SEN01341-11
MOBILE CRUSHER
BR380JG -1E0 SERIAL NUMBERS
2001
and up
SEN01343-11
MOBILE CRUSHER 1SHOP MANUAL
BR380JG-1E0
Machine model
Serial number
BR380JG-1E0
2001 and up
00 Index and foreword
1
Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
BR380JG-1E0
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00 Index and foreword
90 Diagrams and drawings Hydraulic diagrams and drawings Electrical diagrams and drawings
BR380JG-1E0
SEN01343-11
SEN01360-02 SEN01361-01 SEN01362-02
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SEN01343-11
00 Index and foreword
Table of contents
1
00 Index and foreword Index SEN01343-11 Composition of shop manual....................................................................................................... 2 Table of contents ......................................................................................................................... 4 Foreword and general information SEN01344-03 Safety notice................................................................................................................................ 2 How to read the shop manual ..................................................................................................... 7 Explanation of terms for maintenance standard .......................................................................... 9 Handling of electric equipment and hydraulic component........................................................... 11 Handling of connectors newly used for engines .......................................................................... 20 How to read electric wire code .................................................................................................... 23 Precautions when carrying out operation .................................................................................... 26 Method of disassembling and connecting push-pull type coupler ............................................... 29 Standard tightening torque table ................................................................................................. 32 Conversion table ......................................................................................................................... 36 01 Specification Specification and technical data SEN01346-00 Specification dimension drawings ............................................................................................... 2 Specifications .............................................................................................................................. 3 Weight table ................................................................................................................................ 5 Table of fuel, coolant and lubricants ............................................................................................ 6 10 Structure, function and maintenance standard Engine and cooling system SEN01348-00 Engine mount, damper ................................................................................................................ 2 Radiator, oil cooler and aftercooler.............................................................................................. 3 Power train SEN01349-00 Power train .................................................................................................................................. 2 Drive system for components ...................................................................................................... 3 Final drive.................................................................................................................................... 4 Sprocket ...................................................................................................................................... 6 Undercarriage and frame SEN01350-00 Track frame and recoil spring ...................................................................................................... 2 Idler ............................................................................................................................................. 4 Carrier roller ................................................................................................................................ 6 Track roller................................................................................................................................... 7 Track shoe................................................................................................................................... 8 Hydraulic system, Part 1 SEN01351-00 Hydraulic piping drawing ............................................................................................................. 2 Hydraulic tank and hydraulic oil filter ........................................................................................... 3 Hydraulic pump ........................................................................................................................... 4 Hydraulic system, Part 2 SEN01352-00 Control valve ............................................................................................................................... 2 Self pressure reducing valve ....................................................................................................... 10 CLSS ........................................................................................................................................... 15 Functions and operation by valve................................................................................................ 19 Hydraulic system, Part 3 SEN01353-00 Crusher motor ............................................................................................................................. 2 Grizzly feeder motor .................................................................................................................... 6 Conveyor motor........................................................................................................................... 7 Travel motor ................................................................................................................................ 8 Valve control................................................................................................................................ 16
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BR380JG-1E0
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00 Index and foreword
SEN01343-11
Solenoid valve............................................................................................................................. 26 EPC valve ................................................................................................................................... 28 Electromagnetic selector valve ................................................................................................... 32 Hydraulic cylinder........................................................................................................................ 34 Work equipment SEN01354-01 Grizzly feeder semiautomatic system ......................................................................................... 2 Abnormal load stop system ......................................................................................................... 3 Primary belt conveyor ................................................................................................................. 4 Grizzly feeder .............................................................................................................................. 8 Crusher ....................................................................................................................................... 9 Crusher tooth tip adjustment system........................................................................................... 14 Vibrator........................................................................................................................................ 17 Electrical system SEN01355-02 Engine control ............................................................................................................................. 2 Work equipment and pump controller ......................................................................................... 12 Electronic control system ............................................................................................................ 15 Machine monitor system ............................................................................................................. 28 Sensor......................................................................................................................................... 54 KOMTRAX system ...................................................................................................................... 58 20 Standard value table Standard service value table SEN02288-00 Standard value table for engine .................................................................................................. 2 Standard value table for chassis ................................................................................................. 3 30 Testing and adjusting Testing and adjusting, Part 1 SEN02303-04 Special functions of machine monitor.......................................................................................... 2 Measuring engine speed............................................................................................................. 6 Measuring intake air pressure (boost pressure).......................................................................... 7 Checking exhaust gas color ........................................................................................................ 8 Adjusting valve clearance ........................................................................................................... 9 Measuring compression pressure ............................................................................................... 11 Measuring blow-by pressure ....................................................................................................... 13 Measuring engine oil pressure .................................................................................................... 14 Handling fuel system parts .......................................................................................................... 15 Releasing residual pressure from fuel system ............................................................................ 15 Measuring fuel pressure.............................................................................................................. 16 Measuring fuel delivery, return rate and leakage ........................................................................ 18 Bleeding air from fuel circuit ........................................................................................................ 21 Checking fuel circuit for leakage ................................................................................................. 23 Replacing fan belt ....................................................................................................................... 24 Checking and adjusting track shoe tension................................................................................. 25 Measuring and adjusting oil pressure in work equipment and travel circuits .............................. 27 Measuring control circuit basic pressure..................................................................................... 32 Measuring and adjusting oil pressure in pump PC control circuit ............................................... 33 Measuring and adjusting oil pressure in pump LS control circuit ................................................ 36 Measuring solenoid valve output pressure.................................................................................. 40 Measuring PPC valve output pressure........................................................................................ 43 Measuring oil leakage ................................................................................................................. 44 Bleeding air from fuel circuit ........................................................................................................ 21 Testing travel deviation................................................................................................................ 48 Adjusting mirrors ......................................................................................................................... 49 Testing and adjusting, Part 2 SEN02304-00 Special functions of machine monitor.......................................................................................... 2
BR380JG-1E0
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Contents of troubleshooting table................................................................................................ 10
00 Index and foreword
SEN01343-11
Troubleshooting by failure code, Part 2 SEN2091-01 Failure code [7RFAKY] Short circuit in engine stop relay ........................................................... 4 Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay ................................ 6 Failure code [7RFBKB] Short circuit in muck conveyor solenoid ................................................ 8 Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid ..................... 9 Failure code [7RFCKA] Disconnection in magnetic separator solenoid...................................... 10 Failure code [7RFCKB] Short circuit in magnetic separator solenoid ......................................... 11 Failure code [7RFCKY] Short circuit in magnetic separator solenoid ......................................... 12 Failure code [7RFHKB] Short circuit in conveyor forward relay .................................................. 14 Failure code [7RFHKY] Short circuit in conveyor forward relay .................................................. 16 Failure code [7RFKKB] Short circuit in lock cylinder pull relay ................................................... 18 Failure code [7RFKKY] Short circuit in lock cylinder pull relay ................................................... 20 Failure code [7RFLKA] Disconnection in accessory EPC solenoid ............................................ 22 Failure code [7RFLKB] Short circuit in accessory EPC solenoid ................................................ 23 Failure code [7RFLKY] Short circuit in accessory EPC solenoid ................................................ 24 Failure code [7RFMKY] Short circuit in abnormal pressure relay ............................................... 26 Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay .................... 28 Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve ............................ 30 Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve ............................... 31 Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve ............................... 32 Failure code [7RFPKB] Short circuit in lock cylinder push relay ................................................. 34 Failure code [7RFPKY] Short circuit in lock cylinder push relay ................................................. 36 Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor ..................................... 38 Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve ................................... 40 Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve....................................... 42 Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve....................................... 44 Failure code [7RJMMW] Lock cylinder slipping .......................................................................... 45 Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor .................................. 46 Failure code [7RJPKB] Short circuit in radio control work-mode switch ..................................... 48 Failure code [7RJQKB] Short circuit in radio control travel-mode switch .................................... 49 Failure code [7RJRKB] Short circuit on travel signal .................................................................. 50 Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor ............................. 52 Failure code [AA10NX] Air cleaner Clogging .............................................................................. 54 Failure code [AB00KE] Charge voltage too low .......................................................................... 56 Troubleshooting by failure code, Part 3 SEN02092-02 Failure code [B@BAZG] Engine oil pressure too low ................................................................. 4 Failure code [B@BAZK] Engine oil level reduction ..................................................................... 6 Failure code [B@BCNS] Radiator coolant overheat ................................................................... 7 Failure code [B@BCZK] Radiator coolant level reduction .......................................................... 8 Failure code [B@HANS] Hydraulic oil overheat.......................................................................... 10 Failure code [CA111] Abnormality in engine controller................................................................ 10 Failure code [CA115] Abnormality in engine NE and Bkup speed sensors................................. 11 Failure code [CA122] Charge pressure sensor too high ............................................................. 12 Failure code [CA123] Charge pressure sensor too low .............................................................. 14 Failure code [CA131] Throttle sensor too high............................................................................ 16 Failure code [CA132] Throttle sensor too low ............................................................................. 18 Failure code [CA144] Coolant temperature sensor too high ....................................................... 20 Failure code [CA145] Coolant temperature sensor too low ........................................................ 22 Failure code [CA153] Charge temperature sensor too high........................................................ 24 Failure code [CA154] Charge temperature sensor too low ......................................................... 26 Failure code [CA155] Charge temperature too high and engine speed derated......................... 28 Failure code [CA187] Sensor power source 2 too low ................................................................ 30 Failure code [CA221] Ambient pressure sensor too high............................................................ 32 Failure code [CA222] Ambient pressure sensor too low ............................................................. 34 Failure code [CA227] Sensor power source 2 too high............................................................... 36 Failure code [CA234] Engine overspeed .................................................................................... 37 Failure code [CA238] Abnormal power source for Ne speed sensor .......................................... 38 Failure code [CA271] Short circuit in fuel pump actuator............................................................ 39 BR380JG-1E0
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SEN01343-11
00 Index and foreword
Failure code [CA272] Disconnection in fuel pump actuator ........................................................ 40 Failure code [CA322] Disconnection or short circuit in injector No.1 .......................................... 42 Failure code [CA323] Disconnection or short circuit in injector No.5 .......................................... 44 Failure code [CA324] Disconnection or short circuit in injector No.3 .......................................... 46 Failure code [CA325] Disconnection or short circuit in injector No.6 .......................................... 48 Failure code [CA331] Disconnection or short circuit in injector No.2 .......................................... 50 Failure code [CA332] Disconnection or short circuit in injector No.4 .......................................... 52 Troubleshooting by failure code, Part 4 SEN02093-01 Failure code [CA342] Abnormality in engine controller data consistency ................................... 3 Failure code [CA351] Abnormality in injector drive circuit ........................................................... 4 Failure code [CA352] Sensor power source 1 too low ................................................................ 6 Failure code [CA386] Sensor power source 1 too high............................................................... 8 Failure code [CA428] Water detection sensor too high ............................................................... 10 Failure code [CA429] Water detection sensor too low ................................................................ 12 Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 14 Failure code [CA441] Power source voltage too low................................................................... 16 Failure code [CA442] Power source voltage too high ................................................................. 18 Failure code [CA449] Common rail pressure sensor too high (2) ............................................... 20 Failure code [CA451] Common rail pressure sensor too high..................................................... 22 Failure code [CA452] Common rail pressure sensor too low ...................................................... 24 Failure code [CA488] Charge temperature too high and torque derated .................................... 26 Failure code [CA553] Common rail pressure sensor too high (1) ............................................... 27 Failure code [CA559] Supply pump no pressure......................................................................... 28 Failure code [CA689] Abnormality in engine Ne speed sensor................................................... 30 Failure code [CA731] Abnormal phase in engine Bkup speed sensor ........................................ 32 Failure code [CA757] Loss of all engine controller data .............................................................. 34 Failure code [CA778] Abnormality in engine Bkup speed sensor ............................................... 36 Failure code [CA1633] CAN communication error (engine controller) ........................................ 38 Failure code [CA2185] Throttle pedal sensor power source too high ......................................... 40 Failure code [CA2186] Throttle pedal sensor power source too low........................................... 41 Failure code [CA2249] Supply pump no pressure (2) ................................................................. 42 Failure code [CA2311] Abnormal resistance in pump regulator valve......................................... 44 Failure code [CA2555] Disconnection in air intake heater relay.................................................. 46 Failure code [CA2556] Short circuit in air intake heater relay ..................................................... 48 Troubleshooting by failure code, Part 5 SEN02094-00 Failure code [D162KY] Short circuit in horn relay ....................................................................... 4 Failure code [D162KZ] Disconnection or short circuit in horn relay ............................................ 6 Failure code [DA22KK] Solenoid power source too low.............................................................. 8 Failure code [DA25KP] Abnormality in pressure sensor power source....................................... 10 Failure code [DA2RMC] CAN communication error (work equipment and pump controller) ...... 14 Failure code [DA2SKQ] Abnormality in model code input........................................................... 16 Failure code [DAFRMC] CAN communication error (monitor controller)..................................... 18 Failure code [DDA6KA] Disconnection in engine stop switch ..................................................... 20 Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor................................... 22 Failure code [DHPAMA] Abnormality in F pump pressure sensor............................................... 24 Failure code [DHPBMA] Abnormality in R pump pressure sensor .............................................. 26 Failure code [DUB0KY] Short circuit in beacon solid state relay................................................. 28 Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay...................... 30 Failure code [DXA0KA] Disconnection in PC-EPC Solenoid ...................................................... 32 Failure code [DXA0KB] Short circuit in PC-EPC Solenoid .......................................................... 33 Failure code [DXA0KY] Short circuit in PC-EPC Solenoid .......................................................... 34 Failure code [DXE0KA] Disconnection in LS-EPC solenoid........................................................ 35 Failure code [DXE0KB] Short circuit in LS-EPC solenoid ........................................................... 36 Failure code [DXE0KY] Short circuit in LS-EPC solenoid ........................................................... 37 Troubleshooting of electrical system (E-mode) SEN02095-02 Information in troubleshooting table ............................................................................................ 3 E-1 Engine does not start (Engine does not turn) ....................................................................... 4 E-2 The engine stops while it is running...................................................................................... 8
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BR380JG-1E0
00 Index and foreword
SEN01343-11
E-3 The automatic warm-up function does not work................................................................... 10 E-4 Preheater does not operate.................................................................................................. 12 E-5 The whole work equipment stops suddenly.......................................................................... 14 E-6 The red mark of emergency stop is indicated just after the engine is started....................... 16 E-7 The machine monitor does not display any item .................................................................. 20 E-8 Some items are not displayed on the machine monitor........................................................ 22 E-9 Contents of display by machine monitor are different from applicable machine................... 22 E-10 Fuel level monitor was lighted in red while engine running ................................................ 23 E-11 Engine coolant temperature gauge does not indicate normally .......................................... 24 E-12 The fuel level gauge does not display normally. ................................................................. 26 E-13 The hydraulic oil temperature gauge does not display normally ........................................ 27 E-14 The travel, work, and inspection modes do not change. .................................................... 28 E-15 The crusher clearance adjustment mode does not change................................................ 30 E-16 The crusher rotation direction does not change ................................................................. 32 E-17 Machine does not travel ..................................................................................................... 34 E-18 Travel cannot be controlled by radio control....................................................................... 36 E-19 The feeder cannot be turned ON and OFF by radio control ............................................... 40 E-20 One-touch start, stop switch cannot be operated by radio control ..................................... 44 E-21 The monitor switches do not work ...................................................................................... 47 E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor .................................................................... 48 E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor .................................................................... 49 E-24 The KOMTRAX system does not work properly ................................................................. 50 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02306-01 System chart for hydraulic and mechanical systems .................................................................. 4 Information contained in troubleshooting table............................................................................ 6 H-1 The speed or power of the whole work equipment and travel is low.................................... 8 H-2 The engine speed lowers extremely or the engine stalls ..................................................... 10 H-3 The work equipment and travel systems do not work .......................................................... 11 H-4 Abnormal sound comes out from around the hydraulic pump.............................................. 11 H-5 Fine control performance or response is low ....................................................................... 12 H-6 The conveyor does not operate............................................................................................ 13 H-7 The speed or power of the conveyor is low.......................................................................... 14 H-8 The crusher does not operate .............................................................................................. 15 H-9 The speed or power of crusher is low .................................................................................. 16 H-10 The feeder does not operate .............................................................................................. 16 H-11 The feeder does not feed smoothly (Vibration frequency is low)........................................ 17 H-12 The magnetic separator does not operate ......................................................................... 17 H-13 The speed of magnetic separator belt is low ...................................................................... 18 H-14 The side conveyor does not operate .................................................................................. 18 H-15 The speed or power of the side conveyor is low ................................................................ 19 H-16 The primary conveyor and the side conveyor do not move up and down .......................... 20 H-17 The machine deviates during travel ................................................................................... 21 H-18 The travel speed is low....................................................................................................... 23 H-19 The machine is not steered well or steering power is low .................................................. 25 H-20 The travel motor does not work (only one side) ................................................................. 26 H-21 When the travel switch of the radio controller is depressed, the machine does not travel . 26 H-22 The crusher clearance cannot be adjusted ........................................................................ 27 Troubleshooting of engine (S-mode) SEN02307-01 Method of using troubleshooting chart ........................................................................................ 3 S-1 Starting performance is poor ................................................................................................ 6 S-2 Engine does not start............................................................................................................ 7 S-3 Engine does not pick up smoothly ........................................................................................ 10 S-4 Engine stops during operations ............................................................................................ 11 S-5 Engine does not rotate smoothly .......................................................................................... 12 S-6 Engine lack output (or lacks power) ..................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14 BR380JG-1E0
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SEN01343-11
00 Index and foreword
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... S-9 Oil becomes contaminated quickly ....................................................................................... S-10 Fuel consumption is excessive ........................................................................................... S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. S-12 Oil pressure drops .............................................................................................................. S-13 Oil level rises (Entry of coolant/fuel) ................................................................................... S-14 Coolant temperature becomes too high (overheating) ....................................................... S-15 Abnormal noise is made ..................................................................................................... S-16 Vibration is excessive .........................................................................................................
15 16 17 18 19 20 21 22 23
50 Disassembly and assembly General information on disassembly and assembly SEN02737-02 How to read this manual.............................................................................................................. 2 Coating materials list ................................................................................................................... 4 Hydraulic system SEN04492-01 Removal and installation of crusher lock cylinder assembly ....................................................... 2 Disassembly and assembly of crusher lock cylinder assembly................................................... 5 Bleeding air from crusher lock cylinder ....................................................................................... 9 Work equipment SEN02738-02 Removal and installation of cheek plates .................................................................................... 3 Removal and installation of fixed tooth........................................................................................ 7 Removal and installation of swing tooth ...................................................................................... 11 Removal and installation of toggle plate...................................................................................... 16 Replacement of toggle plate........................................................................................................ 21 Replacement of toggle seats ....................................................................................................... 24 Removal and installation of fixed link .......................................................................................... 25 Removal and installation of swing jaw assembly ........................................................................ 28 Removal and installation of crusher main bearing ...................................................................... 32 Removal and installation of crusher motor V-sheave .................................................................. 37 Removal and installation of V-sheave and balance weight ......................................................... 41 Removal and installation of potentiometer .................................................................................. 45 Removal and installation of crusher assembly ............................................................................ 46 Removal and installation of primary belt conveyor assembly...................................................... 49 Replacement of belt .................................................................................................................... 52 Replacement of primary belt conveyor motor.............................................................................. 54 Replacement of primary belt conveyor head pulley frame .......................................................... 56 Procedure for folding engine front cover ..................................................................................... 65 90 Diagrams and drawings Hydraulic diagrams and drawings SEN01361-01 Hydraulic circuit diagram (1/2)..................................................................................................... 3 Hydraulic circuit diagram (2/2)..................................................................................................... 5 Electrical diagrams and drawings SEN01362-02 Electrical circuit diagram (1/4) ..................................................................................................... 3 Electrical circuit diagram (2/4) ..................................................................................................... 5 Electrical circuit diagram (3/4) ..................................................................................................... 7 Electrical circuit diagram (4/4) ..................................................................................................... 9 Connector arrangement diagram (1/2) ........................................................................................ 11 Connector arrangement diagram (2/2) ........................................................................................ 13
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BR380JG-1E0
00 Index and foreword
BR380JG-1E0
SEN01343-11
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SEN01343-11
BR380JG-1E0 Mobile crusher Form No. SEN01343-11
© 202 KOMATSU All Rights Reserved Printed in Japan 2-2 (01)
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This is the sample of the manual if you need complete manual
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