram (3/8)
— Electrical circuit diagram (4/8)
— Electrical circuit diagram (5/8)
— Electrical circuit diagram (6/8)
— Electrical circuit diagram (7/8)
— Electrical circuit diagram (8/8)
Index