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KOMATSU BR380JG-3 MOBILE CRUSHER SHOP MANUAL SEN06703-08 – PDF DOWNLOAD
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Description
KOMATSU BR380JG-3 MOBILE CRUSHER SHOP MANUAL SEN06703-08 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU BR380JG-3 MOBILE CRUSHER SHOP MANUAL SEN06703-08 – PDF DOWNLOAD
Language : English
Pages : 2128
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU BR380JG-3 MOBILE CRUSHER SHOP MANUAL SEN06703-08 – PDF DOWNLOAD
Cover................................................................................................................................. 1 00 Index and foreword............................................................................................................. 3 Index......................................................................................................................... 4 Abbreviation list............................................................................................................. 19 Foreword, safety, and basic information....................................................................................... 22 How to read the shop manual............................................................................................... 22 Safety notice for operation............................................................................................... 25 Precautions to prevent fire............................................................................................... 33 Action if fire occurs..................................................................................................... 34 Precautions when disposing of waste materials............................................................................. 35 Exhaust gas regulations - Actions taken................................................................................... 36 Precautions about DEF..................................................................................................... 37 DEF - Store............................................................................................................... 38 Precautions for handling hydraulic component.............................................................................. 39 Piping - Precautions for disconnection and connection..................................................................... 41 Precautions for handling electrical component............................................................................. 47 Precautions for handling fuel system component............................................................................ 49 Precautions for handling air intake system component...................................................................... 50 Practical use of KOMTRAX.................................................................................................. 51 Disconnection and connection of push-pull type coupler.................................................................... 52 Precautions for disconnecting and connecting connector.................................................................... 56 Procedures for disconnecting and connecting DT connectors................................................................. 60 Procedures for disconnecting and connecting slide lock type connectors.................................................... 61 Procedures for disconnecting and connecting connectors with pull and release type lock.................................... 62 Procedures for disconnecting and connecting connectors with push and release type lock.................................... 63 Procedures for disconnecting and connecting connectors that require rotation of housing to release and apply lock......... 65 How to read wire code..................................................................................................... 66 Description of terms used in maintenance standard......................................................................... 69 Standard tightening torque table.......................................................................................... 71 01 Specifications................................................................................................................. 79 Contents...................................................................................................................... 80 Specifications................................................................................................................ 81 Specification drawing..................................................................................................... 81 Specifications............................................................................................................ 82 Weight table.............................................................................................................. 85 Table of fuel, coolant and lubricants..................................................................................... 86 10 Structure and function......................................................................................................... 89 Contents...................................................................................................................... 90 Urea SCR system............................................................................................................... 92 Urea SCR system component layout drawing.................................................................................. 92 Urea SCR system diagram................................................................................................... 97 Urea SCR system functions................................................................................................. 98 Urea SCR system components................................................................................................ 112 Starting system............................................................................................................... 121 Starting system component layout drawing (Machine with KOMTRAX terminal).................................................. 121 Starting system component layout drawing (Machine with Gateway function controller)....................................... 123 System operating lamp system (Machine with KOMTRAX terminal).............................................................. 125 System operating lamp system (Machine with Gateway function controller)................................................... 126 Battery disconnect switch................................................................................................. 127 Engine system................................................................................................................. 128 Engine system component layout drawing.................................................................................... 128 Engine control system (Machine with KOMTRAX terminal)..................................................................... 130 Engine control system (Machine with Gateway function controller).......................................................... 133 Engine automatic warm-up system........................................................................................... 136 Overheat prevention system................................................................................................ 138 Turbocharger protection system............................................................................................ 140 Engine system component................................................................................................... 142 Cooling system................................................................................................................ 160 Cooling system component layout drawing................................................................................... 160 Control system................................................................................................................ 162 Control system component layout drawing (Machine with KOMTRAX terminal)................................................... 162 Control system component layout drawing (Machine with Gateway function controller)........................................ 165 Machine monitor system (Machine with KOMTRAX terminal).................................................................... 168 Machine monitor system (Machine with Gateway function controller)......................................................... 169 KOMTRAX system (Machine with KOMTRAX terminal)............................................................................ 170 KOMTRAX system (Machine with Gateway function controller)................................................................. 171 Control system component.................................................................................................. 172 Hydraulic system.............................................................................................................. 204 Hydraulic system component layout drawing................................................................................. 204 CLSS...................................................................................................................... 205 Pump and engine combined control system................................................................................... 209 Pump and valve control system............................................................................................. 213 Hydraulic system components............................................................................................... 215 Work equipment system......................................................................................................... 275 Work equipment system component layout drawing............................................................................ 275 Structure of valve control................................................................................................ 278 Grizzly feeder semi automatic control system.............................................................................. 280 Abnormal load shutdown system............................................................................................. 281 Crusher jaw tip adjustment system......................................................................................... 282 Work equipment system components.......................................................................................... 284 Crusher motor............................................................................................................. 284 Travel system................................................................................................................. 296 Travel system component layout drawing.................................................................................... 296 Travel control system diagram............................................................................................. 300 Travel system components.................................................................................................. 302 Undercarriage and frame....................................................................................................... 322 Undercarriage layout drawing.............................................................................................. 322 Work equipment................................................................................................................ 324 Primary conveyor.......................................................................................................... 324 Grizzly feeder............................................................................................................ 326 Crusher................................................................................................................... 327 Vibrator.................................................................................................................. 331 20 Standard value table........................................................................................................... 333 Contents...................................................................................................................... 334 Standard value table for engine............................................................................................... 335 Standard value table for engine: BR380JG-3................................................................................ 335 Standard value table for machine.............................................................................................. 338 Standard value table for machine: BR380JG-3............................................................................... 338 Machine posture and measuring procedure drawings for performance measurement.............................................. 345 30 Testing and adjusting.......................................................................................................... 347 Contents...................................................................................................................... 348 Precautions before work....................................................................................................... 349 Related information on testing and adjusting.................................................................................. 350 Tools for testing and adjusting........................................................................................... 350 Sketches for testing and adjusting tools.................................................................................. 356 Engine and cooling system..................................................................................................... 357 Testing engine speed...................................................................................................... 357 Testing boost pressure.................................................................................................... 359 Testing exhaust gas color................................................................................................. 361 Testing and adjusting valve clearance..................................................................................... 364 Testing compression pressure.............................................................................................. 366 Testing blowby pressure................................................................................................... 371 Testing engine oil pressure............................................................................................... 373 Testing EGR valve and VGT oil pressures................................................................................... 374 Testing fuel pressure..................................................................................................... 376 Testing fuel discharged volume, return rate, and leakage.................................................................. 382 Bleeding air from fuel system............................................................................................. 388 Testing leakage from fuel system.......................................................................................... 389 Handling cylinder cutout mode operation................................................................................... 391 Handling no-injection cranking operation.................................................................................. 392 Test fan belt and alternator belt......................................................................................... 393 Test automatic tensioner.................................................................................................. 394 Writing soot correction by ash influence to engine controller............................................................. 396 Testing SCR-related functions............................................................................................. 397 Flushing DEF tank......................................................................................................... 423 Clean DEF pump............................................................................................................ 428 Undercarriage and frame....................................................................................................... 435 Testing and adjusting track shoe tension.................................................................................. 435 Hydraulic system.............................................................................................................. 437 Releasing remaining pressure from hydraulic system........................................................................ 437 Testing and adjusting oil pressure in work equipment and travel circuits.................................................. 438 Testing control circuit pressure.......................................................................................... 449 Testing and adjusting pump PC control circuit pressure.................................................................... 451 Testing and adjusting pump LS control circuit pressure.................................................................... 454 Testing solenoid valve output pressure.................................................................................... 460 Testing PPC valve outlet pressure......................................................................................... 464 Testing oil leakage....................................................................................................... 466 Bleeding air from hydraulic circuit....................................................................................... 467 Procedure for adjusting mirrors........................................................................................... 471 Electrical system............................................................................................................. 473 Setting and operating machine monitor..................................................................................... 473 Procedure for starting up KOMTRAX terminal................................................................................ 542 Start up KOMTRAX system (Machine with gateway function controller)........................................................ 546 Stop using of KOMTRAX system (Machine with gateway function controller)................................................... 552 Handling voltage circuit of engine controller............................................................................. 554 Handling battery disconnect switch........................................................................................ 555 Testing diode............................................................................................................. 556 Pm Clinic..................................................................................................................... 557 Pm Clinic Service......................................................................................................... 557 Max. range of engine coolant temperature gauge............................................................................ 558 40 Troubleshooting................................................................................................................ 565 Contents...................................................................................................................... 566 Precautions before work....................................................................................................... 578 Information related to troubleshooting........................................................................................ 579 Points to remember when performing troubleshooting........................................................................ 579 Points to remember when performing troubleshooting of urea SCR system..................................................... 580 How to proceed in troubleshooting......................................................................................... 592 Check before starting troubleshooting..................................................................................... 594 Procedure for checking electrical parts................................................................................... 596 Troubleshooting procedure................................................................................................. 601 Symptom of failure and troubleshooting numbers............................................................................ 604 Information described in troubleshooting table............................................................................ 607 Troubleshooting procedure of wiring harness in pressure sensor system..................................................... 609 Connector list and layout (Machine with KOMTRAX terminal)................................................................. 611 Connector list and layout (Machine with Gateway function controller)...................................................... 628 Connector pin numbers and wiring table.................................................................................... 644 T-box and T-adapter list.................................................................................................. 684 Fuse location table (Machine with KOMTRAX terminal)....................................................................... 690 Fuse location table (Machine with Gateway function controller)............................................................ 692 Precautions when cleaning and replacing KDPF (KCSF and KDOC).............................................................. 694 Preparation of short connectors (for troubleshooting for failure codes [CA1883] and [CA3135])............................. 698 Failure codes table....................................................................................................... 700 Troubleshooting by failure code (display of code)............................................................................. 717 Failure code [7RC1KB] Conv. ON Sw.S/C..................................................................................... 717 Failure code [7RC2KA] Conv. OFF Sw.Disc................................................................................... 719 Failure code [7RC5KB] Feeder ON Switch S/C................................................................................ 720 Failure code [7RD2KA] Conv. REV Sol. Disc................................................................................. 721 Failure code [7RD2KB] Conv. REV Sol. S/C.................................................................................. 722 Failure code [7RD2KY] Conv. REV Sol. H.S/C................................................................................ 723 Failure code [7RE1KB] Crusher ON Sw. S/C.................................................................................. 724 Failure code [7RE2KA] Crusher OFF Sw. Disc................................................................................ 726 Failure code [7RE6KB] Muck Conv. On Sw. S/C............................................................................... 728 Failure code [7RE7KA] Muck Conv. OFF Sw.Disc.............................................................................. 730 Failure code [7RE8KB] Magnetic Separator ON Sw. S/C....................................................................... 732 Failure code [7RE9KA] Magnetic Separator OFF Sw. Disc..................................................................... 734 Failure code [7REAKB] Acc.Input1 S/C...................................................................................... 736 Failure code [7REDMA] Conveyor P.Sensor Abnormality....................................................................... 738 Failure code [7REEMA] Muck Conv. P.Sensor Abnormality..................................................................... 740 Failure code [7RENKZ] Clearance Potentio Abnormality...................................................................... 742 Failure code [7REPKA] Grizzly Feeder Stop Sw. Disc........................................................................ 744 Failure code [7RESKB] 1-touch Start Sw. S/C............................................................................... 746 Failure code [7RETKA] 1-touch Stop Sw. Disc............................................................................... 747 Failure code [7RF2KA] Crusher FWD EPC Disc................................................................................ 749 Failure code [7RF2KB] Crusher FWD EPC S/C................................................................................. 750 Failure code [7RF2KY] Crusher FWD EPC H.S/C............................................................................... 751 Failure code [7RF3KA] Crusher REV EPC Disc................................................................................ 752 Failure code [7RF3KB] Crusher REV EPC S/C................................................................................. 753 Failure code [7RF3KY] Crusher REV EPC H.S/C............................................................................... 754 Failure code [7RF4KA] Feeder FWD EPC Disc................................................................................. 755 Failure code [7RF4KB] Feeder FWD EPC S/C.................................................................................. 756 Failure code [7RF4KY] Feeder FWD EPC H.S/C................................................................................ 757 Failure code [7RFAKA] Eng.Stop Relay Disc................................................................................. 758 Failure code [7RFAKB] Eng.Stop Relay S/C.................................................................................. 759 Failure code [7RFAKY] Eng.Stop Relay H.S/C................................................................................ 760 Failure code [7RFBKA] Muck Conv. EPC Disc................................................................................. 761 Failure code [7RFBKB] Muck Conv. EPC S/C.................................................................................. 762 Failure code [7RFBKY] Muck Conv. EPC H.S/C................................................................................ 763 Failure code [7RFHKA] Conv. FWD EPC Disc.................................................................................. 764 Failure code [7RFHKB] Conv. FWD EPC S/C................................................................................... 765 Failure code [7RFHKY] Conv. FWD EPC H.S/C................................................................................. 766 Failure code [7RFKKA] Lock Cyl. Pull Sol. Disc............................................................................ 767 Failure code [7RFKKB] Lock Cyl. Pull Sol. S/C............................................................................. 768 Failure code [7RFKKY] Lock Cyl. Pull Sol. H.S/C........................................................................... 769 Failure code [7RFLKA] Acc. EPC Disc....................................................................................... 770 Failure code [7RFLKB] Acc. EPC S/C........................................................................................ 771 Failure code [7RFLKY] Acc. EPC H.S/C...................................................................................... 772 Failure code [7RFMKA] Abnormal Press.Relay Disc........................................................................... 773 Failure code [7RFMKB] Abnormal Press.Relay S/C............................................................................ 774 Failure code [7RFMKY] Abnormal Press.Relay H.S/C.......................................................................... 775 Failure code [7RFNKA] Lock Cyl. Unlock Sol. Disc.......................................................................... 776 Failure code [7RFNKB] Lock Cyl. Unlock Sol. S/C........................................................................... 777 Failure code [7RFNKY] Lock Cyl. Unlock Sol. H.S/C......................................................................... 778 Failure code [7RFPKA] Lock Cyl. Push Relay Disc........................................................................... 779 Failure code [7RFPKB] Lock Cyl. Push Relay S/C............................................................................ 780 Failure code [7RFPKY] Lock Cyl. Push Relay H.S/C.......................................................................... 781 Failure code [7RGAMA] 2nd Conv. P.Sensor Abnormality...................................................................... 782 Failure code [7RJAKA] Travel Lock EPC Disc................................................................................ 784 Failure code [7RJAKB] Travel Lock EPC S/C................................................................................. 786 Failure code [7RJAKY] Travel Lock EPC H.S/C............................................................................... 788 Failure code [7RJLKA] Magnetic Separator EPC Disc......................................................................... 789 Failure code [7RJLKB] Magnetic Separator EPC S/C.......................................................................... 790 Failure code [7RJLKY] Magnetic Separator EPC H.S/C........................................................................ 791 Failure code [7RJMMW] Lock Cyl. Slide..................................................................................... 792 Failure code [7RJNMA] Vibratory Sieve P.Sensor Abnormality................................................................ 793 Failure code [7RJPKB] Radio Control Work-mode Sw. S/C..................................................................... 795 Failure code [7RJQKB] Radio Control Trav.-mode Sw. S/C.................................................................... 796 Failure code [7RJRKB] On Travel Signal S/C................................................................................ 797 Failure code [7RJSMA] M/Separator P.Sensor Abnormality.................................................................... 799 Failure code [989L00] Engine Controller Lock Caution 1.................................................................... 801 Failure code [989M00] Engine Controller Lock Caution 2.................................................................... 802 Failure code [989N00] Engine Controller Lock Caution 3.................................................................... 803 Failure code [A1U0N3] HC Desorb Request 1................................................................................. 804 Failure code [A1U0N4] HC Desorb Request 2................................................................................. 805 Failure code [AA10NX] Air Cleaner Clogging................................................................................ 806 Failure code [AB00KE] Charge Voltage Low.................................................................................. 808 Failure code [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)......................................... 810 Failure code [AS00N3] Manual Stationary Regeneration Request (SCR)........................................................ 811 Failure code [AS00R2] Warning 2 (SCR Device Abnormality).................................................................. 812 Failure code [AS00R3] Inducement 1 (SCR Device Abnormality)............................................................... 813 Failure code [AS00R4] Inducement 2 (SCR Device Abnormality)............................................................... 814 Failure code [AS00R5] Inducement 3 (SCR Device Abnormality)............................................................... 815 Failure code [AS00R6] Temporary Recovery of Inducement.................................................................... 816 Failure code [AS00ZK] DEF Level Low Error 5............................................................................... 817 Failure code [AS10KM] DEF Injector Overheat Warning....................................................................... 818 Failure code [AS10NR] DEF Injector High Temperature Warning............................................................... 819 Failure code [AS10NT] DEF Injector Overheat Caution....................................................................... 820 Failure code [B@BAZG] Eng Oil Press Low................................................................................... 821 Failure code [B@BAZK] Eng Oil Level Low................................................................................... 822 Failure code [B@BCNS] Eng Water Overheat.................................................................................. 823 Failure code [B@BCQA] Eng Water Level Low................................................................................. 824 Failure code [B@BCZK] Eng Water Level Low................................................................................. 826 Failure code [B@HANS] Hyd Oil Overheat.................................................................................... 828 Failure code [CA115] Engine NE and Bkup Speed Sensor Error................................................................ 829 Failure code [CA122] Charge Air Pressure Sensor High Error................................................................ 830 Failure code [CA123] Charge Air Pressure Sensor Low Error................................................................. 832 Failure code [CA131] Throttle Sensor High Error........................................................................... 834 Failure code [CA132] Throttle Sensor Low Error............................................................................ 836 Failure code [CA144] Coolant Temperature Sensor High Error................................................................ 838 Failure code [CA145] Coolant Temperature Sensor Low Error................................................................. 840 Failure code [CA153] Charge Air Temperature Sensor High Error............................................................. 842 Failure code [CA154] Charge Air Temperature Sensor Low Error.............................................................. 844 Failure code [CA187] Sensor 2 Supply Voltage Low Error.................................................................... 846 Failure code [CA221] Ambient Pressure Sensor High Error................................................................... 848 Failure code [CA222] Ambient Pressure Sensor Low Error.................................................................... 850 Failure code [CA227] Sensor 2 Supply Voltage High Error................................................................... 852 Failure code [CA234] Engine Overspeed..................................................................................... 853 Failure code [CA238] NE Speed Sensor Supply Voltage Error................................................................. 854 Failure code [CA239] NE Speed Sensor Supply Voltage High Error............................................................ 855 Failure code [CA249] Ambient Air Temp Sensor High Error................................................................... 856 Failure code [CA256] Ambient Air Temp Sensor Low Error.................................................................... 858 Failure code [CA271] IMV/PCV1 Short Circuit Error......................................................................... 860 Failure code [CA272] IMV/PCV1 Open Circuit Error.......................................................................... 862 Failure code [CA322] Injector #1 (L#1) Open Circuit or Short Circuit Error................................................ 863 Failure code [CA323] Injector #5 (L#5) Open Circuit or Short Circuit Error................................................ 865 Failure code [CA324] Injector #3 (L#3) Open Circuit or Short Circuit Error................................................ 867 Failure code [CA325] Injector #6 (L#6) Open Circuit or Short Circuit Error................................................ 869 Failure code [CA331] Injector #2 (L#2) Open Circuit or Short Circuit Error................................................ 871 Failure code [CA332] Injector #4 (L#4) Open Circuit or Short Circuit Error................................................ 873 Failure code [CA343] Engine Controller Internal Failure................................................................... 875 Failure code [CA351] Injectors Drive Circuit Error........................................................................ 876 Failure code [CA352] Sensor 1 Supply Voltage Low Error.................................................................... 877 Failure code [CA356] MAF Sensor High Error................................................................................ 879 Failure code [CA357] MAF Sensor Low Error................................................................................. 881 Failure code [CA386] Sensor 1 Supply Voltage High Error................................................................... 883 Failure code [CA428] Water in Fuel Sensor High Error...................................................................... 884 Failure code [CA429] Water in Fuel Sensor Low Error....................................................................... 886 Failure code [CA435] Engine Oil Pressure SW Error......................................................................... 888 Failure code [CA441] Battery Voltage Low Error............................................................................ 889 Failure code [CA442] Battery Voltage High Error........................................................................... 891 Failure code [CA449] Common Rail Pressure High Error 2.................................................................... 892 Failure code [CA451] Common Rail Pressure Sensor High Error............................................................... 893 Failure code [CA452] Common Rail Pressure Sensor Low Error................................................................ 895 Failure code [CA488] Charge Air Temperature High Torque Derate............................................................ 897 Failure code [CA515] Common Rail Pressure Sensor Supply Voltage Low Error................................................. 898 Failure code [CA516] Common Rail Pressure Sensor Supply Voltage Low Error................................................. 900 Failure code [CA553] Common Rail Pressure High Error 1.................................................................... 902 Failure code [CA555] Crankcase Pressure High Error 1...................................................................... 903 Failure code [CA556] Crankcase Pressure High Error 2...................................................................... 904 Failure code [CA559] Common Rail Pressure Low Error 1..................................................................... 905 Failure code [CA595] Turbocharger Speed High Error 2...................................................................... 907 Failure code [CA687] Turbocharger Speed Low Error......................................................................... 908 Failure code [CA689] Engine NE Speed Sensor Error......................................................................... 910 Failure code [CA691] Intake Air Temperature Sensor High Error............................................................. 912 Failure code [CA692] Intake Air Temperature Sensor Low Error.............................................................. 914 Failure code [CA697] Engine Controller Internal Temperature Sensor High Error............................................. 916 Failure code [CA698] Engine Controller Internal Temperature Sensor Low Error.............................................. 917 Failure code [CA731] Engine Bkup Speed Sensor Phase Error................................................................. 918 Failure code [CA778] Engine Bkup Speed Sensor Error....................................................................... 920 Failure code [CA1117] Engine Controller Partial Data Lost Error........................................................... 924 Failure code [CA1664] KDOC Abnormality.................................................................................... 925 Failure code [CA1669] DEF Level Sensor Voltage High Error................................................................. 927 Failure code [CA1673] DEF Level Low Error 3............................................................................... 928 Failure code [CA1677] DEF Temperature Sensor Low Error.................................................................... 929 Failure code [CA1678] DEF Temperature Sensor High Error................................................................... 930 Failure code [CA1682] DEF Pump Priming Error.............................................................................. 931 Failure code [CA1683] DEF Tank Heating Valve Voltage High Error........................................................... 933 Failure code [CA1684] DEF Tank Heating Valve Voltage Low Error............................................................ 935 Failure code [CA1686] DEF Quality Sensor Voltage High Error............................................................... 937 Failure code [CA1691] Defective Regeneration.............................................................................. 938 Failure code [CA1694] SCR Outlet NOx Sensor In Range Error................................................................ 940 Failure code [CA1695] Sensor 5 Supply Voltage High Error.................................................................. 942 Failure code [CA1696] Sensor 5 Supply Voltage Low Error................................................................... 943 Failure code [CA1712] DEF Tank Thawing Error.............................................................................. 945 Failure code [CA1713] DEF Tank Heater Valve Open Stuck Error.............................................................. 947 Failure code [CA1714] DEF Quality Sensor Out of Calibration Error......................................................... 949 Failure code [CA1715] DEF Quality Sensor Internal Circuit Error........................................................... 950 Failure code [CA1776] Sensor Supply Relay Voltage High Error.............................................................. 951 Failure code [CA1777] Sensor Supply Relay Voltage Low Error............................................................... 954 Failure code [CA1843] Crankcase Pressure Sensor High Error................................................................ 956 Failure code [CA1844] Crankcase Pressure Sensor Low Error................................................................. 958 Failure code [CA1879] KDPF Differential Pressure Sensor High Error........................................................ 960 Failure code [CA1881] KDPF Differential Pressure Sensor Low Error......................................................... 962 Failure code [CA1883] KDPF Differential Pressure Sensor In Range Error.................................................... 964 Failure code [CA1885] Turbo Outlet NOx Sensor Circuit Error............................................................... 967 Failure code [CA1887] SCR Outlet NOx Sensor Circuit Error................................................................. 969 Failure code [CA1921] KDPF Soot Accumulation High Error 1................................................................. 971 Failure code [CA1922] KDPF Soot Accumulation High Error 2................................................................. 974 Failure code [CA1942] Crankcase Pressure Sensor In Range Error............................................................ 978 Failure code [CA1993] KDPF Differential Pressure Sensor Low Error......................................................... 979 Failure code [CA2185] Throttle Sensor Supply Voltage High Error........................................................... 981 Failure code [CA2186] Throttle Sensor Supply Voltage Low Error............................................................ 982 Failure code [CA2249] Common Rail Pressure Low Error 2.................................................................... 983 Failure code [CA2271] EGR Valve Position Sensor High Error................................................................ 984 Failure code [CA2272] EGR Valve Position Sensor Low Error................................................................. 986 Failure code [CA2288] Turbocharger Speed High Error 1..................................................................... 989 Failure code [CA2311] IMV Solenoid Error.................................................................................. 990 Failure code [CA2349] EGR Valve Solenoid Open Circuit Error............................................................... 991 Failure code [CA2353] EGR Valve Solenoid Short Circuit Error.............................................................. 993 Failure code [CA2357] EGR Valve Servo Error............................................................................... 994 Failure code [CA2381] VGT Position Sensor High Error...................................................................... 995 Failure code [CA2382] VGT Position Sensor Low Error....................................................................... 997 Failure code [CA2383] VGT Solenoid Open Circuit Error.....................................................................1000 Failure code [CA2386] VGT Solenoid Short Circuit Error....................................................................1002 Failure code [CA2387] VGT Servo Error.....................................................................................1003 Failure code [CA2555] Intake Air Heater Relay Open Circuit Error..........................................................1004 Failure code [CA2556] Intake Air Heater Relay Short Circuit Error.........................................................1006 Failure code [CA2637] KDOC Face Plugging..................................................................................1008 Failure code [CA2639] Manual Stationary Regeneration Request..............................................................1010 Failure code [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error........................................................1012 Failure code [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable................................1017 Failure code [CA2976] DEF Pump Temperature Sensor Signal Error............................................................1019 Failure code [CA3133] KDPF Outlet Pressure Sensor High Error..............................................................1021 Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error...............................................................1023 Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error..........................................................1025 Failure code [CA3142] SCR Temperature Sensor High Error...................................................................1028 Failure code [CA3143] SCR Temperature Sensor Low Error....................................................................1029 Failure code [CA3144] SCR Temperature Sensor In Range Error...............................................................1030 Failure code [CA3146] SCR Outlet Temperature Sensor High Error............................................................1032 Failure code [CA3147] SCR Outlet Temperature Sensor Low Error.............................................................1033 Failure code [CA3148] SCR Outlet Temperature Sensor In Range Error........................................................1034 Failure code [CA3151] SCR Catalyst Efficiency Low Error 2.................................................................1036 Failure code [CA3165] SCR Outlet Temperature High Error...................................................................1041 Failure code [CA3229] SCR Temperature High Error..........................................................................1043 Failure code [CA3231] SCR Temperature High Error - Non Regeneration.......................................................1045 Failure code [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error......................................................1047 Failure code [CA3235] SCR Outlet Temperature High Error - Non Regeneration................................................1050 Failure code [CA3239] DEF Line Heater 2 Voltage High Error................................................................1052 Failure code [CA3241] DEF Line Heater 2 Voltage Low Error.................................................................1054 Failure code [CA3242] DEF Tank Heating Error..............................................................................1057 Failure code [CA3251] KDOC Inlet Temperature High Error...................................................................1059 Failure code [CA3253] KDOC Temperature Error - Non Regeneration...........................................................1061 Failure code [CA3254] KDOC Outlet Temperature High Error 1................................................................1063 Failure code [CA3255] KDPF Temperature Error - Non Regeneration...........................................................1065 Failure code [CA3256] KDPF Outlet Temperature High Error 1................................................................1067 Failure code [CA3311] KDOC Outlet Temperature High Error 2................................................................1069 Failure code [CA3312] KDPF Outlet Temperature High Error 2................................................................1071 Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error.............................................................1073 Failure code [CA3314] KDOC Inlet Temperature Sensor High Error............................................................1074 Failure code [CA3315] KDOC Inlet Temperature Sensor In Range Error........................................................1075 Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error............................................................1077 Failure code [CA3317] KDOC Outlet Temperature Sensor High Error...........................................................1078 Failure code [CA3318] KDOC Outlet Temperature Sensor In Range Error.......................................................1079 Failure code [CA3319] KDPF Outlet Temperature Sensor High Error...........................................................1081 Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error............................................................1082 Failure code [CA3322] KDPF Outlet Temperature Sensor In Range Error.......................................................1083 Failure code [CA3419] MAF Sensor Supply Voltage High Error................................................................1085 Failure code [CA3421] MAF Sensor Supply Voltage Low Error.................................................................1087 Failure code [CA3497] DEF Level Low Error 1...............................................................................1089 Failure code [CA3498] DEF Level Low Error 2...............................................................................1090 Failure code [CA3543] DEF Quality Error (SCR Catalyst Efficiency Low).....................................................1091 Failure code [CA3545] SCR Outlet NOx Sensor Unstable Error................................................................1095 Failure code [CA3547] DEF Level Low Error 4...............................................................................1097 Failure code [CA3558] DEF Pump Voltage High Error.........................................................................1098 Failure code [CA3559] DEF Pump Voltage Low Error..........................................................................1099 Failure code [CA3562] DEF LineHeater Relay 1 Voltage High Error...........................................................1101 Failure code [CA3563] DEF LineHeater Relay 1 Voltage Low Error............................................................1103 Failure code [CA3567] DEF Injector Open Circuit Error or Short Circuit Error..............................................1105 Failure code [CA3568] DEF Injector Malfunction............................................................................1107 Failure code [CA3571] DEF Pump Pressure Sensor High Error.................................................................1109 Failure code [CA3572] DEF Pump Pressure Sensor Low Error..................................................................1111 Failure code [CA3574] DEF Pump Pressure Too Low Error.....................................................................1113 Failure code [CA3575] DEF Pump Pressure Too High Error....................................................................1115 Failure code [CA3577] DEF FCV Voltage High Error..........................................................................1116 Failure code [CA3578] DEF FCV Voltage Low Error...........................................................................1118 Failure code [CA3582] SCR Catalyst Efficiency Low Error 1.................................................................1120 Failure code [CA3583] SCR Outlet NOx Sensor Heater Warming up Error.......................................................1125 Failure code [CA3596] DEF Pump Pressure Unstable Error....................................................................1127 Failure code [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error.....................................................1131 Failure code [CA3681] SCR Outlet NOx Sensor Power Voltage Error...........................................................1133 Failure code [CA3682] Turbo Outlet NOx Sensor Power Voltage Error.........................................................1137 Failure code [CA3713] DEF Line Heater 1 Voltage High Error................................................................1141 Failure code [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error........................................................1144 Failure code [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error......................................................1145 Failure code [CA3725] Turbo Outlet NOx Sensor Unstable Error..............................................................1146 Failure code [CA3741] Rail Press Valve Trip Error.........................................................................1148 Failure code [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error........................................................1149 Failure code [CA3751] SCR Catalyst Degradation Error......................................................................1151 Failure code [CA3755] DEF Dosing Performance Degradation Error............................................................1152 Failure code [CA3866] DEF Low Concentration Error 2.......................................................................1154 Failure code [CA3867] DEF Low Concentration Error 1.......................................................................1156 Failure code [CA3868] DEF Tank Sensor Datalink Timeout Error..............................................................1158 Failure code [CA3899] SCR NH3 Sensor Circuit Error........................................................................1161 Failure code [CA3911] SCR NH3 Sensor Datalink Timeout Error...............................................................1163 Failure code [CA3912] SCR NH3 Sensor Heater Warming up Error..............................................................1166 Failure code [CA3932] SCR NH3 Sensor Heater Voltage High Error............................................................1168 Failure code [CA3933] SCR NH3 Sensor Heater Voltage Low Error.............................................................1170 Failure code [CA3934] SCR NH3 Sensor Power Interrupt Error................................................................1172 Failure code [CA3935] SCR NH3 Sensor Trim Resistance Error................................................................1175 Failure code [CA3936] SCR NH3 Sensor Internal Circuit Error...............................................................1177 Failure code [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error.............................................1179 Failure code [CA4152] SCR Temperature Sensor Datalink Timeout Error.......................................................1183 Failure code [CA4155] DEF Pump Heater Relay Voltage High Error............................................................1186 Failure code [CA4156] DEF Pump Heater Relay Voltage Low Error.............................................................1188 Failure code [CA4157] DEF FCV Malfunction.................................................................................1190 Failure code [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error.............................................1192 Failure code [CA4159] SCR Temperature Sensor Internal Circuit Error.......................................................1193 Failure code [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error.............................................1194 Failure code [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error..............................................1196 Failure code [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error.........................................1198 Failure code [CA4164] SCR Temperature Sensor ECU Voltage High Error.......................................................1199 Failure code [CA4165] SCR Temperature Sensor ECU Voltage Low Error........................................................1201 Failure code [CA4166] SCR Temperature Sensor ECU High Temperature Error...................................................1203 Failure code [CA4168] DEF Pump Heater ON Stuck Error......................................................................1204 Failure code [CA4169] DEF Pump Heater OFF Stuck Error.....................................................................1207 Failure code [CA4171] DEF Pump Thawing Error..............................................................................1209 Failure code [CA4249] DEF Pump Temperature Sensor 1 In Range Error........................................................1212 Failure code [CA4251] DEF Pump Temperature Sensor 2 In Range Error........................................................1214 Failure code [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error..............................................1216 Failure code [CA4261] SCR Temperature Sensor Power Interrupt Error........................................................1218 Failure code [CA4277] DEF Quality Sensor Liquid Distinction Error.........................................................1220 Failure code [CA4281] SCR NH3 Sensor Stuck Response Error.................................................................1222 Failure code [CA4459] DEF LineHeater Relay 2 Voltage High Error...........................................................1225 Failure code [CA4461] DEF LineHeater Relay 2 Voltage Low Error............................................................1227 Failure code [CA4658] DEF Flow Low Error..................................................................................1229 Failure code [CA4731] DEF Temperature Sensor Transmission Data Error......................................................1231 Failure code [CA4732] DEF Level Sensor Transmission Data Error............................................................1232 Failure code [CA4739] DEF Level Sensor Internal Circuit Error.............................................................1233 Failure code [CA4768] Fuel in DEF Tank Error..............................................................................1234 Failure code [CA4769] DEF Level Measurement Impossible....................................................................1235 Failure code [CA4842] DEF High Concentration Error........................................................................1237 Failure code [CA4952] System Operating Lamp Short Circuit (Engine Controller).............................................1239 Failure code [CA5115] DEF Line Heater 1 Voltage Low Error.................................................................1241 Failure code [CA5179] Engine Room Temperature Sensor High Error...........................................................1244 Failure code [CA5181] Engine Room Temperature Sensor Low Error............................................................1246 Failure code [CA5383] Ash Accumulation High Error.........................................................................1248 Failure code [D110KB] Battery Relay Output Short Circuit..................................................................1249 Failure code [D162KY] Horn Relay S/C......................................................................................1250 Failure code [D162KZ] Horn Relay Disc. or S/C.............................................................................1252 Failure code [D19JKZ] Personal Code Relay Open Circuit or Short Circuit...................................................1254 Failure code [D811MC] KOMTRAX Malfunction (Machine with KOMTRAX terminal).................................................1256 Failure code [D811MC] KOMTRAX Malfunction (Machine with Gateway function controller)......................................1257 Failure code [D862KA] GPS Antenna Open Circuit (Machine with KOMTRAX terminal)............................................1258 Failure code [D862KA] GPS Antenna Open Circuit (Machine with Gateway function controller).................................1259 Failure code [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) (Machine with KOMTRAX terminal)........................1260 Failure code [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) (Machine with Gateway function controller).............1262 Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) (Machine with KOMTRAX terminal).......................1264 Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) (Machine with Gateway function controller)............1266 Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) (Machine with KOMTRAX terminal).............................1268 Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) (Machine with Gateway function controller)..................1272 Failure code [D8ARKR] CAN 1 Defective Communication (Machine with Gateway function controller)............................1276 Failure code [D8G1KT] Gateway Function Controller Error...................................................................1280 Failure code [D8G6KT] Malfunction of Communication Terminal...............................................................1281 Failure code [DA22KK] Sol.Power Supply Low Voltage(W/E Controller)........................................................1282 Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error.................................................................1284 Failure code [DA26KP] 5V Sensor 2 Power Voltage Low Error.................................................................1286 Failure code [DA29KQ] Model Selection Signal Mismatch (W/E Controller)....................................................1288 Failure code [DA2LKA] System Operating Lamp Open Circuit (W/ E Controller) (Machine with KOMTRAX terminal)................1289 Failure code [DA2LKA] System Operating Lamp Open Circuit (W/ E Controller) (Machine with Gateway function controller).....1291 Failure code [DA2LKB] System Operating Lamp Short Circuit (W/ E Controller) (Machine with KOMTRAX terminal)...............1293 Failure code [DA2LKB] System Operating Lamp Short Circuit (W/ E Controller) (Machine with Gateway function controller)....1295 Failure code [DAF0MB] Monitor ROM Abnormality.............................................................................1297 Failure code [DAF0MC] Monitor Malfunction.................................................................................1298 Failure code [DAF7KB] Fuel Refract-meter Power Supply Short Circuit.......................................................1299 Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor)...........................................................1300 Failure code [DAFGMC] GPS Module Malfunction (Machine with KOMTRAX terminal)..............................................1301 Failure code [DAFGMC] GPS Module Malfunction (Machine with Gateway function controller)...................................1302 Failure code [DAFLKA] System Operating Lamp Open Circuit (Monitor) (Machine with KOMTRAX terminal)........................1303 Failure code [DAFLKA] System Operating Lamp Open Circuit (Monitor) (Machine with Gateway function controller).............1305 Failure code [DAFLKB] System Operating Lamp Open Circuit (Monitor) (Machine with KOMTRAX terminal)........................1307 Failure code [DAFLKB] System Operating Lamp Open Circuit (Monitor) (Machine with Gateway function controller).............1309 Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) (Machine with KOMTRAX terminal).............................1311 Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) (Machine with Gateway function controller)..................1314 Failure code [DAFSMC] Fuel Refract-meter Serial Communication Malfunction.................................................1317 Failure code [DB2QKR] CAN 2 Defective Communication (Engine Controller) (Machine with KOMTRAX terminal)...................1319 Failure code [DB2QKR] CAN 2 Defective Communication (Engine Controller) (Machine with Gateway function controller)........1324 Failure code [DB2RKR] CAN 1 Defective Communication (Engine Controller) (Machine with KOMTRAX terminal)...................1328 Failure code [DB2RKR] CAN 1 Defective Communication (Engine Controller) (Machine with Gateway function controller)........1334 Failure code [DB90MC] Malfunction (W/E Controller)........................................................................1340 Failure code [DB9QKR] CAN 2 Defective Communication (W/E Con) (Machine with KOMTRAX terminal).............................1341 Failure code [DB9QKR] CAN 2 Defective Communication (W/E Con) (Machine with Gateway function controller)..................1345 Failure code [DB9RKR] CAN 1 Defective Communication (W/E Con) (Machine with KOMTRAX terminal).............................1349 Failure code [DB9RKR] CAN 1 Defective Communication (W/E Con) (Machine with Gateway function controller)..................1353 Failure code [DDA6KA] Engine Stop Sw. Disc................................................................................1357 Failure code [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit.......................................................1359 Failure code [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault.......................................................1361 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit................................................................1362 Failure code [DHAAMA] KDPF Differential Pressure Sensor Frozen............................................................1364 Failure code [DHACMA] KDPF Outlet Pressure Sensor Frozen..................................................................1365 Failure code [DHPAMA] Front Pump Pressure Sensor Defective Function.......................................................1366 Failure code [DHPBMA] Rear Pump Pressure Sensor Defective Function........................................................1368 Failure code [DUB0KY] Beacon Solid State Relay S/C........................................................................1369 Failure code [DUB0KZ] Beacon S.S. Relay Disc. or S/C......................................................................1371 Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit.............................................................1373 Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit............................................................1374 Failure code [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit..............................................................1375 Failure code [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit.............................................................1376 Failure code [DXE0KA] LS-EPC Solenoid Open Circuit........................................................................1377 Failure code [DXE0KB] LS-EPC Solenoid Short Circuit.......................................................................1378 Failure code [F311KA] Centralized Warning Lamp Signal 1 Open Circuit......................................................1379 Failure code [F311KB] Centralized Warning Lamp Signal 1 Short Circuit.....................................................1381 Failure code [F312KA] Centralized Warning Lamp Signal 2 Open Circuit......................................................1383 Failure code [F312KB] Centralized Warning Lamp Signal 2 Short Circuit.....................................................1385 Failure code [F313KA] Communication Terminal Startup Signal Open Circuit..................................................1387 Failure code [F313KB] Communication Terminal Startup Signal Short Circuit.................................................1388 Failure code [F314KA] Software Update Signal Open Circuit.................................................................1389 Failure code [F314KB] Software Update Signal Short Circuit................................................................1391 Failure code [F315KB] Engine Controller WAKE Signal Open Circuit..........................................................1393 Failure code [F315KY] Engine Controller WAKE Signal Short Circuit.........................................................1395 Failure code [F316KB] 3rd Party Component Startup Signal Open Circuit.....................................................1397 Failure code [F316KY] 3rd Party Component Startup Signal Short Circuit....................................................1399 Failure code [F318KB] Communication Terminal Power Supply 1 Short Circuit.................................................1401 Failure code [F318KY] Communication Terminal Power Supply 1 Hot Short Circuit.............................................1402 Failure code [F31AKB] Ethernet Power Supply Short Circuit.................................................................1403 Failure code [F31AKY] Ethernet Power Supply Hot Short Circuit.............................................................1405 Failure code [F31BKB] 5V Sensor Power Supply Short Circuit................................................................1407 Failure code [F31BKY] 5V Sensor Power Supply Hot Short Circuit............................................................1409 Failure code [F31CKB] 12V Sensor Power Supply Short Circuit...............................................................1411 Failure code [F31CKY] 12V Sensor Power Supply Hot Short Circuit...........................................................1413 Failure code [F31DKB] 24V Sensor Power Supply Short Circuit...............................................................1415 Failure code [F31DKY] 24V Sensor Power Supply Hot Short Circuit...........................................................1417 Failure code [F31EKB] 24V Sensor Power Supply Booster Output Short Circuit................................................1419 Failure code [F31EKY] 24V Sensor Power Supply Booster Output Hot Short Circuit............................................1421 Troubleshooting of electrical system (E mode).................................................................................1423 Information described in troubleshooting table............................................................................1423 E-1 Engine does not start. (Engine does not crank.).......................................................................1425 E-2 Manual preheating does not work.......................................................................................1429 E-3 Automatic preheating does not work....................................................................................1432 E-4 Preheat monitor does not light up when preheating operation is performed..............................................1434 E-5 Machine monitor displays nothing when starting switch is turned to ON position........................................1436 E-6 Engine oil level monitor lights up yellow when starting switch is in ON position but engine is stopped................1438 E-7 Radiator coolant level monitor lights up yellow when starting switch is in ON position but engine is stopped..........1439 E-8 Engine coolant temperature monitor lights up white while engine is running............................................1440 E-9 Hydraulic oil temperature monitor lights up white while engine is running.............................................1441 E-10 Air cleaner clogging monitor lights up yellow while engine is running................................................1442 E-11 Charge level monitor lights up red while engine is running...........................................................1443 E-12 Fuel level monitor lights up red while engine is running.............................................................1444 E-13 Water separator monitor lights up red while engine is running........................................................1445 E-14 Engine coolant temperature monitor lights up red while engine is running.............................................1446 E-15 Engine oil pressure monitor lights up red while engine is running....................................................1447 E-16 Hydraulic oil temperature monitor lights up red while engine is running..............................................1448 E-17 Indicator of fuel gauge remains at the minimum or maximum display position...........................................1449 E-18 Indication of fuel gauge does not agree with actual fuel level.......................................................1450 E-19 Indicator of engine coolant temperature gauge remains at the minimum or maximum display position.....................1451 E-20 Indication of engine coolant temperature gauge does not agree with actual coolant temperature........................1452 E-21 Indicator of hydraulic oil temperature gauge remains at the minimum or maximum display position......................1453 E-22 Indication of hydraulic oil temperature gauge does not agree with actual oil temperature.............................1454 E-23 Machine monitor displays nothing partially on screen.................................................................1455 E-24 Function switches do not work........................................................................................1456 E-25 Automatic warm-up operation system does not work (in cold season)....................................................1457 E-26 Travel speed monitor does not light up or go off when travel speed switch is operated................................1458 E-27 Current travel speed is not changed when travel speed setting is switched. (Engine speed does not change)............1459 E-28 Alarm buzzer does not stop sounding..................................................................................1460 E-29 Machine monitor does not display service meter when starting switch is in OFF position...............................1461 E-30 Machine monitor cannot be switched to service mode...................................................................1462 E-31 All work equipment stop suddenly.....................................................................................1463 E-32 Message of "Under emergency stop" is displayed red immediately after engine is started...............................1465 E-33 Alarm buzzer does not sound while machine is traveling...............................................................1467 E-34 Alarm buzzer does not stop sounding while machine is not traveling...................................................1470 E-35 Horn does not sound..................................................................................................1472 E-36 Horn does not stop sounding..........................................................................................1474 E-37 Operation mode does not switch between Travel, Work, and Inspection modes............................................1476 E-38 Crusher clearance adjustment mode cannot be switched.................................................................1478 E-39 Crusher rotation cannot be switched between normal and reverse rotations.............................................1479 E-40 Machine cannot travel................................................................................................1480 E-41 Machine cannot travel under radio control............................................................................1482 E-42 Feeder cannot be turned on or off under radio control................................................................1485 E-43 One-touch start and stop of work equipment cannot be performed under radio control...................................1488 E-44 Nothing is displayed when monitor switches are operated..............................................................1491 E-45 Crusher cannot be controlled using crusher manual forward and reverse rotation switches on monitor...................1492 E-46 Conveyor cannot be controlled using conveyor manual forward and reverse rotation switches on monitor.................1493 E-47 KOMTRAX system does not operate normally.............................................................................1494 Troubleshooting for hydraulic and mechanical system (H mode)..................................................................1495 Information described in troubleshooting table............................................................................1495 H-1 All work equipment and travel system move too slow or lack power......................................................1497 H-2 Engine speed drops significantly or engine stalls.....................................................................1498 H-3 All work equipment and travel system do not operate...................................................................1499 H-4 Unusual noise is heard from around hydraulic pump.....................................................................1500 H-5 Fine control performance or its practicability is poor................................................................1501 H-6 Conveyor does not operate.............................................................................................1502 H-7 Conveyor moves too slow or lacks power................................................................................1503 H-8 Crusher does not operate..............................................................................................1504 H-9 Crusher does not rotate smoothly or lacks power.......................................................................1505 H-10 Feeder does not operate..............................................................................................1506 H-11 Feed performance of feeder is poor. (Vibration frequency is small.)..................................................1507 H-12 Magnetic separator does not operate..................................................................................1508 H-13 Magnetic separator belt moves too slow...............................................................................1509 H-14 Muck discharge conveyor does not operate.............................................................................1510 H-15 Muck discharge conveyor moves too slow or lacks power................................................................1511 H-16 Primary conveyor and muck discharge conveyor do not move up and down.................................................1512 H-17 Machine deviates during traveling....................................................................................1513 H-18 Travel speed is too slow.............................................................................................1514 H-19 Machine is hard to be steered or steering system lacks power.........................................................1515 H-20 Track does not operate (only either side)............................................................................1516 H-21 Machine cannot travel when travel switch on radio control unit is pressed............................................1517 H-22 Crusher clearance cannot be opened nor closed........................................................................1518 Troubleshooting of engine (S mode)............................................................................................1519 Information described in troubleshooting table (S mode)...................................................................1519 S-1 Engine does not crank when starting switch is turned to "START" position..............................................1520 S-2 Engine cranks but no exhaust gas is discharged........................................................................1521 S-3 Fuel is injected but engine does not start. (Engine cranks but cannot start due to incomplete combustion.)............1522 S-4 Engine startability is poor...........................................................................................1523 S-5 Engine pickup is poor.................................................................................................1525 S-6 Running engine stops..................................................................................................1527 S-7 Engine rotation is unstable...........................................................................................1529 S-8 Engine output is insufficient. (Engine lacks power.)..................................................................1530 S-9 KDPF is clogged early.................................................................................................1532 S-10 Engine oil consumption is excessive..................................................................................1534 S-11 Engine oil is contaminated early.....................................................................................1535 S-12 Fuel consumption is excessive........................................................................................1536 S-13 Oil gets mixed in coolant. (Or coolant blows back and reduces.)......................................................1537 S-14 Engine oil pressure drops............................................................................................1538 S-15 Fuel gets mixed in engine oil........................................................................................1539 S-16 Water gets mixed in engine oil. (Engine oil becomes cloudy.).........................................................1540 S-17 Coolant temperature rises too high. (Coolant overheats.).............................................................1541 S-18 Unusual noise is heard...............................................................................................1542 S-19 Vibrations are too large.............................................................................................1543 S-20 Air cannot be bled from fuel circuit.................................................................................1544 S-21 Active regeneration is performed too frequently......................................................................1545 S-22 Active regeneration duration is too long.............................................................................1546 S-23 White smoke is exhausted during active regeneration..................................................................1547 S-24 DEF consumption is excessive.........................................................................................1548 S-25 Abnormal (irritating) odor is smelled................................................................................1549 S-26 Foreign material gets mixed in DEF. (DEF level increases.)...........................................................1550 50 Disassembly and assembly.......................................................................................................1551 Contents......................................................................................................................1552 Precautions before work.......................................................................................................1554 Related information on disassembly and assembly...............................................................................1555 How to read this manual...................................................................................................1555 Coating materials list....................................................................................................1556 Special tools list........................................................................................................1560 Sketches of special tools.................................................................................................1569 Engine and cooling system.....................................................................................................1573 Removal and installation of supply pump assembly..........................................................................1573 Removal and installation of injector assembly.............................................................................1578 Removal and installation of cylinder head assembly........................................................................1588 Removal and installation of EGR valve assembly............................................................................1613 Removal and installation of EGR cooler assembly...........................................................................1616 Removal and installation of starting motor assembly.......................................................................1625 Removal and installation of alternator belt...............................................................................1631 Removal and installation of radiator assembly.............................................................................1635 Removal and installation of hydraulic oil cooler assembly.................................................................1640 Removal and installation of aftercooler assembly..........................................................................1646 Removal and installation of engine and main pump assembly.................................................................1649 Removal and installation of engine front oil seal.........................................................................1673 Removal and installation of engine rear oil seal..........................................................................1679 Removal and installation of fuel cooler assembly..........................................................................1683 Removal and installation of engine hood assembly..........................................................................1685 Removal and installation of fuel tank assembly............................................................................1692 Removal and installation of DEF tank assembly.............................................................................1701 Removal and installation of DEF tank sensor flange assembly...............................................................1713 Removal and installation of DEF tank sensor...............................................................................1715 Removal and installation of DEF tank strainer.............................................................................1721 Removal and installation of DEF tank filler port filter...................................................................1722 Removal and installation of KDPF assembly.................................................................................1726 Disassembly and assembly of KDPF assembly.................................................................................1730 Removal and installation of SCR assembly..................................................................................1737 Removal and installation of KDPF and SCR assembly.........................................................................1741 Removal and installation of bracket for KDPF and SCR assembly.............................................................1752 Removal and installation of KCCV assembly.................................................................................1765 Removal and installation of DEF mixing tube...............................................................................1767 Removal and installation of DEF injector..................................................................................1776 Removal and installation of DEF pump assembly.............................................................................1782 Removal and installation of DEF hose......................................................................................1788 Removal and installation of air cleaner assembly..........................................................................1803 Power train...................................................................................................................1810 Removal and installation of travel motor, final drive assembly............................................................1810 Disassembly and assembly of final drive assembly..........................................................................1812 Undercarriage and frame.......................................................................................................1823 Separation and connection of track shoe assembly..........................................................................1823 Removal and installation of sprocket......................................................................................1827 Removal and installation of idler and idler cushion assembly..............................................................1829 Disassembly and assembly of idler assembly................................................................................1831 Disassembly and assembly of idler cushion assembly........................................................................1836 Disassembly and assembly of track roller assembly.........................................................................1839 Disassembly and assembly of carrier roller assembly.......................................................................1843 Hydraulic system..............................................................................................................1847 Removal and installation of hydraulic tank assembly.......................................................................1847 Removal and installation of main pump assembly............................................................................1855 Removal and installation of control valve assembly........................................................................1861 Removal and installation of crusher motor assembly........................................................................1875 Removal and installation of lock cylinder assembly........................................................................1879 Disassembly and assembly of lock cylinder assembly........................................................................1886 Removal and installation of primary conveyor motor........................................................................1890 Removal and installation of grizzly feeder motor assembly.................................................................1893 Removal and installation of magnetic separator motor assembly.............................................................1895 Work equipment................................................................................................................1898 Removal and installation of cheek plate...................................................................................1898 Removal and installation of fixed jaw plate...............................................................................1905 Removal and installation of swing jaw plate...............................................................................1910 Removal and installation of toggle plate..................................................................................1915 Removal and installation of fixed link....................................................................................1924 Removal and installation of swing jaw assembly............................................................................1927 Removal and installation of V-sieve and balance weight....................................................................1932 Removal and installation of crusher assembly..............................................................................1941 Removal and installation of primary conveyor assembly.....................................................................1949 Removal and installation of belt..........................................................................................1954 Replacement of primary conveyor head pulley frame.........................................................................1956 Removal and installation of crusher main bearing..........................................................................1966 Removal and installation of crusher motor and V-sieve.....................................................................1972 Removal and installation of potentiometer.................................................................................1978 Removal and installation of engine front cover............................................................................1980 Electrical system.............................................................................................................1986 Removal and installation of engine controller assembly....................................................................1986 Removal and installation of work equipment controller assembly............................................................1990 Removal and installation of machine monitor assembly......................................................................1992 Removal and installation of pump swash plate sensor.......................................................................1995 Removal and installation of mass air flow and temperature sensor..........................................................1997 Removal and installation of KCCV crankcase pressure sensor................................................................1999 Removal and installation of SCR temperature sensor........................................................................2001 Removal and installation of KOMTRAX terminal assembly.....................................................................2006 Removal and installation of Gateway function controller assembly..........................................................2008 60 Maintenance standard...........................................................................................................2015 Contents......................................................................................................................2016 Engine and cooling system.....................................................................................................2017 Maintenance standard for engine mount.....................................................................................2017 Maintenance standard for cooling system...................................................................................2019 Power train...................................................................................................................2021 Maintenance standard for final drive......................................................................................2021 Maintenance standard for sprocket.........................................................................................2023 Undercarriage and frame.......................................................................................................2025 Maintenance standard for track frame and idler cushion....................................................................2025 Maintenance standard for idler............................................................................................2027 Maintenance standard for track roller.....................................................................................2029 Maintenance standard for carrier roller...................................................................................2031 Maintenance standard for track shoe.......................................................................................2032 Maintenance standard for triple grouser shoe..............................................................................2035 Hydraulic system..............................................................................................................2036 Maintenance standard for hydraulic tank...................................................................................2036 Maintenance standard for main pump........................................................................................2037 Maintenance standard for LS-EPC valve.....................................................................................2039 Maintenance standard for PC-EPC valve.....................................................................................2040 Maintenance standard for control valve....................................................................................2041 Maintenance standard for crusher motor....................................................................................2052 Maintenance standard for solenoid valve...................................................................................2054 Maintenance standard for EPC valve........................................................................................2055 Maintenance standard for travel motor.....................................................................................2057 Maintenance standard for travel PPC valve.................................................................................2060 Work equipment................................................................................................................2063 Maintenance standard for primary conveyor.................................................................................2063 Maintenance standard for vibrator.........................................................................................2065 Maintenance standard for conveyor lift cylinder...........................................................................2066 Maintenance standard for muck discharge conveyor lift cylinder............................................................2067 Maintenance standard for lock cylinder....................................................................................2068 90 Circuit diagrams...............................................................................................................2069 Contents......................................................................................................................2070 Hydraulic circuit diagram.....................................................................................................2071 Symbols used on hydraulic circuit diagram.................................................................................2071 Hydraulic circuit diagram (1/2)...........................................................................................2075 Hydraulic circuit diagram (2/2)...........................................................................................2077 Electrical circuit diagram....................................................................................................2079 Symbols used on electrical circuit diagram................................................................................2079 Electrical circuit diagram (Machine with KOMTRAX terminal) (1/8)..........................................................2083 Electrical circuit diagram (Machine with KOMTRAX terminal) (2/8)..........................................................2085 Electrical circuit diagram (Machine with KOMTRAX terminal) (3/8)..........................................................2087 Electrical circuit diagram (Machine with KOMTRAX terminal) (4/8)..........................................................2089 Electrical circuit diagram (Machine with KOMTRAX terminal) (5/8)..........................................................2091 Electrical circuit diagram (Machine with KOMTRAX terminal) (6/8)..........................................................2093 Electrical circuit diagram (Machine with KOMTRAX terminal) (7/8)..........................................................2095 Electrical circuit diagram (Machine with KOMTRAX terminal) (8/8)..........................................................2095 Electrical circuit diagram (Machine with Gateway function controller) (1/9)...............................................2099 Electrical circuit diagram (Machine with Gateway function controller) (2/9)...............................................2101 Electrical circuit diagram (Machine with Gateway function controller) (3/9)...............................................2103 Electrical circuit diagram (Machine with Gateway function controller) (4/9)...............................................2105 Electrical circuit diagram (Machine with Gateway function controller) (5/9)...............................................2107 Electrical circuit diagram (Machine with Gateway function controller) (6/9)...............................................2109 Electrical circuit diagram (Machine with Gateway function controller) (7/9)...............................................2111 Electrical circuit diagram (Machine with Gateway function controller) (8/9)...............................................2113 Electrical circuit diagram (Machine with Gateway function controller) (9/9)...............................................2115 INDEX.............................................................................................................................2117
DESCRIPTION:
KOMATSU BR380JG-3 MOBILE CRUSHER SHOP MANUAL SEN06703-08 – PDF DOWNLOAD
Composition of Shop Manual
This shop manual contains technical information needed to perform services in a workshop. The manual is classified as follows for easy reference.
00 Index and foreword
This section describes the index, foreword, safety, and basic information.
01 Specifications
This section describes the specifications of the machine.
10 Structure and function
This section describes the structure and function of each device by system. “STRUCTURE AND FUNCTION” is designed to deepen your understanding of the structure of each device and to be a reference material for performing troubleshooting as well.
20 Standard value table
This section describes standard values for new machine and failure criterion for performing testing and adjusting and troubleshooting. Use this standard value table to obtain standard values for testing and adjusting and failure
criteria for troubleshooting.
30 Testing and adjusting
This section describes measuring instruments, measuring methods, and adjustment procedures of each part. Standard values and failure criteria specified in “Testing and adjusting” are also shown in STANDARD VALUE
TABLE. Use it together with this section.
40 Troubleshooting
This section describes procedures for performing diagnosis of failed parts and remedies to take when the machine has a problem. Troubleshooting section is classified into failure modes.
50 Disassembly and assembly
This manual describes special tools and work procedures that are needed for removal and installation of the devices and parts, and disassembly and assembly of them as well. Precautions to be followed for safe work are also described. In addition, this manual shows tightening torques and type, quantity, and weight of coating material, oil and grease, and coolant that are needed for the work.
60 Maintenance standard
This section describes the maintenance standard of each device.. The maintenance standard contains judgment criteria and remedies in disassembly and service.
80 Appendix
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 31/12/24
