MOBILECRUSHER BR380JG-1E0
MachinemodelSerialnumber
BR380JG-1E02001andup
90DiagramsanddrawingsSEN01360-02
HydraulicdiagramsanddrawingsSEN01361-01
ElectricaldiagramsanddrawingsSEN01362-02
00Indexandforeword IndexSEN01343-11
ForewordandgeneralinformationSEN01344-03 Safetynotice................................................................................................................................2 Howtoreadtheshopmanual.....................................................................................................7
01Specification
SpecificationandtechnicaldataSEN01346-00
Specificationdimensiondrawings...............................................................................................2
10Structure,functionandmaintenancestandard
EngineandcoolingsystemSEN01348-00
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Troubleshootingbyfailurecode,Part2SEN2091-01
Failurecode[7RFAKY]Shortcircuitinenginestoprelay...........................................................4
Failurecode[7RFAKZ]Disconnectionorshortcircuitinenginestoprelay................................6
Failurecode[7RFBKB]Shortcircuitinmuckconveyorsolenoid................................................8
Failurecode[7RFBKZ]Disconnectionorshortcircuitinmuckconveyorsolenoid.....................9
Failurecode[7RFCKA]Disconnectioninmagneticseparatorsolenoid......................................10
Failurecode[7RFCKB]Shortcircuitinmagneticseparatorsolenoid.........................................11
Failurecode[7RFCKY]Shortcircuitinmagneticseparatorsolenoid.........................................12
Failurecode[7RFHKB]Shortcircuitinconveyorforwardrelay..................................................14
Failurecode[7RFHKY]Shortcircuitinconveyorforwardrelay..................................................16
Failurecode[7RFKKB]Shortcircuitinlockcylinderpullrelay...................................................18
Failurecode[7RFKKY]Shortcircuitinlockcylinderpullrelay...................................................20
Failurecode[7RFLKA]DisconnectioninaccessoryEPCsolenoid............................................22
Failurecode[7RFLKB]ShortcircuitinaccessoryEPCsolenoid................................................23
Failurecode[7RFLKY]ShortcircuitinaccessoryEPCsolenoid................................................24
Failurecode[7RFMKY]Shortcircuitinabnormalpressurerelay...............................................26
Failurecode[7RFMKZ]Disconnectionorshortcircuitinabnormalpressurerelay....................28
Failurecode[7RFNKA]Disconnectioninlockcylinderunlocksolenoidvalve............................30
Failurecode[7RFNKB]Shortcircuitinlockcylinderunlocksolenoidvalve...............................31
Failurecode[7RFNKY]Shortcircuitinlockcylinderunlocksolenoidvalve...............................32
Failurecode[7RFPKB]Shortcircuitinlockcylinderpushrelay.................................................34
Failurecode[7RFPKY]Shortcircuitinlockcylinderpushrelay.................................................36
Failurecode[7RGAMA]Abnormalityin2ndconveyorpressuresensor.....................................38
Failurecode[7RJAKA]DisconnectionintravellockEPCsolenoidvalve...................................40
Failurecode[7RJAKB]ShortcircuitintravellockEPCsolenoidvalve.......................................42
Failurecode[7RJAKY]ShortcircuitintravellockEPCsolenoidvalve.......................................44
Failurecode[7RJMMW]Lockcylinderslipping..........................................................................45
Failurecode[7RJNMA]Abnormalityinvibratoryscreenpressuresensor..................................46
Failurecode[7RJPKB]Shortcircuitinradiocontrolwork-modeswitch.....................................48
Failurecode[7RJQKB]Shortcircuitinradiocontroltravel-modeswitch....................................49
Failurecode[7RJRKB]Shortcircuitontravelsignal..................................................................50
Failurecode[7RJSMA]Abnormalityinmagneticseparatorpressuresensor.............................52
Failurecode[AA10NX]AircleanerClogging..............................................................................54
Failurecode[AB00KE]Chargevoltagetoolow..........................................................................56
Troubleshootingbyfailurecode,Part3SEN02092-02
Failurecode[B@BAZG]Engineoilpressuretoolow.................................................................4
Failurecode[B@BAZK]Engineoillevelreduction.....................................................................6
Failurecode[B@BCNS]Radiatorcoolantoverheat...................................................................7
Failurecode[B@BCZK]Radiatorcoolantlevelreduction..........................................................8
Failurecode[B@HANS]Hydraulicoiloverheat..........................................................................10
Failurecode[CA111]Abnormalityinenginecontroller................................................................10
Failurecode[CA115]AbnormalityinengineNEandBkupspeedsensors.................................11
Failurecode[CA122]Chargepressuresensortoohigh.............................................................12
Failurecode[CA123]Chargepressuresensortoolow..............................................................14
Failurecode[CA131]Throttlesensortoohigh............................................................................16
Failurecode[CA132]Throttlesensortoolow.............................................................................18
Failurecode[CA144]Coolanttemperaturesensortoohigh.......................................................20
Failurecode[CA145]Coolanttemperaturesensortoolow........................................................22
Failurecode[CA153]Chargetemperaturesensortoohigh........................................................24
Failurecode[CA154]Chargetemperaturesensortoolow.........................................................26
Failurecode[CA155]Chargetemperaturetoohighandenginespeedderated.........................28
Failurecode[CA187]Sensorpowersource2toolow................................................................30
Failurecode[CA221]Ambientpressuresensortoohigh............................................................32
Failurecode[CA222]Ambientpressuresensortoolow.............................................................34
Failurecode[CA227]Sensorpowersource2toohigh...............................................................36
Failurecode[CA234]Engineoverspeed....................................................................................37
Failurecode[CA238]AbnormalpowersourceforNespeedsensor..........................................38
Failurecode[CA271]Shortcircuitinfuelpumpactuator............................................................39
Failurecode[CA272]Disconnectioninfuelpumpactuator........................................................40
Failurecode[CA322]DisconnectionorshortcircuitininjectorNo.1..........................................42
Failurecode[CA323]DisconnectionorshortcircuitininjectorNo.5..........................................44
Failurecode[CA324]DisconnectionorshortcircuitininjectorNo.3..........................................46
Failurecode[CA325]DisconnectionorshortcircuitininjectorNo.6..........................................48
Failurecode[CA331]DisconnectionorshortcircuitininjectorNo.2..........................................50
Failurecode[CA332]DisconnectionorshortcircuitininjectorNo.4..........................................52
Troubleshootingbyfailurecode,Part4SEN02093-01
Failurecode[CA342]Abnormalityinenginecontrollerdataconsistency...................................3
Failurecode[CA351]Abnormalityininjectordrivecircuit...........................................................4
Failurecode[CA352]Sensorpowersource1toolow................................................................6
Failurecode[CA386]Sensorpowersource1toohigh...............................................................8
Failurecode[CA428]Waterdetectionsensortoohigh...............................................................10
Failurecode[CA429]Waterdetectionsensortoolow................................................................12
Failurecode[CA435]Abnormalityinengineoilpressureswitch................................................14
Failurecode[CA441]Powersourcevoltagetoolow...................................................................16
Failurecode[CA442]Powersourcevoltagetoohigh.................................................................18
Failurecode[CA449]Commonrailpressuresensortoohigh(2)...............................................20
Failurecode[CA451]Commonrailpressuresensortoohigh.....................................................22
Failurecode[CA452]Commonrailpressuresensortoolow......................................................24
Failurecode[CA488]Chargetemperaturetoohighandtorquederated....................................26
Failurecode[CA553]Commonrailpressuresensortoohigh(1)...............................................27
Failurecode[CA559]Supplypumpnopressure.........................................................................28
Failurecode[CA689]AbnormalityinengineNespeedsensor...................................................30
Failurecode[CA731]AbnormalphaseinengineBkupspeedsensor........................................32
Failurecode[CA757]Lossofallenginecontrollerdata..............................................................34
Failurecode[CA778]AbnormalityinengineBkupspeedsensor...............................................36
Failurecode[CA1633]CANcommunicationerror(enginecontroller)........................................38
Failurecode[CA2185]Throttlepedalsensorpowersourcetoohigh.........................................40
Failurecode[CA2186]Throttlepedalsensorpowersourcetoolow...........................................41
Failurecode[CA2249]Supplypumpnopressure(2).................................................................42
Failurecode[CA2311]Abnormalresistanceinpumpregulatorvalve.........................................44
Failurecode[CA2555]Disconnectioninairintakeheaterrelay..................................................46
Failurecode[CA2556]Shortcircuitinairintakeheaterrelay.....................................................48
Troubleshootingbyfailurecode,Part5SEN02094-00
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)SEN02095-02 Informationintroubleshootingtable............................................................................................3
E-1Enginedoesnotstart(Enginedoesnotturn).......................................................................4
E-2Theenginestopswhileitisrunning......................................................................................8
E-3Theautomaticwarm-upfunctiondoesnotwork...................................................................10
E-4Preheaterdoesnotoperate..................................................................................................12
E-5Thewholeworkequipmentstopssuddenly..........................................................................14
E-6Theredmarkofemergencystopisindicatedjustaftertheengineisstarted.......................16
E-7Themachinemonitordoesnotdisplayanyitem..................................................................20
E-8Someitemsarenotdisplayedonthemachinemonitor........................................................22
E-9Contentsofdisplaybymachinemonitoraredifferentfromapplicablemachine...................22
E-10Fuellevelmonitorwaslightedinredwhileenginerunning................................................23
E-11Enginecoolanttemperaturegaugedoesnotindicatenormally..........................................24
E-12Thefuellevelgaugedoesnotdisplaynormally..................................................................26
E-13Thehydraulicoiltemperaturegaugedoesnotdisplaynormally........................................27
E-14Thetravel,work,andinspectionmodesdonotchange.....................................................28
E-15Thecrusherclearanceadjustmentmodedoesnotchange................................................30
E-16Thecrusherrotationdirectiondoesnotchange.................................................................32
E-17Machinedoesnottravel.....................................................................................................34
E-18Travelcannotbecontrolledbyradiocontrol.......................................................................36
E-19ThefeedercannotbeturnedONandOFFbyradiocontrol...............................................40
E-20One-touchstart,stopswitchcannotbeoperatedbyradiocontrol.....................................44
E-21Themonitorswitchesdonotwork......................................................................................47
E-22Thecrushercannotbeoperatedwiththecrushermanual FORWARD/REVERSEswitchonthemonitor....................................................................48
E-23Theconveyorcannotbeoperatedwiththeconveyormanual FORWARD/REVERSEswitchonthemonitor....................................................................49
E-24TheKOMTRAXsystemdoesnotworkproperly.................................................................50
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN02306-01 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-14Thesideconveyordoesnotoperate..................................................................................18
H-15Thespeedorpowerofthesideconveyorislow................................................................19
H-16Theprimaryconveyorandthesideconveyordonotmoveupanddown..........................20
H-17Themachinedeviatesduringtravel...................................................................................21
H-18Thetravelspeedislow.......................................................................................................23
H-19Themachineisnotsteeredwellorsteeringpowerislow..................................................25
H-20Thetravelmotordoesnotwork(onlyoneside).................................................................26
H-21Whenthetravelswitchoftheradiocontrollerisdepressed,themachinedoesnottravel.26
H-22Thecrusherclearancecannotbeadjusted........................................................................27
Troubleshootingofengine(S-mode)SEN02307-01 Methodofusingtroubleshootingchart........................................................................................3
S-1Startingperformanceispoor................................................................................................6
S-2Enginedoesnotstart............................................................................................................7
S-3Enginedoesnotpickupsmoothly........................................................................................10
S-4Enginestopsduringoperations............................................................................................11
S-5Enginedoesnotrotatesmoothly..........................................................................................12
S-6Enginelackoutput(orlackspower).....................................................................................13
S-7Exhaustsmokeisblack(incompletecombustion)................................................................14
S-8Oilconsumptionisexcessive(orexhaustsmokeisblue)....................................................15
S-9Oilbecomescontaminatedquickly.......................................................................................16
S-10Fuelconsumptionisexcessive...........................................................................................17
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown)..................................18
S-12Oilpressuredrops..............................................................................................................19
S-13Oillevelrises(Entryofcoolant/fuel)...................................................................................20
S-14Coolanttemperaturebecomestoohigh(overheating).......................................................21
S-15Abnormalnoiseismade.....................................................................................................22
S-16Vibrationisexcessive.........................................................................................................23
50Disassemblyandassembly
GeneralinformationondisassemblyandassemblySEN02737-02
Howtoreadthismanual..............................................................................................................2
Coatingmaterialslist...................................................................................................................4
HydraulicsystemSEN04492-01
Removalandinstallationofcrusherlockcylinderassembly.......................................................2
Disassemblyandassemblyofcrusherlockcylinderassembly...................................................5
Bleedingairfromcrusherlockcylinder.......................................................................................9
WorkequipmentSEN02738-02
Removalandinstallationofcheekplates....................................................................................3
Removalandinstallationoffixedtooth........................................................................................7
Removalandinstallationofswingtooth......................................................................................11
Removalandinstallationoftoggleplate......................................................................................16
Replacementoftoggleplate........................................................................................................21
Replacementoftoggleseats.......................................................................................................24
Removalandinstallationoffixedlink..........................................................................................25
Removalandinstallationofswingjawassembly........................................................................28
Removalandinstallationofcrushermainbearing......................................................................32
RemovalandinstallationofcrushermotorV-sheave..................................................................37
RemovalandinstallationofV-sheaveandbalanceweight.........................................................41
Removalandinstallationofpotentiometer..................................................................................45
Removalandinstallationofcrusherassembly............................................................................46
Removalandinstallationofprimarybeltconveyorassembly......................................................49 Replacementofbelt....................................................................................................................52
Replacementofprimarybeltconveyormotor..............................................................................54
Replacementofprimarybeltconveyorheadpulleyframe..........................................................56 Procedureforfoldingenginefrontcover.....................................................................................65
90Diagramsanddrawings
HydraulicdiagramsanddrawingsSEN01361-01
Hydrauliccircuitdiagram(1/2).....................................................................................................3
Hydrauliccircuitdiagram(2/2).....................................................................................................5
ElectricaldiagramsanddrawingsSEN01362-02
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.SEN01343-11
©202KOMATSU AllRightsReserved PrintedinJapan2-2(01)
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