MeasuringandadjustingoilpressureinpumpPCcontrolcircuit...................................................32
MeasuringandadjustingoilpressureinpumpLScontrolcircuit...................................................35
Measuringsolenoidvalveoutputpressure.....................................................................................39
MeasuringPPCvalveoutputpressure...........................................................................................43
Measuringoilleakage....................................................................................................................44
Bleedingairfromeachpart............................................................................................................45
Testingtraveldeviation...................................................................................................................48
Adjustingmirrors............................................................................................................................49
Testingandadjusting,Part2SEN03153-00
Specialfunctionsofmachinemonitor...............................................................................................2
Testingandadjusting,Part3SEN03154-01
Checkandadjustmentofjawcrusher..............................................................................................2
Checkandadjustmentofoutletclearance.......................................................................................4
TestingandadjustingtensionofcrusherdriveV-belt.....................................................................19
Checkandadjustmentofprimaryconveyor...................................................................................20
Inspectionandmaintenanceofmagneticseparator.......................................................................26
Checkandadjustmentofmuckdischargeconveyor......................................................................28
Handlingvoltagecircuitofenginecontroller...................................................................................30
ProcedureforturningonKOMTRAXterminal................................................................................31
KOMTRAXterminallampindications.............................................................................................34
Preparationworkfortroubleshootingforelectricalsystem.............................................................37
Procedurefortestingdiodes..........................................................................................................39
40Troubleshooting
FailurecodetableandfuselocationsSEN03156-01
Failurecodetable.............................................................................................................................2
Fuselocations..................................................................................................................................6
GeneralinformationontroubleshootingSEN03157-02
Pointstorememberwhentroubleshooting.......................................................................................2
Sequenceofeventsintroubleshooting............................................................................................3
Checksbeforetroubleshooting.........................................................................................................4
Classificationandproceduresoftroubleshooting.............................................................................6
Contentsoftroubleshootingtable.....................................................................................................7
Connectiontableforconnectorpinnumbers..................................................................................12
T-branchboxandT-branchadaptertable....................................................................................49
Troubleshootingbyfailurecode,Part1SEN03158-00
Failurecode[7RC1KB]ShortcircuitconveyorONswitch................................................................4
Failurecode[7RC2KA]DisconnectioninconveyorOFFswitch......................................................6
Failurecode[7RC5KB]ShortcircuitinfeederONswitch................................................................8
Failurecode[7RD2KB]Shortcircuitindischargeconveyorreversesolenoid...............................10
Failurecode[7RD2KZ]Disconnectionorshortcircuitindischargeconveyorreversesolenoid....11
Failurecode[7RE1KB]ShortcircuitincrusherONswitch.............................................................12
Failurecode[7RE2KA]DisconnectionincrusherOFFswitch.......................................................14
Failurecode[7RE6KB]ShortcircuitinmuckdischargeconveyorONswitch................................16
Failurecode[7RE7KA]DisconnectioninmuckdischargeconveyorOFFswitch..........................18
Failurecode[7RE8KB]ShortcircuitinmagneticseparatorONswitch..........................................20
Failurecode[7RE9KA]DisconnectioninmagneticseparatorOFFswitch....................................22
Failurecode[7REAKB]Shortcircuitinaccessoryinputcircuit1...................................................24
Failurecode[7REDMA]Abnormalityinconveyorpressuresensor...............................................26
Failurecode[7REEMA]Abnormalityinmuckconveyorpressuresensor......................................28
Failurecode[7REHKB]Shortcircuitinaccessoryinputcircuit2...................................................30
Failurecode[7RENKZ]Abnormalityinclearancepotentiometer...................................................32
Failurecode[7REPKA]DisconnectioninfeederOFFswitch.........................................................34
Failurecode[7RESKB]Shortcircuitinone-touchstartswitch.......................................................36
Failurecode[7RETKA]Disconnectioninone-touchstopswitch...................................................38
Failurecode[7RF2KA]DisconnectionincrusherforwardEPCvalve............................................40
Failurecode[7RF2KB]ShortcircuitincrusherforwardEPCvalve...............................................41
Failurecode[7RF2KY]ShortcircuitincrusherforwardEPCvalve...............................................42
Failurecode[7RF3KA]DisconnectionincrusherreverseEPCvalve............................................43
Failurecode[7RF3KB]ShortcircuitincrusherreverseEPCvalve...............................................44
Failurecode[7RF3KY]ShortcircuitincrusherreverseEPCvalve...............................................45
Failurecode[7RF4KA]DisconnectioninfeederforwardEPCvalve.............................................46
Failurecode[7RF4KB]ShortcircuitinfeederforwardEPCvalve.................................................47
Failurecode[7RF4KY]ShortcircuitinfeederforwardEPCvalve.................................................48
Failurecode[7RF8KA]Disconnectioninaccessory2EPCvalve.................................................49
Failurecode[7RF8KB]Shortcircuitinaccessory2EPCvalve.....................................................50
Failurecode[7RF8KY]Shortcircuitinaccessory2EPCsolenoid................................................51
Troubleshootingbyfailurecode,Part2SEN03159-00
Failurecode[7RFAKY]Shortcircuitinenginestoprelay................................................................4
Failurecode[7RFAKZ]Disconnectionorshortcircuitinenginestoprelay.....................................6
Failurecode[7RFBKB]Shortcircuitinmuckconveyorsolenoid.....................................................8
Failurecode[7RFBKZ]Disconnectionorshortcircuitinmuckconveyorsolenoid..........................9
Failurecode[7RFHKA]DisconnectioninconveyorforwardEPCvalve........................................10
Failurecode[7RFHKB]ShortcircuitinconveyorforwardEPCvalve............................................11
Failurecode[7RFHKY]ShortcircuitinconveyorforwardEPCvalve............................................12
Failurecode[7RFKKB]Shortcircuitinlockcylinderpullrelay......................................................14
Failurecode[7RFKKY]Shortcircuitinlockcylinderpullrelay......................................................16
Failurecode[7RFLKA]Disconnectioninaccessory1EPCsolenoid............................................18
Failurecode[7RFLKB]Shortcircuitinaccessory1EPCsolenoid................................................19
Failurecode[7RFLKY]Shortcircuitinaccessory1EPCsolenoid................................................20
Failurecode[7RFMKY]Shortcircuitinabnormalpressurerelay..................................................22
Failurecode[7RFMKZ]Disconnectionorshortcircuitinabnormalpressurerelay.......................24
Failurecode[7RFNKA]Disconnectioninlockcylinderunlocksolenoidvalve...............................26
Failurecode[7RFNKB]Shortcircuitinlockcylinderunlocksolenoidvalve..................................27
Failurecode[7RFNKY]Shortcircuitinlockcylinderunlocksolenoidvalve..................................28
Failurecode[7RFPKB]Shortcircuitinlockcylinderpushrelay....................................................30
Failurecode[7RFPKY]Shortcircuitinlockcylinderpushrelay....................................................32
Failurecode[7RGAMA]Abnormalityin2ndconveyorpressuresensor........................................34
Failurecode[7RJAKA]DisconnectionintravellockEPCsolenoidvalve......................................36
Failurecode[7RJAKB]ShortcircuitintravellockEPCsolenoidvalve..........................................38
Failurecode[7RJAKY]ShortcircuitintravellockEPCsolenoidvalve..........................................40
Failurecode[7RJDMA]Abnormalityincrusherforwardpressuresensor.....................................42
Failurecode[7RJEMA]Abnormalityincrusherreversepressuresensor......................................44
Failurecode[7RJLKA]DisconnectioninmagneticseparatorEPCvalve......................................46
Failurecode[7RJLKB]ShortcircuitinmagneticseparatorEPCvalve..........................................47
Failurecode[7RJLKY]ShortcircuitinmagneticseparatorEPCvalve..........................................48
Failurecode[7RJMMW]Lockcylinderslipping.............................................................................50
Failurecode[7RJPKB]Shortcircuitinradiocontrolwork-modeswitch........................................52
Failurecode[7RJQKB]Shortcircuitinradiocontroltravel-modeswitch.......................................54
Failurecode[7RJRKB]Shortcircuitontravelsignal.....................................................................56
Failurecode[7RJSMA]Abnormalityinmagneticseparatorpressuresensor................................58
Failurecode[AA10NX]AircleanerClogging.................................................................................60
Failurecode[AB00KE]Chargevoltagetoolow.............................................................................62
Troubleshootingbyfailurecode,Part3SEN03160-01
Failurecode[B@BAZG]Engineoilpressuretoolow......................................................................3
Failurecode[B@BAZK]Engineoillevelreduction..........................................................................4
Failurecode[B@BCNS]Enginecoolantoverheat...........................................................................5
Failurecode[B@BCZK]Radiatorcoolantlevelreduction...............................................................6
Failurecode[B@HANS]HydraulicOilOverheat.............................................................................7
Failurecode[CA111]ECMCriticalInternalFailure..........................................................................8
Failurecode[CA115]EngNeandBkupSpeedSensError...........................................................10
Failurecode[CA122]ChgAirPressSensorHighError................................................................11
Failurecode[CA123]ChgAirPressSensorLowError.................................................................13
Failurecode[CA131]ThrottleSensorHighError..........................................................................14
Failurecode[CA132]ThrottleSensorLowError...........................................................................16
Failurecode[CA135]EngOilPressSensorHighError.................................................................17
Failurecode[CA141]EngOilPressSensorLowError..................................................................19
Failurecode[CA144]CoolantTempSensHighError....................................................................20 Failurecode[CA145]CoolantTempSensLowError.....................................................................22
Failurecode[CA153]ChgAirTempSensorHighError.................................................................23
Failurecode[CA154]ChgAirTempSensorLowError..................................................................25 Failurecode[CA187]SensSupply2VoltLowError......................................................................25
Failurecode[CA221]AmbientPressSensHighError...................................................................26 Failurecode[CA222]AmbientPressSensLowError...................................................................28 Failurecode[CA227]SensSupply2VoltHighError.....................................................................29 Failurecode[CA234]EngOverspeed............................................................................................31 Failurecode[CA238]NeSpeedSensSupplyVoltError................................................................32 Failurecode[CA263]FuelTempSensorHighError......................................................................34 Failurecode[CA265]FuelTempSensorLowError.......................................................................36 Failurecode[CA273]PCV2ShortError.........................................................................................37
Failurecode[CA274]PCV2OpenError........................................................................................38 Failurecode[CA322]Inj#1(L#1)Open/ShortError......................................................................40 Failurecode[CA323]Inj#5(L#5)Open/ShortError......................................................................42 Failurecode[CA324]Inj#3(L#3)Open/ShortError......................................................................44 Failurecode[CA325]Inj#6(L#6)Open/ShortError......................................................................46 Failurecode[CA331]Inj#2(L#2)Open/ShortError......................................................................48 Failurecode[CA332]Inj#4(L#4)Open/ShortError......................................................................50 Troubleshootingbyfailurecode,Part4SEN03161-00 Failurecode[CA342]CalibrationCodeIncompatibility....................................................................3 Failurecode[CA351]INJ.DriveCircuitError...................................................................................4 Failurecode[CA352]SensSupply1VoltLowError........................................................................6 Failurecode[CA386]SensSupply1VoltHighError.......................................................................8 Failurecode[CA441]BatteryVoltageLowError............................................................................10 Failurecode[CA442]BatteryVoltageHighError...........................................................................12 Failurecode[CA449]RailPressVeryHighError...........................................................................13 Failurecode[CA451]RailPressSensorHighError......................................................................14 Failurecode[CA452]RailPressSensorLowError.......................................................................16 Failurecode[CA553]RailPressHighError...................................................................................16 Failurecode[CA554]RailPressSensorInRangeError...............................................................17 Failurecode[CA559]RailPressLowError....................................................................................18 Failurecode[CA689]EngNeSpeedSensorError........................................................................22 Failurecode[CA731]EngBkupSpeedSensPhaseError............................................................24 Failurecode[CA757]AllPersistentDataLostError......................................................................25 Failurecode[CA778]EngBkupSpeedSensorError....................................................................26 Failurecode[CA1228]EGRValveServoError1...........................................................................28 Failurecode[CA1625]EGRValveServoError2...........................................................................29 Failurecode[CA1633]CANCommunicationError(enginecontroller)..........................................30 Failurecode[CA2185]ThrotSensSupVoltHighError.................................................................32 Failurecode[CA2186]ThrotSensSupVoltLowError..................................................................34 Failurecode[CA2249]RailPressVeryLowError.........................................................................35 Failurecode[CA2271]EGRValveLiftPositionSensHighError...................................................36
Failurecode[CA2272]EGRValveLiftPositionSensLowError....................................................38
Failurecode[CA2351]EGRValveSolCurrentHighError............................................................39
Failurecode[CA2352]EGRValveSolCurrentLowError.............................................................41
Failurecode[CA2555]GridHeaterRelayOpenError...................................................................42
Failurecode[CA2556]GridHeaterRelayShortError...................................................................44
Troubleshootingbyfailurecode,Part5SEN03162-00
Failurecode[D162KY]Shortcircuitinhornrelay............................................................................4
Failurecode[D162KZ]Disconnectionorshortcircuitinhornrelay.................................................6
Failurecode[DA22KK]Solenoidpowersourcetoolow...................................................................8
Failurecode[DA25KP]Abnormalityinpressuresensorpowersource..........................................10
Failurecode[DA2RMC]CANcommunicationerror(workequipmentandpumpcontroller).........14
Failurecode[DA2SKQ]Abnormalityinmodelcodeinput..............................................................16
Failurecode[DAFRMC]CANcommunicationerror(monitorcontroller).......................................18
Failurecode[DDA6KA]Disconnectioninenginestopswitch........................................................20
Failurecode[DGH2KB]Shortcircuitinhydraulicoiltemperaturesensor......................................22
Failurecode[DHPAMA]AbnormalityinFpumppressuresensor..................................................24
Failurecode[DHPBMA]AbnormalityinRpumppressuresensor.................................................26
Failurecode[DUB0KY]Shortcircuitinbeaconsolidstaterelay...................................................28
Failurecode[DUB0KZ]Disconnectionorshortcircuitinbeaconsolidstaterelay.........................30
Failurecode[DXA0KA]DisconnectioninPC-EPCSolenoid.........................................................32
Failurecode[DXA0KB]ShortcircuitinPC-EPCSolenoid.............................................................33
Failurecode[DXA0KY]ShortcircuitinPC-EPCSolenoid.............................................................34
Failurecode[DXE0KA]DisconnectioninLS-EPCsolenoid..........................................................35
Failurecode[DXE0KB]ShortcircuitinLS-EPCsolenoid..............................................................36
Failurecode[DXE0KY]ShortcircuitinLS-EPCsolenoid..............................................................37
Troubleshootingofelectricalsystem(E-mode)SEN03163-01 Informationintroubleshootingtable.................................................................................................3
E-1Enginedoesnotstart(Enginedoesnotturn)............................................................................4
E-2Theenginestopswhileitisrunning..........................................................................................8
E-3Automaticwarming-updoesnotoperate.................................................................................10
E-4Preheaterdoesnotoperate.....................................................................................................12
E-5Thewholeworkequipmentstopssuddenly.............................................................................14
E-6Theredmarkofemergencystopisindicatedjustaftertheengineisstarted..........................18
E-7Themachinemonitordoesnotdisplayanyitem.....................................................................22
E-8Someitemsarenotdisplayedonthemachinemonitor...........................................................24
E-9Contentsofdisplaybymachinemonitoraredifferentfromapplicablemachine......................24
E-10Fuellevelmonitorwaslightedinredwhileenginerunning...................................................25
E-11Enginecoolanttemperaturegaugedoesnotindicatenormally.............................................26
E-12Thefuellevelgaugedoesnotdisplaynormally.....................................................................28
E-13Thehydraulicoiltemperaturegaugedoesnotdisplaynormally...........................................29
E-14Thetravel,work,andinspectionmodesdonotchange........................................................30
E-15Thecrusherclearanceadjustmentmodedoesnotchange...................................................32
E-16Thecrusherrotationdirectiondoesnotchange....................................................................34
E-17Machinedoesnottravel........................................................................................................36
E-18Travelcannotbecontrolledbyradiocontrol..........................................................................38
E-19ThefeedercannotbeturnedONandOFFbyradiocontrol..................................................42
E-20One-touchstart,stopswitchcannotbeoperatedbyradiocontrol........................................46
E-21Themonitorswitchesdonotwork.........................................................................................49
E-22ThecrushercannotbeoperatedwiththecrushermanualFORWARD/REVERSEswitch onthemonitor.................................................................................................................50
E-23TheconveyorcannotbeoperatedwiththeconveyormanualFORWARD/REVERSE switchonthemonitor.......................................................................................................51
E-24KOMTRAXsystemdoesnotoperatenormally......................................................................52 Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN03164-00 Systemchartforhydraulicandmechanicalsystems.......................................................................4 Informationcontainedintroubleshootingtable.................................................................................6
H-1Thespeedorpowerofthewholeworkequipmentandtravelislow.........................................8
H-2Theenginespeedlowersextremelyortheenginestalls........................................................10
H-3Theworkequipmentandtravelsystemsdonotwork.............................................................11
H-4Abnormalsoundcomesoutfromaroundthehydraulicpump.................................................11
H-5Finecontrolperformanceorresponseislow..........................................................................12
H-6Theconveyordoesnotoperate...............................................................................................13
H-7Thespeedorpoweroftheconveyorislow.............................................................................14
H-8Thecrusherdoesnotoperate.................................................................................................15
H-9Thespeedorpowerofcrusherislow.....................................................................................16
H-10Thefeederdoesnotoperate.................................................................................................16
H-11Thefeederdoesnotfeedsmoothly(Vibrationfrequencyislow)...........................................17
H-12Themagneticseparatordoesnotoperate............................................................................17
H-13Thespeedofmagneticseparatorbeltislow.........................................................................18
H-14Themuckdischargeconveyordoesnotoperate..................................................................18
H-15Thespeedorpowerofthemuckdischargeconveyorislow.................................................19
H-16Theprimaryconveyordoesnotmoveupanddown..............................................................19
H-17Themuckdischargeconveyordoesnotmoveupanddown................................................20
H-18Theopenandclosehopperdoesnotmoveupanddown.....................................................21
H-19Themachinedeviatesduringtravel.......................................................................................22
H-20Thetravelspeedislow..........................................................................................................24
H-21Themachineisnotsteeredwellorsteeringpowerislow.....................................................26
H-22Thetravelmotordoesnotwork(onlyoneside)....................................................................27
H-23Whenthetravelswitchofthewiredremotecontrolorradiocontrollerisdepressed, themachinedoesnottravel............................................................................................28
H-24Thecrusherclearancecannotbeadjusted...........................................................................29 Troubleshootingofengine(S-mode)SEN03165-01 Methodofusingtroubleshootingchart.............................................................................................4
S-1Startingperformanceispoor......................................................................................................8
S-2Enginedoesnotstart...............................................................................................................10
S-3Enginedoesnotpickupsmoothly...........................................................................................14
S-4Enginestopsduringoperations...............................................................................................15
S-5Enginedoesnotrotatesmoothly.............................................................................................16
S-6Enginelacksoutput(orlackspower).......................................................................................17
S-7Exhaustsmokeisblack(incompletecombustion)...................................................................18
S-8Oilconsumptionisexcessive(orexhaustsmokeisblue).......................................................20
S-9Oilbecomescontaminatedquickly..........................................................................................21
S-10Fuelconsumptionisexcessive..............................................................................................22
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown).....................................23
S-12Oilpressuredrops.................................................................................................................24
S-13Oillevelrises(Entryofcoolantorfuel)..................................................................................25
S-14Coolanttemperaturebecomestoohigh(overheating)..........................................................27
S-15Abnormalnoiseismade........................................................................................................28
S-16Vibrationisexcessive............................................................................................................29
50Disassemblyandassembly
GeneralinformationondisassemblyandassemblySEN03441-03
Howtoreadthismanual...................................................................................................................2
Coatingmaterialslist........................................................................................................................4
Specialtoollist..................................................................................................................................8
Sketchesofspecialtools................................................................................................................11
EngineandcoolingsystemSEN03442-01
Removalandinstallationoffuelsupplypumpassembly..................................................................2
Removalandinstallationoffuelinjectorassembly...........................................................................6
Removalandinstallationofenginefrontseal.................................................................................13
Removalandinstallationofenginerearseal.................................................................................16
Removalandinstallationofcylinderheadassembly......................................................................21
Removalandinstallationofengineandhydraulicpumpassembly................................................32
Removalandinstallationofradiatorassembly...............................................................................39
Removalandinstallationofhydraulicoilcoolerassembly.............................................................41
Removalandinstallationofaftercoolerassembly..........................................................................43
Removalandinstallationoffueltankassembly.............................................................................45
PowertrainSEN03443-00
Removalandinstallationoffinaldriveassembly..............................................................................2
Disassemblyandassemblyoffinaldriveassembly.........................................................................4
UndercarriageandframeSEN03444-01
Disassemblyandassemblyoftrackrollerassembly........................................................................2
Disassemblyandassemblyofidlerassembly..................................................................................3
Disassemblyandassemblyofrecoilspring.....................................................................................6
Removalandinstallationofsprocket................................................................................................8
Repairofguideplatewithwearplates.............................................................................................9
Spreadingandinstallationoftrackshoeassembly........................................................................11
HydraulicsystemSEN03445-00
Removalandinstallationofhydraulictankassembly.......................................................................2
Removalandinstallationofhydraulicpumpassembly....................................................................6
Removalandinstallationofcontrolvalveassembly.........................................................................9
Disassemblyandassemblyofcontrolvalveassembly..................................................................16
Removalandinstallationofcrushermotorassembly.....................................................................20
Removalandinstallationofcrusherlockcylinderassembly..........................................................21
Disassemblyandassemblyofcrusherlockcylinderassembly......................................................24
Bleedingairfromcrusherlockcylinder..........................................................................................28
Removalandinstallationofprimarybeltconveyormotor..............................................................30
Removalandinstallationoffeedervibratormotorassembly.........................................................33
Removalandinstallationofmuckdischargeconveyormotorassembly........................................35 Removalandinstallationofmagneticseparatormotorassembly..................................................36
WorkequipmentSEN03446-01
Removalandinstallationofcheekplates.........................................................................................3
Removalandinstallationoffixedtooth............................................................................................7
Removalandinstallationofswingtooth.........................................................................................11
Removalandinstallationoftoggleplate........................................................................................16
Removalandinstallationofmuckdischargeconveyorassembly(ifequipped).............................67
Removalandinstallationofmuckdischargeconveyorheadpulley(ifequipped)..........................70
Removalandinstallationofmuckdischargeconveyortailpulley(ifequipped).............................75
Removalandinstallationofmagneticseparatorassembly............................................................77
ElectricalsystemSEN03447-00
Removalandinstallationofenginecontrollerassembly..................................................................2
Removalandinstallationofworkequipmentandpumpcontrollerassembly...................................3
90Diagramsanddrawings
HydraulicdiagramsanddrawingsSEN02618-01
Hydrauliccircuitdiagram(1/2).........................................................................................................3
Hydrauliccircuitdiagram(2/2).........................................................................................................5
ElectricaldiagramsanddrawingsSEN02619-02
Electricalcircuitdiagram(1/4)..........................................................................................................3
Electricalcircuitdiagram(2/4)..........................................................................................................5
Electricalcircuitdiagram(3/4)..........................................................................................................7
Electricalcircuitdiagram(4/4)..........................................................................................................9
Connectorarrangementdiagram(1/2)...........................................................................................11
Connectorarrangementdiagram(2/2)...........................................................................................13
FormNo.SEN02604-08
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