Page 1 SEN01341-03 MOBILE CRUSHER BR380JG -1E0 2001 SERIAL NUMBERS and up...
Page 3 SEN01343-03 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 00 Index and foreword Index Composition of shop manual .......................... 2 Table of contents ............................. 4 BR380JG-1E0...
Page 4 SEN01343-03 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 5 00 Index and foreword SEN01343-03 Troubleshooting of hydraulic and mechanical system (H-mode) SEN02306-01 Troubleshooting of engine (S-mode) SEN02307-00 50 Disassembly and assembly SEN01359-00 General information on disassembly and assembly SEN02737-00 Work equipment SEN02738-00 90 Diagrams and drawings SEN01360-01 Hydraulic diagrams and drawings SEN01361-00 Electrical diagrams and drawings SEN01362-01...
Page 6: Table Of Contents
SEN01343-03 00 Index and foreword Table of contents 00 Index and foreword Index SEN01343-03 Composition of shop manual....................... Table of contents ......................... Foreword and general information SEN01344-00 Safety notice..........................How to read the shop manual ..................... Explanation of terms for maintenance standard................Handling electric equipment and hydraulic component...............
Page 7 00 Index and foreword SEN01343-03 Hydraulic system, Part 3 SEN01353-00 Crusher motor ..........................Grizzly feeder motor........................Conveyor motor........................... Travel motor ..........................Valve control..........................16 Solenoid valve..........................26 EPC valve ........................... 28 Electromagnetic selector valve ....................32 Hydraulic cylinder........................34 Work equipment SEN01354-00 Grizzly feeder semiautomatic system ..................
Page 8 SEN01343-03 00 Index and foreword Testing and adjusting, Part 2 SEN02304-00 Special functions of machine monitor..................Testing and adjusting, Part 3 SEN02305-01 Check and adjustment of jaw crusher ..................Check and adjustment of outlet clearance .................. Adjusting tension of crusher drive V-belt ..................37 Check and adjustment of primary conveyor ................
Page 9 00 Index and foreword SEN01343-03 Troubleshooting by failure code, Part 2 SEN02091-00 Failure code [7RFAKY] Short circuit in engine stop relay ............Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay ........ Failure code [7RFBKB] Short circuit in muck conveyor solenoid ..........Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid .....
Page 10 SEN01343-03 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 ..........
Page 11 00 Index and foreword SEN01343-03 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 ..............
Page 12 SEN01343-03 00 Index and foreword S-8 Oil consumption is excessive (or exhaust smoke is blue) ............ 15 S-9 Oil becomes contaminated quickly ..................16 S-10 Fuel consumption is excessive ................... 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........18 S-12 Oil pressure drops ......................
Page 13 00 Index and foreword SEN01343-03 BR380JG-1E0...
Page 15 SEN01344-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 00 Index and foreword Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard ..................... 9 Handling electric equipment and hydraulic component .................11 How to read electric wire code........................
Page 16: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 17 00 Index and foreword SEN01344-00 When disassembling or assembling, sup- When removing piping, stop the fuel or oil port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips stands before starting work. onto the floor, wipe it up immediately. Fuel Remove all mud and oil from the steps or or oil on the floor can cause you to slip other places used to get on and off the...
Page 18 SEN01344-00 00 Index and foreword Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily.
Page 19 00 Index and foreword SEN01344-00 13) If the hoist stops because of a power fail- If the load is unstable or the wire rope or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. turning on a switch which was turned OFF Do not lift up the load slantingly.
Page 20 SEN01344-00 00 Index and foreword Precautions for disconnecting and con- necting hoses and tubes in air conditioner circuit Disconnection Collect the air conditioner refrigerant gas (R134a). If the refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, when collecting or adding it, you must be qualified for handling the refrigerant and put on protective...
Page 21: How To Read The Shop Manual
Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. BR380JG-1E0...
Page 22 SEN01344-00 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 23: Explanation Of Terms For Maintenance Standard
00 Index and foreword SEN01344-00 Explanation of terms for maintenance standard The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 24 SEN01344-00 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 25: Handling Electric Equipment And Hydraulic Component
00 Index and foreword SEN01344-00 Handling electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 26 SEN01344-00 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken.
Page 27 00 Index and foreword SEN01344-00 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
Page 28 SEN01344-00 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
Page 29 00 Index and foreword SEN01344-00 Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
Page 30 SEN01344-00 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
Page 31 00 Index and foreword SEN01344-00 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
Page 32 SEN01344-00 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
Page 33 00 Index and foreword SEN01344-00 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
Page 34 SEN01344-00 00 Index and foreword Connectors newly used for Tier 3 engines Slide lock type Pull lock type (PACKARD-2) (FRAMATOME-3, FRAMATOME-2) 107 – 170, 12V140 engine 107 – 170, 12V140 engines Various temperature sensors Various pressure sensors and NE Example) speed sensor Intake air temperature sensor in Examples)
Page 35 00 Index and foreword SEN01344-00 Push lock type 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engine Example)
Page 36 SEN01344-00 00 Index and foreword Turn-housing type (Round green connector) 125 – 170, 12V140 engine While pressing lock (E) of the connector, 140 engine pullout connector (5) in the direction of the Example) arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc.
Page 37: How To Read Electric Wire Code
00 Index and foreword SEN01344-00 How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols.
Page 38 SEN01344-00 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
Page 39 00 Index and foreword SEN01344-00 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
Page 40: Precautions When Carrying Out Operation
SEN01344-00 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly.
Page 41 00 Index and foreword SEN01344-00 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Page 42 SEN01344-00 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
Page 43: Method Of Disassembling And Connecting Push-Pull Type Coupler
00 Index and foreword SEN01344-00 Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
Page 44 SEN01344-00 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
Page 45 00 Index and foreword SEN01344-00 Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end.
Page 46: Standard Tightening Torque Table
SEN01344-00 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque...
Page 47 00 Index and foreword SEN01344-00 Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
Page 48 SEN01344-00 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
Page 49 00 Index and foreword SEN01344-00 Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Thread size Tightening torque inch...
Page 50: Conversion Table
SEN01344-00 00 Index and foreword Conversion table Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below. Example: Method of using the conversion table to convert from millimeters to inches Convert 55 mm into inches.
Page 51 00 Index and foreword SEN01344-00 Millimeters to inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181...
Page 52 SEN01344-00 00 Index and foreword Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379...
Page 53 00 Index and foreword SEN01344-00 kg/cm to lb/in 1 kg/cm = 14.2233 lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...
Page 54 SEN01344-00 00 Index and foreword Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi- grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren- heit temperatures and read the corresponding Centigrade temperature in the column at the left.
Page 56: Specification
SEN01346-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 01 Specification Specification and technical data Specification dimension drawings ........................2 Specifications ..............................3 Weight table ..............................5 Table of fuel, coolant and lubricants........................ 6 BR380JG-1E0...
Page 57: Specification Dimension Drawings
SEN01346-00 01 Specification Specification dimension drawings Dimensions Unit: mm A Overall length 12,500 B Overall height 3,200 C Overall width (when transporting) 2,870 (2,810) D Width of track Tread 2,280 Length of track on ground 3,275 BR380JG-1E0...
Page 58: Specifications
01 Specification SEN01346-00 Specifications Machine model BR380JG-1E0 Serial Number 2001 and up Operating weight 34,000 Maximum feed-in material dimensions 1,000 × 900 × 475 (Concrete) Maximum feed-in material dimensions 425 × 425 × 425 (Stone) Travel speed km/h Lo: 0.8, Mi: 2.3, Hi: 3.0 Gradeability deg.
Page 59 SEN01346-00 01 Specification Machine model BR380JG-1E0 Serial Number 2001 and up Type – Grizzly feeder with 2-level deck and speed controller Type of vibrator – Horizontal double shaft type Dimensions of trough 1,000 x 3,220 Vibration frequency c.p.m Variable, 1,000 (Rating) Drive method –...
Page 60: Weight Table
01 Specification SEN01346-00 Weight table This weight table is a reference for handling and transportation of components. Unit: kg Machine model BR380JG-1E0 Serial Number 2001 and up Engine assembly • Engine • Damper • Hydraulic pump Radiator and oil cooler assembly Hydraulic tank and filter assembly (Excluding hydraulic oil) Fuel tank assembly (Excluding fuel) Main frame...
Page 61: Table Of Fuel, Coolant And Lubricants
SEN01346-00 01 Specification Table of fuel, coolant and lubricants a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual. BR380JG-1E0...
Page 62 01 Specification SEN01346-00 Unit: l BR380JG-1E0 Reservoir Specified (l) Refill (l) Engine oil pan 25.4 Damper case — Jaw crusher motor bearing case Final drive case (each) Grizzly feeder vibrator case Hydraulic system Fuel tank — Cooling system 20.6 — BR380JG-1E0...
Page 64: Structure, Function And Maintenance Standard
SEN01348-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Engine and cooling system Engine mount, damper............................ 2 Radiator, oil cooler and aftercooler ......................... 3 BR380JG-1E0...
Page 65: Engine Mount, Damper
SEN01348-00 10 Structure, function and maintenance standard Engine mount, damper Drive plate Muffler Outline Torsion spring Rear engine mount The damper assembly is a wet type. Oil capacity: 0.8 l Stopper pin Front engine mount Friction plate Damper assembly BR380JG-1E0...
Page 66: Radiator, Oil Cooler And Aftercooler
10 Structure, function and maintenance standard SEN01348-00 Radiator, oil cooler and aftercooler Radiator outlet hose Outline Shroud Radiator Radiator : Aluminum wave type, 4 rows Oil cooler : CF40-1 Radiator cap Oil cooler Radiator inlet hose 10. Aftercooler 11. Fuel cooler Reservoir tank BR380JG-1E0...
Page 68: Power Train
SEN01349-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Power train Power train..............................2 Drive system for components ......................... 3 Final drive ............................... 4 Sprocket ................................6 BR380JG-1E0...
Page 69: Structure, Function And Maintenance Standard
SEN01349-00 10 Structure, function and maintenance standard Power train 1. Idler 9. Primary belt conveyor motor 2. Jaw crusher motor (KFM125B-5) (MSE02-2-123-R02-1240-K000) 3. Final drive 10. Control valve 4. Travel motor (HMV110ADT-2) 11. Option connection port (side conveyor) 5. Option connection port (magnetic separator) 12. Primary belt conveyor lift cylinder 6.
Page 70: Drive System For Components
10 Structure, function and maintenance standard SEN01349-00 Drive system for components BR380JG-1E0...
Page 71: Final Drive
SEN01349-00 10 Structure, function and maintenance standard Final drive BR380JG-1E0...
Page 72 10 Structure, function and maintenance standard SEN01349-00 Level plug No. 1 planetary gear (Number of teeth: 42) Drain plug No. 1 sun gear (Number of teeth: 10) No. 2 sun gear (Number of teeth: 21) No. 1 planetary carrier Cover No.
Page 73: Sprocket
SEN01349-00 10 Structure, function and maintenance standard Sprocket Unit: mm Check Item Criteria Remedy Standard size Repair limit Wear of tooth tip 294.5 282.5 Build-up welding Thickness of tooth root for rebuilding or Width of tooth replace Repair limit: 6 Wear of tooth shape (measure with the full-size drawing of sprocket tooth shape) BR380JG-1E0...
Page 74 10 Structure, function and maintenance standard SEN01349-00 Full-size drawing of sprocket tooth shape BR380JG-1E0...
Page 76 SEN01350-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Undercarriage and frame Track frame and recoil spring.......................... 2 Idler ................................. 4 Carrier roller ..............................6 Track roller ..............................7 Track shoe ..............................
Page 77: Track Frame And Recoil Spring
SEN01350-00 10 Structure, function and maintenance standard Track frame and recoil spring Idler Standard shoe Track frame Shoe width: 500 mm Carrier roller Link pitch: 190 mm Final drive Number of shoes (Each side): 45 Track roller Track shoe Center guard Front guard Specifications Number of track rollers: 5 (Each side)
Page 78 10 Structure, function and maintenance standard SEN01350-00 Unit: mm Check item Criteria Remedy Vertical width of idler guide Standard size Tolerance Repair limit Track frame — — Repair by build- Idler support — — up welding or Lateral width of idler guide replace Track frame —...
Page 79: Idler
SEN01350-00 10 Structure, function and maintenance standard Idler BR380JG-1E0...
Page 80 10 Structure, function and maintenance standard SEN01350-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of protruding — Outside diameter of tread Rebuild or Thickness of tread replace Step measurement of tread Total width — Width of tread 37.5 —...
Page 81: Carrier Roller
SEN01350-00 10 Structure, function and maintenance standard Carrier roller Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange — Outside diameter of tread Width of tread — Thickness of tread Width of flange — Tolerance Standard Standard Clearance...
Page 82: Track Roller
10 Structure, function and maintenance standard SEN01350-00 Track roller Unit: mm Check item Criteria Remedy Standard size Repair limit Outside diameter of flange — Outside diameter of tread Thickness of tread 44.5 38.5 Rebuild or replace Overall width — Inside width —...
Page 83: Track Shoe
SEN01350-00 10 Structure, function and maintenance standard Track shoe a P portion shows the link of bushing press fitting end. BR380JG-1E0...
Page 84 10 Structure, function and maintenance standard SEN01350-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Link pitch 190.25 193.25 Reverse or When turned replace Standard size Bushing outside diameter Normal load Impact load — Standard size Repair limit Link height Repair or replace...
Page 85 SEN01350-00 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Tightening torque Additional tightening (Nm {kgm}) angle (deg.) a. Regular link 490 ± 49 Triple shoe 120 ± 10 {50 ± 5} Shoe bolt Retighten Tightening torque Additional tightening Lower limit torque (Nm {kgm})
Page 86 10 Structure, function and maintenance standard SEN01350-00 Triple grouser shoe Unit: mm Check item Criteria Remedy Standard size Repair limit Height Thickness Length of base Rebuild or replace Length at tip Standard size Repair limit Thickness 34.5 24.5 BR380JG-1E0...
Page 88: Hydraulic Sysmtem, Part 1
SEN01351-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Hydraulic sysmtem, Part 1 Hydraulic piping drawing..........................2 Hydraulic tank and hydraulic oil filter ......................3 Hydraulic pump ............................... 4 BR380JG-1E0...
Page 89: Hydraulic Piping Drawing
SEN01351-00 10 Structure, function and maintenance standard Hydraulic piping drawing 1. Left travel motor 2. Crusher motor 3. Lock cylinder 4. Hydraulic tank 5. Control valve 6. Hydraulic pump 7. Right travel motor 8. Feeder motor BR380JG-1E0...
Page 90: Hydraulic Tank And Hydraulic Oil Filter
10 Structure, function and maintenance standard SEN01351-00 Hydraulic tank and hydraulic oil filter 1. Hydraulic tank Specifications 2. Oil filler cap Tank capacity: 200 l 3. Filter element Amount of oil inside tank: 143 l 4. Strainer Pressure valve 5. Bypass valve Relief cracking pressure: 16.7 ±...
Page 91: Hydraulic Pump
SEN01351-00 10 Structure, function and maintenance standard Hydraulic pump HPV95 + 95 BR380JG-1E0...
Page 92 10 Structure, function and maintenance standard SEN01351-00 Outline This pump consists of 2 variable capacity swash plate piston pumps, PC valve, LS valve, and EPC valve. PC mode selector current ISIG: LS set selector current PAF: Front pump delivery port PAR: Rear pump delivery port PBF:...
Page 93 SEN01351-00 10 Structure, function and maintenance standard 1. Front shaft 2. Cradle 3. Front case 4. Rocker cam 5. Shoe 6. Piston 7. Cylinder block 8. Valve plate 9. End cap 10. Rear shaft 11. Rear case 12. Servo piston 13.
Page 94 10 Structure, function and maintenance standard SEN01351-00 Function Rocker cam (4) conducts high pressure oil to the cylinder surface (B) with cradle (2), which The pump converts the engine rotation and is secured to the case, and forms a static pres- torque transmitted to its shaft to oil pressure sure bearing when it slides.
Page 95 SEN01351-00 10 Structure, function and maintenance standard Operation of pump Cylinder block (7) rotates together with shaft As center line (X) of rocker cam (4) matches (1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between along cylindrical surface (B), so angle (a)
Page 96 10 Structure, function and maintenance standard SEN01351-00 Control of delivery If the swash plate angle (a) becomes larger, the difference between volumes (E) and (F) b e c o m e s l a r g e r a n d p u m p d e l i v e r y ( Q ) increases.
Page 97 SEN01351-00 10 Structure, function and maintenance standard 1. LS valve : Pump port Sleeve PDP : Drain port Piston PLP : LS control pressure output port Spool PLS : LS pressure input port Spring : Pump port Sheet PPL : Control pressure input port Sleeve PSIG : LS mode selector pilot port Plug...
Page 98 10 Structure, function and maintenance standard SEN01351-00 Operation 1) When the control valve is situated at neutral The LS valve is a 3-way selector valve, with Spool (6) is pushed to the right, and port (C) pressure (PLS) (LS pressure) from the outlet and port (D) will be connected.
Page 99 SEN01351-00 10 Structure, function and maintenance standard 2) Action for the direction of maximizing the pump delivery When the difference between pump discharge If the output pressure of the EPC valve for the pressure (PP) and LS pressure (PLS), in other LS valve enters port (G), rightward force is w o r d s , L S d i ffe r e n t i a l p r e s s u r e ( dP L S) generated on piston (7).
Page 100 10 Structure, function and maintenance standard SEN01351-00 3) Action for the direction of minimizing the pump delivery When differential pressure (dPLS) becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure (PP) rises) because of the rightward move (it reduces discharge amount) of servo piston (12), pump pressure (PP) pushes spool (6) to the right.
Page 101 SEN01351-00 10 Structure, function and maintenance standard 4) When servo piston is balanced Let us take the area receiving the pressure at Force of spring (4) is adjusted in such that the the large diameter end of the piston as (A1), position of the balanced stop of this spool (6) the area receiving the pressure at the small may be determined when (PP) –...
Page 102 10 Structure, function and maintenance standard SEN01351-00 2. PC valve : Pump port Plug PA2 : Pump pressure pilot port Servo piston assembly PDP : Drain port PM : Mode selector pressure pilot port Spool PPL : Control pressure output port (to LS valve) Retainer Sheet Cover...
Page 103 SEN01351-00 10 Structure, function and maintenance standard Operation 1) When pump controller is normal (1) When the load on the actuator is small and pump discharge pressures (PP1) and (PP2) are low Action of PC-EPC valve solenoid (1) a Other pump's pressure denotes the pressure Command current (X) is being sent to PC-EPC valve solenoid (1) from the pump controller.
Page 104 10 Structure, function and maintenance standard SEN01351-00 Action of spring Load of springs (4) and (6) on the PC valve is Self pressure (PP1) enters port (B) and the determined by the swash plate position. small diameter end of servo piston (9), and As servo piston (9) moves to right, spring (6) is other pump pressure (PP2) enters port (A).
Page 105 SEN01351-00 10 Structure, function and maintenance standard As the spring force is weakened, spool (3) moves to the right, the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are con- nected.
Page 106 10 Structure, function and maintenance standard SEN01351-00 (2) When load on actuator is large and pump discharge pressure is high Outline When servo piston (9) moves to the right, springs (4) and (6) are compressed and push When the load is large and pump discharge back spool (3).
Page 107 SEN01351-00 10 Structure, function and maintenance standard The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their positions can be represented by the broken line in the figure springs (4) and (6) form the double springs.
Page 108 10 Structure, function and maintenance standard SEN01351-00 3. LS (PC)-EPC valve C : To LS (PC) valve P : From self pressure reducing valve T : To tank Connector Coil Body Spring Spool Plunger BR380JG-1E0...
Page 109 SEN01351-00 10 Structure, function and maintenance standard Function Operation The EPC valve consists of the proportional 1) When signal current is 0 (coil is solenoid portion and the hydraulic valve por- de-energized) tion. When it receives signal current (i) from the When there is no signal current flowing from the controller, it generates the EPC output pres- controller to coil (2), coil (2) is de-energized.
Page 110 10 Structure, function and maintenance standard SEN01351-00 2) When signal current is very small 3) When signal current is maximum (coil is energized) (coil is energized) When a very small signal current flows to coil As the signal current flows to coil (2), coil (2) is (2), coil (2) is energized, and a propulsion force energized.
Page 112: Hydraulic System, Part 2
SEN01352-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Hydraulic system, Part 2 Control valve ..............................2 Self pressure reducing valve......................... 10 CLSS................................15 Functions and operation by valve ......................... 19 Functions and operation by valve .........................
Page 113: Control Valve
SEN01352-00 10 Structure, function and maintenance standard Control valve 8-spool valve BR380JG-1E0...
Page 114 10 Structure, function and maintenance standard SEN01352-00 Outline This control valve consists of a 6-spool valve and 2 service valves and is equipped with a merge-divider valve. The component valves are assembled into 1 unit with bolts and the paths are connected internally.
Page 115 SEN01352-00 10 Structure, function and maintenance standard 1. Unload valve 6. Left travel spool 2. Main relief valve 7. Grizzly feeder spool 3. Magnetic separator spool 8. Crusher spool 4. Side conveyor spool 9. Right travel spool 5. Accessory spool 10.
Page 116 10 Structure, function and maintenance standard SEN01352-00 1. Lock cylinder reset spool 5. Suction valve 2. Right travel spool 6. Pressure compensation valve 3. Crusher spool 7. Pressure compensation valve 4. Safety-suction valve 8. Plug Unit: mm Check item Criteria Remedy Standard size Repair limit...
Page 117 SEN01352-00 10 Structure, function and maintenance standard 1. Feeder spool 8. Unload valve 2. Left travel spool 9. Main relief valve 3. Accessory spool 10. Pressure compensation valve 4. Safety-suction valve 11. Pressure compensation valve 5. Safety-suction valve 12. Merge-divider valve (Travel junction valve) 6.
Page 118 10 Structure, function and maintenance standard SEN01352-00 Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed Spool return spring Outside diameter length load length load 94.1 N 75.3 N 54.2 x 34.8 53.5 —...
Page 119 SEN01352-00 10 Structure, function and maintenance standard 1. Side conveyor and magnetic separator spool 5. Main relief valve 2. Safety-suction valve 6. Merge-divider valve (For LS) 3. Pressure compensation valve 7. Merge-divider valve (Main) 4. Unload valve 8. LS bypass valve Unit: mm Check item Criteria...
Page 120: Self Pressure Reducing Valve
SEN01352-00 10 Structure, function and maintenance standard Self pressure reducing valve a. Port (P1) (from front pump) b. Port (PR) (supply to electromagnetic valve, PPC valve, EPC valve) c. Port (T) (to hydraulic tank) d. Port (PC) (to front pump LS valve) BR380JG-1E0...
Page 121 10 Structure, function and maintenance standard SEN01352-00 1. Sequence valve 2. Poppet 3. Pressure reducing valve 4. Ball Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed Spring (pressure Outside diameter length load length load...
Page 122 SEN01352-00 10 Structure, function and maintenance standard Function This valve reduces the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valve and PPC valve. Operation When engine is stopped. Poppet (5) is pushed against the seat by spring (6), and the passage from port (PR) o (T) is closed.
Page 123 10 Structure, function and maintenance standard SEN01352-00 At hold and when load pressure (P2) is low. When load pressure (P2) is high. NOTE: When load pressure (P2) is lower than output If load pressure (P2) increases and the pump pressure (PR) of the self pressure reducing valve. discharge amount also increases because of Valve (2) receives force in the direction to operations, pressure (P1) also increases...
Page 124 SEN01352-00 10 Structure, function and maintenance standard When there is abnormally high pressure. When pressure (PR) of the self pressure reducing valve becomes abnormally high, ball (10) pushes against the force of spring (9), separates from the seat, and allows hydraulic oil to flow from output port (PR) o (T), so pres- sure (PR) goes down.
Page 125: Clss
10 Structure, function and maintenance standard SEN01352-00 CLSS Outline of CLSS Features Configuration CLSS stands for Closed center Load Sensing Sys- CLSS is configured with variable capacity pis- tem, which has the following characteristics: ton pumps, control valves, and respective actuators.
Page 126 SEN01352-00 10 Structure, function and maintenance standard Basic principle 1. Pump swash plate angle control The pump swash plate angle (pump delivery) The pump swash plate angle shifts toward the is controlled so that LS differential pressure maximum position if LS differential pressure (dPLS) (the difference between pump pressure (dPLS) is lower than the set pressure of the LS PP and control valve outlet port LS pressure...
Page 127 10 Structure, function and maintenance standard SEN01352-00 2. Pressure compensation control A pressure compensation valve is installed to the outlet port side of the control valve to bal- ance the load. When actuators are operated together, the p r e s s u r e d i f f e r e n c e ( d P ) b e t w e e n t h e upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pres-...
Page 128 SEN01352-00 10 Structure, function and maintenance standard 3. System diagram a This shows actuator (6A) at stroke end relief in the merge mode (on the BR380JG-1E0, this is always in the divide mode). 1A. Main pump 5A. Control valve 9A. Tank passage 1B.
Page 129: Functions And Operation By Valve
10 Structure, function and maintenance standard SEN01352-00 Functions and operation by valve Hydraulic circuit diagram and the name of valves 1. Relief valve (Set pressure: 37.2 ± 0.5 MPa {380 ± 5 kg/cm 2. Unload valve (Cracking pressure: 2.9 ± 0.5 MPa {30 ± 5 kg/cm 3.
Page 130 SEN01352-00 10 Structure, function and maintenance standard Unload valve 1. When the unload valve is actuating LS circuit Tank circuit Valve Spring Pump circuit Function Operation Drains an oil discharge for the portion of the Pressure of pump circuit (3) is received by the minimum pump swash plate angle while all end of valve (2).
Page 131 10 Structure, function and maintenance standard SEN01352-00 2. Operation of relief valve During operation (a work within a scope of dis- charge by a minimum swash plate angle), the (Cut-off Control Actuated) discharge pressure for the portion of minimum pump swash plate angle is set to LS pressure Function + P1 pressure.
Page 132 SEN01352-00 10 Structure, function and maintenance standard Introduction of LS pressure Hydraulic pump Main spool Pressure compensation valve Valve Check valve LS circuit LS shuttle valve Function Introduces the upstream pressure (down- stream pressure of the spool meter-in) of pres- sure compensation valve (3) and leads to LS shuttle valve (7) as the LS pressure.
Page 133 10 Structure, function and maintenance standard SEN01352-00 LS bypass valve Hydraulic pump Main spool Pressure compensation valve LS shuttle valve LS bypass valve LS circuit Function Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b). Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres- sure.
Page 134 SEN01352-00 10 Structure, function and maintenance standard Pressure compensation valve 1. During independent operation and under maximum load pressure (If the load pressure is higher than other work equipment during a combined operation) Hydraulic pump Piston Valve Spring Shuttle valve LS shuttle valve Function As principle, port (C) and spring chamber (E)
Page 135 10 Structure, function and maintenance standard SEN01352-00 2. When compensated (If the load pressure is lower than other work equipment during a combined operation) Function The pressure compensation valve closes under LS pressure of port (D), and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
Page 136 SEN01352-00 10 Structure, function and maintenance standard 3. Pressure compensation valve area ratio Function The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2). Area ratio = (A2)/(A1) If area ratio = 1 : The spool meter-in downstream pressure will be equal to the maximum load pressure, and the pressure will be divided according to the opening area ratio.
Page 137 10 Structure, function and maintenance standard SEN01352-00 Pressure compensation valve inner shuttle valve 1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B) Hydraulic pump Valve Pressure compensation valve inner shuttle valve Piston Function Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection...
Page 138 SEN01352-00 10 Structure, function and maintenance standard 2. In the case of travel Outline Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensa- tion valve without shuttle valve (3) is adopted. BR380JG-1E0...
Page 139 10 Structure, function and maintenance standard SEN01352-00 Merge-divider valve 1. When flows from the pumps merge [if pilot pressure (PS) is OFF] a On the BR380JG-1E0, pilot pressure (PS) is always ON and the flow is always divided. Main spool LS circuit (if equipped 4 side) Spring LS circuit (conveyor PAISE/LOWER side)
Page 140 SEN01352-00 10 Structure, function and maintenance standard 2. When flows from the pumps divide [if pilot pressure (PS) is ON] Operation Pilot pressure (PS) turns ON, and shifts main spool (1) to the right, and ports (E) and (F) are divided.
Page 141 10 Structure, function and maintenance standard SEN01352-00 Travel junction valve 1. When pilot pressure is turned ON Function Operation This valve connects the L.H. and R.H. travel Pilot pressure from the travel junction solenoid circuits through travel junction valve so that the valve contracts spring (1), and travel junction hydraulic oil will be supplied evenly to both spool (2) moves to the left to the stroke end.
Page 142 SEN01352-00 10 Structure, function and maintenance standard 2. When pilot pressure is turned OFF Operation If the oil flow rates to the L.H. and R.H. travel motors become different from each other, the If pilot pressure (PST) from the solenoid valve oil flows through the route between port (PTL), is 0, travel junction spool (2) is pressed by the travel junction spool (2), and port (PTR) so that...
Page 144: Hydraulic System, Part 3
SEN01353-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Hydraulic system, Part 3 Crusher motor ..............................2 Grizzly feeder motor............................6 Conveyor motor .............................. 7 Travel motor ..............................8 Valve control ..............................
Page 145: Crusher Motor
SEN01353-00 10 Structure, function and maintenance standard Crusher motor Type: KMF125B-5 MA: From control valve Specifications MB: From control valve Model: KMF125B-5 From back pressure compensation valve Theoretical delivery: 125.0 cm /rev To tank Set pressure of safety valve:36.7 MPa {375 kg/cm Rated speed: 1,780 rpm BR380JG-1E0...
Page 146 10 Structure, function and maintenance standard SEN01353-00 1. Drive shaft 6. Cylinder block 11. Check valve 2. Spacer 7. Valve plate 12. Check valve spring 3. Case 8. Center shaft 13. Shuttle valve 4. Housing 9. Center spring 14. Shuttle valve spring 5.
Page 147 SEN01353-00 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Free length × Installed Installed Free Installed If damaged Check valve spring Outside diameter length load length load or deformed, 3.5 N 2.8 N replace 62.5 ×...
Page 148 10 Structure, function and maintenance standard SEN01353-00 Relief valve portion When stopping crusher When the crusher OFF switch is pressed, the supply of pressure oil from the pump to port Outline (MA) is stopped. With the oil from the outlet The relief valve portion consists of check port of the motor, the return circuit to the tank is valves (2) and (3), shuttle valves (4) and (5),...
Page 149: Grizzly Feeder Motor
SEN01353-00 10 Structure, function and maintenance standard Grizzly feeder motor P1: From control valve Specifications P2: From control valve Model: MSF-53 To hydraulic tank Theoretical delivery: 53.4 cc/rev Rated pressure: 20.6 MPa {210 kg/cm Max. speed: 3,000 rpm BR380JG-1E0...
Page 150: Conveyor Motor
10 Structure, function and maintenance standard SEN01353-00 Conveyor motor From control valve Specifications From control valve Model: MSE02-2-123-R02-1240-K000 To hydraulic tank Theoretical delivery: 398 cc/rev Max. pressure: 34.3 MPa {350 kg/cm Max. speed: 165 rpm BR380JG-1E0...
Page 151: Travel Motor
SEN01353-00 10 Structure, function and maintenance standard Travel motor HMV110ADT-2 Specifications MA. MA pressure pickup port MB. MB pressure pickup port Model BR380JG-1E0 From travel speed solenoid valve Item PA. From control valve Type HMV110ADT-2 PB. From control valve Theoretical To tank Max.
Page 152 10 Structure, function and maintenance standard SEN01353-00 1. Regulator piston 9. Check valve spring 17. Valve plate 2. Spring 10. Output shaft 18. Counterbalance valve 3. Regulator valve 11. Rocker cam 19. Ring 4. Spring 12. Retainer guide 20. Spool return spring 5.
Page 153 SEN01353-00 10 Structure, function and maintenance standard Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed Check valve spring Outside diameter length load length load 2.55 N 1.96 N 31.6 x 6.5 24.2 —...
Page 154 10 Structure, function and maintenance standard SEN01353-00 Operation of parking brake When stopping travel As the travel lever is placed in neutral, counter- When starting to travel balance valve spool (19) returns to the neutral As the travel lever is operated, pressurized oil position and closing the parking brake circuit.
Page 155 SEN01353-00 10 Structure, function and maintenance standard Brake valve Operation when pressurized oil is supplied The brake valve consists of suction safety Operating the travel lever conducts the pres- valve (18A) and counterbalance valve (18). surized oil from the control valve to port (PA). Functions and operations of respective compo- The pressurized oil push-opens suction safety nents shall conform to the following.
Page 156 10 Structure, function and maintenance standard SEN01353-00 The pressurized oil on the supply side flows to Operation of brake during travelling downhill chamber (S1) via orifice (E1) and orifice (E2) of If indication of the machine runaway is sensed the spool (19). while travelling downhill, the motor will be As the pressure in chamber (S1) goes above caused to rotate without load to decrease the...
Page 157 SEN01353-00 10 Structure, function and maintenance standard 2) Safety valve When the pressure rises above the set pressure of the suction safety valve, poppet (1) opens. The pressurized oil passes through notch (A1) Function of spool (19) into chamber (MA) of the circuit at As long as the machine travel is stopped (or it the opposite side.
Page 158: Valve Control
SEN01353-00 10 Structure, function and maintenance standard Valve control 1. Hydraulic pump 6. Travel PPC valve Positions of lever 2. Control valve 7. Travel lock EPC valve A. Neutral 3. Left travel lever 8. EPC valve B. Travel "Forward" 4. Right travel lever 9.
Page 159 10 Structure, function and maintenance standard SEN01353-00 Travel PPC valve From self pressure reducing valve P1: L.H. reverse P2: L.H. forward P3: R.H. reverse P4: R.H. forward P5: Travel signal P6: Steering signal To tank BR380JG-1E0...
Page 160 SEN01353-00 10 Structure, function and maintenance standard BR380JG-1E0...
Page 161 10 Structure, function and maintenance standard SEN01353-00 Plate Body Piston Collar Centering spring Metering spring Valve Damper Steering signal spool 10. Steering signal spool spring Unit: mm Check item Criteria Remedy Standard size Repair limit Free length x Installation Installation Installation Free length Centering spring...
Page 162 SEN01353-00 10 Structure, function and maintenance standard 1. Pressure reducing valve function The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle between drain chamber (D) and pump pres- Operation sure chamber (PP)] does not change until retainer (9) contacts spool (1).
Page 163 10 Structure, function and maintenance standard SEN01353-00 During fine control Therefore, the pilot pressure oil from the self (When control lever is returned) pressure reducing valve passes through fine When lever (5) starts to be returned, spool (1) control hole (f) and flows to chamber (A) from is pushed up by the force of centering spring port (P1) to push the control valve spool.
Page 164 SEN01353-00 10 Structure, function and maintenance standard Operation 1) When in neutral No output is made from respective output ports [from port (P1) to (P4)], travel signal [port (P5)] and steering signal [port (P6)]. BR380JG-1E0...
Page 165 10 Structure, function and maintenance standard SEN01353-00 2) During straight travel a The Illustration shows the circuit for travelling straight forward. When operating L.H. motor forward [port (P2) output] and R.H. motor forward [port (P4) out- put], pressure of both L.H. spring chamber (k) and R.H.
Page 166 SEN01353-00 10 Structure, function and maintenance standard 3) When steered or pivot-turned a The Illustration shows the circuit for travelling left forward (slow) and right forward (fast) operation. If the operation quantities of both levers are dif- Port (P4) pressure of the L.H. or R.H. PPC ferent from each other as in the steering opera- valves, whichever having a higher output pres- tion (if the difference of the pilot pressure...
Page 167 10 Structure, function and maintenance standard SEN01353-00 4) When counter-rotated a The illustration shows the circuit for travelling left reverse and right forward. When operating L.H. motor reverse [port (P1) output] and R.H. motor forward [port (P4) out- put], pressure of the R.H. spring chamber (l) only rises high.
Page 168: Solenoid Valve
SEN01353-00 10 Structure, function and maintenance standard Solenoid valve For straight travel and 2-stage relief, magnetic separator, side conveyor, bear lock reset, and travel lock 1. Straight travel and 2-stage relief To tank 2. Magnetic separator Control valve PST (Straight travel) (2-stage relief) 3.
Page 169 10 Structure, function and maintenance standard SEN01353-00 1. Connector 5. Spool 2. Movable core 6. Block 3. Coil 7. Spring 4. Cage Operation When solenoid is de-energized When solenoid is energized When the signal current does not flow from the When the signal current flows from the control- controller, solenoid (3) is de-energized.
Page 170: Epc Valve
SEN01353-00 10 Structure, function and maintenance standard EPC valve 1. Accessory EPC valve 7. Spool To hydraulic tank 2. Feeder forward EPC valve 8. Spring C1. To control valve (Port P1) 3. Crusher forward EPC valve 9. Rod C2. To control valve (Port P5) 4.
Page 171 10 Structure, function and maintenance standard SEN01353-00 Travel lock EPC valve 1. Body 4. Coil C. To control valve 2. Spool 5. Plunger P. From 5-spool ON/OFF valve 3. Rod 6. Connector T. To hydraulic tank Unit: mm Check item Criteria Remedy Standard size...
Page 172 SEN01353-00 10 Structure, function and maintenance standard Function Operation The EPC valve consists of the proportional When signal current is 0 solenoid portion and the hydraulic valve por- (coil is de-energized) tion. When there is no signal current flowing from When it receives signal current (i) from the the controller to coil (14), coil (14) is de-ener- pump controller, it generates the EPC output...
Page 173 10 Structure, function and maintenance standard SEN01353-00 When signal current is very small When signal current is maximum (coil is energized) (coil is energized) When a very small signal current flows to coil As the signal current flows to coil (5), coil (5) is (5), coil (5) is energized, and a propulsion force energized.
Page 174: Electromagnetic Selector Valve
SEN01353-00 10 Structure, function and maintenance standard Electromagnetic selector valve For lock cylinder 1. Body Specifications 2. Spring Model: DSG-01-3C4-D24 3. Coil assembly Rated pressure: 4. Push pin 30.9 MPa {315 kg/cm 5. Spool Rated oil flow: 40 l/min. 6. Cap nut Voltage: DC 24 V A.
Page 175 10 Structure, function and maintenance standard SEN01353-00 For Conveyor motor cylinder 1. Body Specifications 2. Spring Model: DSG-01-3C2-D24 3. Coil assembly Rated pressure: 4. Push pin 30.9 MPa {315 kg/cm Rated oil flow: 20 l/min. 5. Spool 6. Cap nut Voltage: DC 24 V A.
Page 176: Hydraulic Cylinder
SEN01353-00 10 Structure, function and maintenance standard Hydraulic cylinder Conveyor elevation cylinder Side conveyor cylinder Lock cylinder BR380JG-1E0...
Page 177 10 Structure, function and maintenance standard SEN01353-00 Unit: mm Check item Criteria Remedy Tolerance Standard Standard Clearance Name of size Clearance limit cylinder Shaft Hole Clearance between piston –0.020 +0.081 0.011 – Conveyor 0.487 rod and bushing elevation –0.072 –0.009 0.153 Side –0.020...
Page 179 SEN01354-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Work equipment Grizzly feeder semiautomatic system ......................2 Abnormal load stop system..........................3 Primary belt conveyor ............................. 4 Grizzly feeder..............................8 Crusher ................................
Page 180: Grizzly Feeder Semiautomatic System
SEN01354-00 10 Structure, function and maintenance standard Grizzly feeder semiautomatic system Function This system receives the signal from the front pump pressure sensor installed to main pump outlet circuit (1) and inputs it to the CR710 con- troller in control box (2). If this system detects an overload on the crusher, it stops supplying material from grizzly feeder (3) to the crusher.
Page 181: Abnormal Load Stop System
10 Structure, function and maintenance standard SEN01354-00 Abnormal load stop system Function This system receives the signal from the pres- sure sensor installed to the inlet circuit of each actuator and inputs it to the CR710 controller for control. If the inlet pressure of each actua- tor increases above the set pressure, the whole work equipment, excluding the engine and travel unit, stops immediately.
Page 182: Primary Belt Conveyor
SEN01354-00 10 Structure, function and maintenance standard Primary belt conveyor BR380JG-1E0...
Page 183 10 Structure, function and maintenance standard SEN01354-00 BR380JG-1E0...
Page 184 SEN01354-00 10 Structure, function and maintenance standard Conveyor belt Bearing unit Rubber Belt cleaner Carrier roller Guide roller Return roller (Outside) Rubber Scraper rubber 10. Rubber 11. Rubber 12. Slide plate 13. Rubber 14. Bearing 15. Frame 16. Head pulley 17.
Page 185: Grizzly Feeder
SEN01354-00 10 Structure, function and maintenance standard Grizzly feeder Hopper (Fixed type) M-type chute selector lever Upper grizzly bar Lower grizzly bar Feeder fixing pin (For transportation) M-type chute Vibrator Grizzly feeder Trough surface BR380JG-1E0...
Page 186: Crusher
10 Structure, function and maintenance standard SEN01354-00 Crusher Supply opening guard Oil filler plug Scattering prevention guard V-sheave Water sprinkler pipe Drain plug V-belt Turnbuckle Crusher motor 10. Crusher assembly BR380JG-1E0...
Page 187 SEN01354-00 10 Structure, function and maintenance standard BR380JG-1E0...
Page 188 10 Structure, function and maintenance standard SEN01354-00 Cheek plate Protector V-belt Lock cylinder Crusher motor Swing tooth wedge bolt Fixing link Toggle seat Toggle plate 10. Toggle seat 11. Swing jaw 12. Swing tooth 13. Crusher chamber 14. Fixed tooth 15.
Page 189 SEN01354-00 10 Structure, function and maintenance standard Principle of crushing With the movement of swing jaw (1), contact (a) caused by the eccentricity of crankshaft (2) and the rocking motion of toggle plate (3) moves in a circle. The closer it comes to con- tact (c), the more it moves in a narrow oval movement.
Page 190: Crusher Tooth Tip Adjustment System
SEN01354-00 10 Structure, function and maintenance standard Crusher tooth tip adjustment system Fixed tooth Swing tooth Fixing link Revolution angle sensor Toggle plate Lock cylinder Swing jaw BR380JG-1E0...
Page 191 10 Structure, function and maintenance standard SEN01354-00 Function Revolution angle sensor (3) senses tooth moving distance (b) through swing jaw (8), toggle plate (7), fixing link (6), and rod (5). The controller operate lock cylinder (4) so that tooth clearance (a) set by the machine monitor will be obtained.
Page 192 SEN01354-00 10 Structure, function and maintenance standard Revolution angle sensor Revolution angle sensor Wiring harness Connector Specifications Type of sensor: Resistance board type Total resistance: 5 kz ± 20% Mechanical revolution angle:200° ± 4° Electrical revolution angle: 180° ± 2° Rated voltage: 0.5 W (25°C) BR380JG-1E0...
Page 193: Vibrator
10 Structure, function and maintenance standard SEN01354-00 Vibrator Grizzly feeder motor Shaft Bearing Gear Housing Unbalance weight Drain plug Oil level gauge Filler plug 10. Breather 11. V-checker installation position (at maintenance) Gear matches and unites two marks (B). BR380JG-1E0...
Page 194 SEN01354-00 10 Structure, function and maintenance standard Check item Criteria Remedy Standard value Repair limit Frequency (min.) con- firmed by V checker 550 (cpm) 468 – 632 Replace Frequency (max.) con- 1,050 (cpm) 1,000 – 1,100 firmed by V checker Vibrator case oil level Center of level window ±...
Page 196 SEN01355-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure, function and maintenance standard Electrical system Engine control ..............................2 Work equipment and pump controller ......................12 Electronic control system ..........................15 Machine monitor system ..........................28 Sensor................................
Page 197: Engine Control
SEN01355-00 10 Structure, function and maintenance standard Engine control Starting motor Outline Supply pump The engine can be started and stopped with Engine controller starting switch (5) only. Fuel control dial The control signal of fuel control dial (4) is Starting switch input to engine controller (3), which controls Battery relay...
Page 198 10 Structure, function and maintenance standard SEN01355-00 Operation of system Stopping engine Starting engine When detecting that the starting switch is set to the “STOP” position, the engine controller cuts When the starting switch is turned to the the signal of the supply pump drive solenoid to START position, the starting signal flows to the stop the engine.
Page 199 SEN01355-00 10 Structure, function and maintenance standard Component Fuel control dial Knob Dial Spring Ball Potentiometer Connector BR380JG-1E0...
Page 200 10 Structure, function and maintenance standard SEN01355-00 Function Turning knob (1) rotates the shaft of potentiom- eter (5). The rotation of the shaft changes the resis- tance of the variable resistor in potentiometer (5), sending any throttle signal to the engine controller.
Page 201 SEN01355-00 10 Structure, function and maintenance standard Engine controller Input and output signals CN-CE01 Meanings of signal classes in the terminal Input/ Pin No. Signal name table shown below are as follows. output A: Power NC(*) — B: Input NC(*) —...
Page 202 10 Structure, function and maintenance standard SEN01355-00 CN-CE01 CN-CE02 Input/ Input/ Pin No. Signal name Pin No. Signal name output output NC(*) — NC(*) NC(*) — NC(*) NC(*) NC(*) IMA PWM RETURN NC(*) Air pressure sensor supply NC(*) NC(*) — NC(*) NC(*) NC(*)
Page 203 SEN01355-00 10 Structure, function and maintenance standard Coolant temperature sensor Connector Sensor O-ring Oil pressure switch Connector Sensor O-ring BR380JG-1E0...
Page 204 10 Structure, function and maintenance standard SEN01355-00 Rotation sensor Connector Sensor O-ring Boost pressure and temperature sensor Connector Sensor O-ring BR380JG-1E0...
Page 205 SEN01355-00 10 Structure, function and maintenance standard WIF (water-in-fuel detection) sensor Connector Tube Sensor O-ring Engine oil level sensor Connector Bracket Float Switch BR380JG-1E0...
Page 206: Work Equipment And Pump Controller
SEN01355-00 10 Structure, function and maintenance standard Work equipment and pump controller BR380JG-1E0...
Page 207 10 Structure, function and maintenance standard SEN01355-00 Input and output signals CN-C1 CN-C2 Input/ Input/ Pin No. Signal name Pin No. Signal name Output Output Secondary conveyor press. sensor Input Output R pump pressure sensor Input Clearance setting mode select Input switch (Auto) Vibrator screen press.
Page 208 SEN01355-00 10 Structure, function and maintenance standard CN-C3 Input/ Pin No. Signal name Output PWR_IN_BATT Input PWR_IN_BRY Input GND_ACT — Output Conveyor FWD. solenoid relay Output LS EPC Output Output Conveyor REV. solenoid relay Output Radio Ctrl work switch Input Feeder ON switch Input PWR_IN_BATT...
Page 209: Electronic Control System
10 Structure, function and maintenance standard SEN01355-00 Electronic control system Control function Engine and pump composite control function Pump and valve control function Electronic control system Auto-warm-up and overheat prevention function Travel control function Self-diagnosis function a For the self-diagnosis function, see “Troubleshooting”. BR380JG-1E0...
Page 210 SEN01355-00 10 Structure, function and maintenance standard Travel control function BR380JG-1E0...
Page 211 10 Structure, function and maintenance standard SEN01355-00 BR380JG-1E0...
Page 212 SEN01355-00 10 Structure, function and maintenance standard Engine and pump compound control function BR380JG-1E0...
Page 213 10 Structure, function and maintenance standard SEN01355-00 Function Matching point: 107.0 kW/1,800 rpm {143.5 HP/1,800 rpm} The work equipment and pump controller con- trols the pump so that it can absorb all the Engine speed is always controlled so that it is torque at the output points of the engine kept around the matching point specified depending on the pump absorption torque...
Page 214 SEN01355-00 10 Structure, function and maintenance standard Pump and valve control function BR380JG-1E0...
Page 215 10 Structure, function and maintenance standard SEN01355-00 LS control function The change point (LS set differential pressure) of the pump discharge in the LS valve is changed by changing the output pressure from the LS-EPC valve to the LS valve according to the operating condition of the actuator.
Page 216 SEN01355-00 10 Structure, function and maintenance standard Automatic engine warm-up and overheat prevention function Function automatic engine warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts. The overheat prevention function reduces the pump load when coolant or hydraulic oil tem- perature is too high during operation to protect the engine from overheating.
Page 217 10 Structure, function and maintenance standard SEN01355-00 Automatic engine warm-up function After the engine is started, if the engine coolant temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All of following conditions) Operated Coolant temperature: Below 30°C Engine speed: 1,200 rpm...
Page 218 SEN01355-00 10 Structure, function and maintenance standard Travel control function Function This function is used to control the pump and select the manual or automatic travel speed change mode for travel performance matched to the contents of work and jobsite during travel.
Page 219 10 Structure, function and maintenance standard SEN01355-00 Travel speed change function Manual change with travel speed selector switch If the travel speed selector switch is changed over Lo, Mi and Hi, the work equipment and pump controller controls the pump capacity at each gear speed as shown below to change the travel speed.
Page 220 SEN01355-00 10 Structure, function and maintenance standard System component parts Plug Switch Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm Resetting (OFF) pressure:0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm Function The travel PPC valve has 2 travel PPC oil pressure switches, which check the travel lever...
Page 221 10 Structure, function and maintenance standard SEN01355-00 Pump pressure sensor Sensor Connector Function The relationship between the pressure applied to sensors (P) and output voltage (E) is shown The pump pressure sensor is installed to the in the figure below. inlet circuit of the control valve.
Page 222: Machine Monitor System
SEN01355-00 10 Structure, function and maintenance standard Machine monitor system Each sensor Caution signal Coolant temperature, hydraulic oil tempera- Work equipment and pump controller ture, fuel level signal Sensor signal Machine monitor Power source Switch Battery The monitor system monitors the condition of The machine monitor also has various mode the machine with sensors installed on various selector switches and functions to operate the...
Page 223 SEN01355-00 10 Structure, function and maintenance standard Machine monitor Outline The machine monitor has the functions to display various items and the functions to select modes and electric parts. The machine monitor has a CPU (Central Process- ing Unit) in it to process, display, and output the information.
Page 224 10 Structure, function and maintenance standard SEN01355-00 Input and output signals CN 1 CN 3 Input/ Input/ Pin No. Signal name Pin No. Signal name output output Key switch (Battery) Input — Key switch (Battery) Output — — — Key switch (C) Input —...
Page 225 SEN01355-00 10 Structure, function and maintenance standard Monitor display and operation section Display section A : Screen of check before starting E1: Main screen of inspection mode (manual) B : Main screen of working mode E2: Main screen of inspection mode (semi automatic) C : Main screen of travel mode E3: Main screen of inspection mode (automatic) D : Screen of maintenance overtime...
Page 226 10 Structure, function and maintenance standard SEN01355-00 Preheating monitor Engine coolant temperature monitor Radiator coolant level caution Engine coolant temperature gauge Charge level caution Engine oil pressure caution Travel speed monitor Service meter Engine oil level caution 10. Air cleaner clogging 11.
Page 227 SEN01355-00 10 Structure, function and maintenance standard Monitor items and display Symbol Display item Display method Time to continue setting Condition of preheating monitor Up to 30 sec Lighting Preheating 30 sec – 40 sec Flashing After 40 sec Engine coolant temperature Hydraulic oil temperature See gauge display on the next page Fuel level...
Page 228 10 Structure, function and maintenance standard SEN01355-00 Temperature or Gauge Range Indicator Buzzer sound volume Green Engine coolant temperature (°C) Green Green White Green Hydraulic oil temperature (°C) Green Green White Green 244.5 Green Green Fuel level (l) Green Green BR380JG-1E0...
Page 229 SEN01355-00 10 Structure, function and maintenance standard When any item has exceeded the maintenance period when check before starting is performed (all caution lamps light up) When the check before starting is performed, if an item which has exceeded the maintenance period lights up, the hydraulic oil temperature gauge and hydraulic oil temperature monitor are turned OFF and the follow- ing cautions are displayed.
Page 230 10 Structure, function and maintenance standard SEN01355-00 Display Symbol Displayed item Display range Display method section Working mode In working mode Set mode is displayed. In travel mode Travel speed Set mode is displayed. Lo, Mi, Hi In inspection mode Inspection mode Set mode is displayed.
Page 231 SEN01355-00 10 Structure, function and maintenance standard When machine is stopped in emergency Engine stop switch ON warning If the machine is stopped in an emergency, the fol- If engine stop switch (2) is depressed, the whole lowing are displayed. work equipment stops, the engine stops, the horn sounds, and the items shown below are displayed.
Page 232 SEN01355-00 10 Structure, function and maintenance standard Operation section Crusher clearance adjustment switch Crusher manual rotation switch Conveyor manual rotation switch Crusher speed setting screen selector switch Feeder speed setting screen selector switch Crusher load setting screen selector switch Operation switch Buzzer cancel switch Maintenance switch 10.
Page 233 10 Structure, function and maintenance standard SEN01355-00 Crusher clearance adjustment switch This switch is used to adjust the crusher clear- ance manually. This switch is effective when the manual adjustment mode (M mode) is selected in the inspection mode. Crusher manual rotation switch This switch is used to rotate the crusher manu- ally.
Page 234 SEN01355-00 10 Structure, function and maintenance standard Display and function of screen Work mode If work mode (B) is selected with the mode selector Travel mode/Work mode switch (1), you can check the operating condition of each work equipment and find out the work equip- The monitor screen is set in the travel mode, ment receiving an overload or abnormal load.
Page 235 10 Structure, function and maintenance standard SEN01355-00 If an abnormal load is applied and a red lamp lights up (See the table on the next page), depress return switch (9) or restart the abnor- mally loaded work equipment, and the lamp is reset.
Page 236 SEN01355-00 10 Structure, function and maintenance standard Inspection mode If work mode (B) is selected with the mode selector switch (2), you can check the operat- ing condition of each work equipment and find out the work equipment receiving an overload or abnormal load.
Page 237 10 Structure, function and maintenance standard SEN01355-00 a The input range of crusher clearance set value (12) is 50 – 150 mm. When settle switch (7) is depressed, if the input value is out of the above range, it is returned to the former value. Automatic (A) Just after this screen appears, the cursor is at clearance set settle monitor (11).
Page 238 SEN01355-00 10 Structure, function and maintenance standard Crusher mode setting function Feeder speed setting function This function is used to set the feeder speed. This function is used to set the crusher speed. The material is sent to the crusher at a proper This function is used while the ordinary screen speed by selecting the feeder speed according (travel mode, work mode, or inspection mode)
Page 239 10 Structure, function and maintenance standard SEN01355-00 Crusher load setting function This function is used to set the crusher load. The material is crushed properly, regardless of its type, by adjusting the crusher pressure switch in proportion to the load level. This function is used while the ordinary screen (travel mode, work mode, or inspection mode) is displayed.
Page 240 SEN01355-00 10 Structure, function and maintenance standard Maintenance function Method of checking condition of maintenance items a Perform the following while the operator W h e n e a c h o f t h e 1 0 m a i n t e n a n c e i t e m s approaches the time of maintenance such as screen is displayed.
Page 241 10 Structure, function and maintenance standard SEN01355-00 Maintenance operation After selecting, depress input check switch (3), and the maintenance reset screen appears. Check the contents of the maintenance reset screen. If there is no problem, depress input check switch (3) to display the check screen. If you made a mistake in selecting the item, etc., depress return switch (4) to return to the mainte- nance table screen.
Page 242 SEN01355-00 10 Structure, function and maintenance standard Brightness, contrast adjustment function Press control switch (2) and adjust the bright- ness and contrast as desired. This function is used to adjust the brightness and contrast of the display. Control switch Actuation Adjustment method Flow level bar graph extends to the right...
Page 243 10 Structure, function and maintenance standard SEN01355-00 Password function While the screen is waiting for an input, input the 8- digit number "19210513" with the numeral keys. If a password is set in advance, the engine does After the last digit (3) is input, the screen to check not start unless the password is input.
Page 244 SEN01355-00 10 Structure, function and maintenance standard On the input screen (where symbols of a lock Function of checking service meter and a key are displayed), input a 4-digit num- When the starting switch is turned OFF, if ber and depress input check switch (3). return switch (1) and operation switch (2) of the After the input check switch is depressed, the monitor are depressed and held simulta-...
Page 245 10 Structure, function and maintenance standard SEN01355-00 Function of displaying user code If there are multiple service codes/failure codes which cause the service codes, all of If there is any trouble in operation of the them are displayed at intervals of 3 seconds. machine, the user code is displayed on the Even if there is a service code/failure code monitor to urge the operator to take remedy.
Page 246: Sensor
SEN01355-00 10 Structure, function and maintenance standard Sensor The signals from the sensors are input to the panel directly. Either side of a sensor of contact type is always connected to the chassis ground. Sensor name Type of sensor When normal When abnormal Engine oil level Contact...
Page 247 10 Structure, function and maintenance standard SEN01355-00 Engine oil level sensor, Hydraulic oil level sensor Connector Float Bracket Switch Engine oil pressure sensor (For low pressure) Plug Diaphragm Contact ring Spring Contact Terminal BR380JG-1E0...
Page 248 SEN01355-00 10 Structure, function and maintenance standard Coolant temperature sensor, Hydraulic oil temperature sensor Thermistor Tube Body Wire Tube Connector Fuel level sensor Float Connector Cover Variable resistor BR380JG-1E0...
Page 249 10 Structure, function and maintenance standard SEN01355-00 Air cleaner clogging sensor BR380JG-1E0...
Page 251: Standard Value Table
SEN02288-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 20 Standard value table Standard service value table Standard value table for engine ......................2 Standard value table for chassis ......................3 BR380JG-1E0...
Page 252: Standard Value Table For Engine
SEN02288-00 20 Standard value table Standard value table for engine Applicable model BR380JG-1E0 SAA6D107E-1 Engine Standard value for new Item Measurement condition Unit Judgement criteria machine High idle 2,330 ± 50 2,330 ± 50 • Coolant temperature: Engine speed Low idle 1,050 ±...
Page 253: Standard Value Table For Chassis
20 Standard value table SEN02288-00 Standard value table for chassis Applicable Model BR380JG-1E0 Cate- Standard Permissible Check Item Measurement Condition Unit gory value value • Engine coolant temperature: To be within operating range 2 pumps • Oil temperature: 45 – 55°C in relief 2,050 ±...
Page 254 SEN02288-00 20 Standard value table Applicable Model BR380JG-1E0 Categ Standard Permissible Check Item Measurement Condition Unit value value • Oil temperature: 45 – 55°C • Run engine at full throttle 3.9 ± 1.0 3.9 ± 1.0 Unload pressure • Set all levers in neutral {40 ±...
Page 255 20 Standard value table SEN02288-00 Applicable Model BR380JG-1E0 Categ Standard Permissible Check Item Measurement Condition Unit value value Hydraulic drift of travel • Stop engine • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket side up •...
Page 256 SEN02288-00 20 Standard value table Applicable Model BR380JG-1 Cate Check Item Measurement Condition Unit Standard value Permissible value gory 297 – 363 280 – 380 Standard pulley 153 – 187 136 – 204 1) Crusher speed (Forward) 261 – 319 246 –...
Page 257 20 Standard value table SEN02288-00 Cate Discharge amount of main piston pump (each 1 pump) gory Pump speed: At 2050 rpm, PC current 310 mA Test pump dis- Discharge pres- Standard value for Judgement stan- Check Average pressure charge pressure sure of other pump discharge amount dard lower limit Q...
Page 259: Testing And Adjusting Testing And Adjusting, Part
SEN02303-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting Testing and adjusting, Part 1 Tools for testing, adjusting, and troubleshooting..................... 3 Measuring engine speed..........................6 Measuring intake air pressure (boost pressure) ..................... 7 Checking exhaust gas color..........................
Page 260 SEN02303-00 30 Testing and adjusting Measuring control circuit basic pressure....................... 29 Measuring and adjusting oil pressure in pump PC control circuit ..............30 Measuring and adjusting oil pressure in pump LS control circuit ..............33 Measuring solenoid valve output pressure....................37 Measuring PPC valve output pressure......................
Page 261: Tools For Testing, Adjusting, And Troubleshooting
30 Testing and adjusting SEN02303-00 Tools for testing, adjusting, and troubleshooting Sym- Testing/Adjusting item Part No. Part name Remarks Measuring intake air pres- – 101 – 200 kPa 799-201-2202 Boost gauge kit sure (boost pressure) {– 760 – 1,500 mmHg} 1 799-201-9001 Handy smoke checker Checking exhaust gas Bosch index: 0 –...
Page 262 SEN02303-00 30 Testing and adjusting Sym- Testing/Adjusting item Part No. Part name Remarks Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 799-101-5002 Hydraulic tester {25, 60, 400, 600 kg/cm Measuring basic pressure Pressure gauge: 58.8 MPa 790-261-1204 Digital hydraulic tester of control circuit {600 kg/cm 799-401-3100 Adapter Size: 02...
Page 263 30 Testing and adjusting SEN02303-00 Sym- Testing/Adjusting item Part No. Part name Remarks Removal and installation Commercially 21 mm deep socket of engine coolant temper- — Socket available (MITOLOY 4ML-21 or equivalent) ature sensor a For the model names and part Nos. of the T-boxes and T-adapters used for troubleshooting for the machine monitor, controllers, sensors, actuators, electrical equipment, and wiring harnesses, see “Trou- bleshooting (General information on troubleshooting), List of T-boxes and T-adapters”.
Page 264: Measuring Engine Speed
SEN02303-00 30 Testing and adjusting Measuring engine speed a Measure the engine speed with the monitoring function of the machine monitor. a Measure the engine speed under the following condition. Engine coolant temperature: Within oper- ating range Hydraulic oil temperature: Within operat- ing range Preparation work Operate the machine monitor so that the...
Page 265: Measuring Intake Air Pressure (Boost Pressure)
30 Testing and adjusting SEN02303-00 Measuring intake air pressure Run the engine at middle or higher speed and bleed oil from the hose. (boost pressure) a Insert the connecting parts of the gauge a Measuring tools for intake air pressure (boost and hose about a half and open the self- pressure) seal on the hose side repeatedly, and the...
Page 266: Checking Exhaust Gas Color
SEN02303-00 30 Testing and adjusting Checking exhaust gas color a Checking tools for exhaust gas color Symbol Part No. Part name 799-210-9001 Handy smoke checker Commercially Smoke meter available Stop the machine on a level ground. Be careful not to touch any hot part when removing or installing the checking tools.
Page 267: Adjusting Valve Clearance
30 Testing and adjusting SEN02303-00 Adjusting valve clearance Rotate the crankshaft forward with gear C1 and set wide slit (b) of the rotation sensor ring a Measuring tools for valve clearance to projection top (a) of front cover. a Projection top (a) must be within the range Symbol Part No.
Page 268 SEN02303-00 30 Testing and adjusting Adjust the valve clearance according to the fol- lowing procedure. While fixing adjustment screw (3), loosen locknut (4). Insert clearance gauge C2 in the clearance between rocker arm (5) and crosshead (6) a n d a d j u s t t h e v a l v e c l e a r a n c e w i t h adjustment screw (3).
Page 269: Measuring Compression Pressure
30 Testing and adjusting SEN02303-00 Measuring compression pressure1 Disconnect injector wiring harness. Using tool D2, remove injector (4). a Measuring tools for compression pressure Symbol Part No. Part name 795-502-1590 Compression gauge 795-799-6700 Puller 795-790-4410 Adapter 6754-11-3130 Gasket Stop the machine on a level ground. a Measure the compression pressure under the following condition.
Page 270 SEN02303-00 30 Testing and adjusting Disconnect CE03 connector (5) of the engine After finishing measurement, remove the mea- controller. suring tools and return the removed parts. a Install the injector and inlet connector If the connector is not disconnected, the engine will start during measure- according to the following procedure.
Page 271: Measuring Blow-By Pressure
30 Testing and adjusting SEN02303-00 Measuring blow-by pressure While running the engine at high idle, relieve the travels (Right and left) and measure the a Measuring tools for blow-by pressure blow-by pressure. a Read the gauge when the pointer is stabi- Symbol Part No.
Page 272: Measuring Engine Oil Pressure
SEN02303-00 30 Testing and adjusting Measuring engine oil pressure Run the engine and measure the engine oil pressure at high idle and low idle. a Measuring tools for engine oil pressure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-2320 Hydraulic gauge Stop the machine on a level ground.
Page 273: Handling Fuel System Parts
30 seconds after the engine is a Precautions for replacing fuel filter cartridge stopped. Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts cartridge. are removed, the residual pressure in the fuel Since the common rail fuel injection system circuit must be released completely.
Page 274: Measuring Fuel Pressure
SEN02303-00 30 Testing and adjusting Measuring fuel pressure Install adapter G2 and nipple [1] of hydraulic tester G1 and connect them to a Measuring tools for fuel pressure oil pressure gauge [2]. a Use the oil pressure gauge of 2.5 MPa Symbol Part No.
Page 275 30 Testing and adjusting SEN02303-00 Measuring pressure in fuel return circuit After finishing measurement, remove the Open the engine hood and remove fuel measuring tools and return the removed pressure pickup plug (2) from the fuel parts. return block. Fuel pressure pickup plug: 24 ±...
Page 276: Measuring Fuel Return Rate And Leakage
SEN02303-00 30 Testing and adjusting Measuring fuel return rate and leakage a Measuring tools for fuel return rate and leakage Symbol Part No. Part name 795-790-4700 Tester kit 795-790-6700 Adapter 6754-71-5340 Connector 6754-71-5350 Washer Commercially Measuring cylinder available Commercially Stopwatch available Run the engine at low idle and measure the return rate in 1 minute with measuring...
Page 277 30 Testing and adjusting SEN02303-00 Measuring leakage from pressure limiter Open the engine hood and disconnect return hose (2) of the pressure limiter. a Install the seal washer to the connec- tor bolt. After finishing measurement, remove the mea- suring tools and return the removed parts. Joint bolt: 24 ±...
Page 278: Bleeding Air From Fuel Circuit
SEN02303-00 30 Testing and adjusting Bleeding air from fuel circuit Install connector bolt [3] of adapter H2 instead of the removed connector bolt, a If fuel is used up or if a fuel circuit part is and connect test hose [4]. removed and installed, bleed air from the fuel a Lay the test hose so that it will not circuit according to the following procedure.
Page 279 30 Testing and adjusting SEN02303-00 a Air bleeding route of fuel circuit Fuel tank o Pre-filter o Feed pump o Main filter o Metering unit o Fuel tank BR380JG-1E0...
Page 280: Checking Fuel Circuit For Leakage
SEN02303-00 30 Testing and adjusting Checking fuel circuit for leakage Check the fuel piping and devices for fuel leak- age. Very high pressure is generated in the high- a Check mainly around the high-pressure pressure circuit of the fuel system. If fuel circuit parts coated with the color checker leaks while the engine is running, it is dan- for fuel leakage.
Page 281: Checking And Adjusting Track Shoe Tension
30 Testing and adjusting SEN02303-00 Checking and adjusting track Adjusting shoe tension a If the track shoe tension is abnormal, adjust it according to the following procedure. Checking Run the engine at low idle and drive the Increasing tension machine forward by the length of track on Add grease through grease fitting (1) with ground, and then stop slowly.
Page 282 SEN02303-00 30 Testing and adjusting Decreasing tension Loosen valve (2) to discharge grease, and then tighten it. Do not loosen the valve more than 1 turn. If it is loosened more, it may jump out because of the high-pres- sure grease in it. To check that the tension is normal, run the engine at low idle and move the machine forward by the length of track on...
Page 283: Measuring And Adjusting Oil Pressure In Work Equipment And Travel Circuits
30 Testing and adjusting SEN02303-00 Measuring and adjusting oil Preparation work Stop the engine and gradually loosen pressure in work equipment and the oil filler cap of the hydraulic tank to travel circuits release the air from the tank. a Measuring and adjusting tools for oil pressure Remove oil pressure pickup plugs (1) and in work equipment and travel circuits (2).
Page 284 SEN02303-00 30 Testing and adjusting Combination of pump, actuator, and valve Measuring travel relief pressure a When the oil from the pumps is divided, Run the engine and lock the travel mecha- the front pump and rear pump act inde- nism.
Page 285 30 Testing and adjusting SEN02303-00 Adjusting Adjusting work equipment safety valves a If the work equipment safety valves are a The unload valve cannot be adjusted. abnormal, adjust safety valves (7), (8), (10) and (11) of the work equipment Adjusting main relief pressure (Travel) according to the following procedure.
Page 286 SEN02303-00 30 Testing and adjusting (9): Accessory valve After finishing adjustment, check The solenoid selector valve drives again that the oil pressure is normal actuators of 3 kinds. according to the above described a Adjusting relief pressure (High pressure measurement procedure. a If the high pressure setting side is setting side) Primary conveyor motor...
Page 287: Measuring Control Circuit Basic Pressure
30 Testing and adjusting SEN02303-00 Measuring control circuit basic Install nipple [2] and oil pressure gauge [1] of hydraulic tester K1. pressure a Use the oil pressure gauge of 5.9 MPa {60 a Measuring tools for control circuit basic pres- kg/cm sure Symbol...
Page 288: Measuring And Adjusting Oil Pressure In Pump Pc Control Circuit
SEN02303-00 30 Testing and adjusting Measuring and adjusting oil pressure in pump PC control circuit a Measuring and adjusting tools for oil pressure in pump PC control circuit Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5220 Nipple (10 ×...
Page 289 30 Testing and adjusting SEN02303-00 Measuring PC-EPC valve output pressure Remove oil pressure pickup plug (5). Install nipples L2 and connect them to oil pressure gauges [1] of hydraulic tester L1. a Use the oil pressure gauges of 5.9 MPa {60 kg/cm Start the engine.
Page 290 SEN02303-00 30 Testing and adjusting a Measuring condition and method of Loosen locknut (8). a Before judgment: If the output pressures are loosening locknut, make in the following range, the PC-EPC counter mark at the adjustment screw end valve is normal. so that you can see the position of the locknut before the adjustment (and you All work...
Page 291: Measuring And Adjusting Oil Pressure In Pump Ls Control Circuit
30 Testing and adjusting SEN02303-00 Measuring and adjusting oil Measuring LS valve output pressure (servo piston inlet pressure) pressure in pump LS control a Measure the LS valve output pressure circuit (servo piston inlet pressure) and pump a Measuring and adjusting tools for oil pressure discharge pressure simultaneously and in pump LS control circuit compare them.
Page 292 SEN02303-00 30 Testing and adjusting Install nipple M2 and connect them to oil Start the engine. pressure gauge [1] of hydraulic tester M1. While running the engine at high idle, a Use the oil pressure gauges of 58.8 measure the pump discharge pressure MPa {600 kg/cm and LS valve output pressure (servo pis- ton inlet pressure) simultaneously under...
Page 293 30 Testing and adjusting SEN02303-00 (3): Front LS pressure pickup plug The figure shows the LS pressure side. (4): Rear LS pressure pickup plug Run the engine. Install nipple M2 and connect it to differen- While running the engine at high idle tial pressure gauge M3 or the oil pressure under the condition shown in the table, gauge [1] of hydraulic tester M1.
Page 294 SEN02303-00 30 Testing and adjusting Measuring LS-EPC valve output pressure Adjusting Remove oil pressure pickup plug (5). Adjusting LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following procedure. (6): Front pump LS valve (7): Rear pump LS valve Install nipple M2 and connect it to oil pres- sure gauge of hydraulic tester M1.
Page 295: Measuring Solenoid Valve Output Pressure
30 Testing and adjusting SEN02303-00 Measuring solenoid valve output pressure a Measuring tools for solenoid valve output pres- sure Symbol Part No. Part name 799-101-5002 Hydraulic tester 790-261-1204 Digital hydraulic tester 799-401-3100 Adapter (Size 02) Stop the machine on a level ground. Stop the engine and loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic...
Page 296 SEN02303-00 30 Testing and adjusting Run the engine at high idle, operate the control Operation table of magnetic separator solenoid levers and switches to turn the solenoid valve valve ON or OFF, and measure the oil pressure. Operating condition Operation a For the conditions for turning the solenoid valve ON and OFF, see the operation Magnetic separator signal...
Page 297 30 Testing and adjusting SEN02303-00 Operation table of crusher reverse EPC valve Output: Left Operating condition MPa {kg/cm Approx. 2.9 Crusher reverse signal {30} (Crusher speed: MAX) 0 {0} Operation table of vibratory sieve solenoid valve (if equipped) Operating condition Operation Vibratory sieve signal (Vibratory sieve ON switch is...
Page 298: Measuring Ppc Valve Output Pressure
SEN02303-00 30 Testing and adjusting Measuring PPC valve output Install nipple P2 and connect it to oil pressure gauge [1] of hydraulic tester P1. pressure a Use the oil pressure gauge of 5.9 MPa {60 a Measuring tools for PPC valve output pressure kg/cm Symbol Part No.
Page 299: Measuring Oil Leakage
30 Testing and adjusting SEN02303-00 Measuring oil leakage Run the engine at high idle, relieve the travel circuit, and measure the oil leakage. a Measuring tools for oil leakage Before operating the travel lever, check the position and locking direction of Symbol Part No.
Page 300: Bleeding Air From Each Part
SEN02303-00 30 Testing and adjusting Bleeding air from each part Air bleeding procedure Air bleeding item Bleeding Bleeding Checking Bleeding Bleeding Bleeding air from air from oil level air from Starting air from air from grizzly belt con- and start- hydraulic engine crusher...
Page 301 30 Testing and adjusting SEN02303-00 a If the oil does not flow out of the air bleeder: If the oil does not flow out, stop the Leave bleeder (1) loosened, disconnect engine, disconnect the drain hose, and fill drain hose (2), and remove elbow (3). the motor case with oil.
Page 302 SEN02303-00 30 Testing and adjusting Bleeding air from conveyor motor 1) Run the engine at low idle, loosen drain hose (1), and check that oil flows out of the drain hose. 2) If the oil does not flow out, stop the engine, and fill the motor case with hydraulic oil.
Page 303: Testing Travel Deviation
30 Testing and adjusting SEN02303-00 Testing travel deviation a When traveling on flat ground Set the machine in the travel posture. a To set the machine in the travel posture, raise the primary belt conveyor and hitch mount hook (1) in fixing position for travel (a) securely.
Page 304: Adjusting Mirrors
SEN02303-00 30 Testing and adjusting Adjusting mirrors BR380JG-1E0...
Page 305 30 Testing and adjusting SEN02303-00 Adjusting mirror (a1) Loosen bolt (1) of the mirror and adjust the mirror so that the operator can best see the view in front of the machine which is a blind corner from the operator's seat. a When installing the mirror, adjust so that it is possible to see any persons at the front left and right edges of the machine (both sides of...
Page 307: Testing And Adjusting, Part 2
SEN02304-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting Testing and adjusting, Part 2 Special functions of machine monitor ......................2 BR380JG-1E0...
Page 308: Special Functions Of Machine Monitor
SEN02304-00 30 Testing and adjusting Special functions of machine monitor [1]: Figure input switch 1 ]: Return switch [2]: Figure input switch 2 ]: Upward move switch [3]: Figure input switch 3 ]: Downward move switch [4]: Figure input switch 4 [ ]: Input confirmation switch [5]: Figure input switch 5 [6]: Figure input switch 6...
Page 309 This mode is used for special setting, testing, adjusting or troubleshooting. Operator menu Service menu 1 Password input and setting function 20 Function of monitoring [01] 2 KOMATSU logo display screen Electrical systems Function of abnor- mality record [02] 3 Check before starting function...
Page 310 Above display is available only when the maintenance function is selected. KOMATSU logo display screen KOMATSU logo is displayed for 2 seconds as a password is entered (as a password is speci- fied) or the starting switch is turned ON.
Page 311 30 Testing and adjusting SEN02304-00 Caution items display function Function of working mode Succeeding display of the check before start- If the working mode is selected with the mode ing scre en, an ap plica ble caution m ark selector switch of the main control box, the appears pointing a check before starting item operator can check the operating condition of on which a problem was found.
Page 312 SEN02304-00 30 Testing and adjusting Function of setting feeder speed 11. Function of setting crusher load The operator can adjust the feeder speed with The operator can adjust the crusher load with the feeder speed setting switch of the machine the crusher load setting switch of the machine monitor.
Page 313 30 Testing and adjusting SEN02304-00 13. Check of maintenance information function 15. Caution generation display function The maintenance switch allows checking If a caution is warned for a caution item, appli- detailed information of the maintenance items cable symbol mark is displayed large for 2 sec- (specified maintenance time and elapsed onds and then it remains on the screen in a time).
Page 314 SEN02304-00 30 Testing and adjusting a User codes and actions requested to operator User code Failure mode Action Pump controller malfunctions and have inspection carried out PC-EPC valve error immediately. Engine controller power source error Engine controller drive system circuit Have inspection carried out immediately.
Page 315 30 Testing and adjusting SEN02304-00 17. Failure code display function (3) Telephone number Operating the following switch while an user code is on the screen, sequentially displays the failure code, the phone mark (if registered) and phone number (if registered). Switching operation: ( ) E 0 2 a The telephone mark and telephone num-...
Page 316 SEN02304-00 30 Testing and adjusting Failure code table User Failure Alarm Applicable History Failure contents code code buzzer equipment classification — 7RC1KB Short circuit conveyor ON switch Electrical system — 7RC2KA Disconnection in conveyor OFF switch Electrical system — 7RC5KB Short circuit in feeder ON switch Electrical system —...
Page 317 30 Testing and adjusting SEN02304-00 User Failure Alarm Applicable History Failure contents code code buzzer equipment classification — 7RJAKB Short circuit in travel lock EPC solenoid valve Electrical system — 7RJAKY Short circuit in travel lock EPC solenoid valve Electrical system —...
Page 318 SEN02304-00 30 Testing and adjusting User Failure Alarm Applicable History Failure contents code code buzzer equipment classification CA488 Charge temperature too high and torque derated Electrical system CA553 Common rail pressure sensor too high (1) Electrical system CA559 Supply pump no pressure Electrical system CA689 Abnormality in engine Ne speed sensor...
Page 319 30 Testing and adjusting SEN02304-00 a Entry order of items in table The items are entered in the order of their failure codes (incremental order). a User code Attached : If the failure code is detected, the user code, failure code, and telephone No. (if regis- tered) are displayed on the ordinary screen to notify the operator of the abnormality.
Page 320 SEN02304-00 30 Testing and adjusting 18. Function of monitoring emergency stop 19. Function for conveyor position display Warning for turning emergency stop Conveyor position display in operation switch ON mode When an emergency stop switch installed If the operation mode is selected with the around the machine is depressed;...
Page 321 30 Testing and adjusting SEN02304-00 Service menu operation and display Displaying menu screen The display is changed to the initial display of Service Menu program. Select an appropriate Switching to service menu item from among the menu. a When using the service menu, switch the screen through the following special operation.
Page 322 SEN02304-00 30 Testing and adjusting 20. Monitoring [01] function Select menu “99999” and press The machine monitor monitors signals from the [ ] switch. a When you have registered all the switch sensor actuators on various machine parts. It allows displaying and checking the items that can be registered, the monitored information through following opera- screen will be automatically switched...
Page 323 30 Testing and adjusting SEN02304-00 Monitoring items table Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks meter inch charge 00200 Controller Model Select — — — PUMP 00201 Machine ID — — — 01002 Engine speed r/min 01601 2nd Eng.
Page 324 SEN02304-00 30 Testing and adjusting Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks meter inch charge 37300 Fuel Rate 01602 2nd Eng. Speed Command PUMP 13113 Main Pump Absorb Torque lbft PUMP Key Switch PUMP Start PUMP 04500 Monitor input 1...
Page 325 30 Testing and adjusting SEN02304-00 Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks meter inch charge 02202 Switch Input 7 Key Switch(ACC) ON•OFF PUMP Mag. Sep. Sol. PUMP 25500 Solenoid Valve Lock.Cyl. Unlock ON•OFF PUMP Muck Conv.
Page 326 SEN02304-00 30 Testing and adjusting 21. Function of abnormality record [02] Contents of display of electrical system abnormality record information screen The machine monitor records and classifies (1): Occurrence order of abnormalities the past failure information as into the electri- f r o m l a t e s t o n e / To ta l n u m b e r o f cal and mechanical failures.
Page 327 30 Testing and adjusting SEN02304-00 Resetting electrical systems abnormality From the reset screen, do the switch record operation according to the screen a Resetting abnormality record (dele- instructions. a When a specific individual infor- tion) is possible only with the electri- cal system.
Page 328 SEN02304-00 30 Testing and adjusting 22. Function of maintenance record [03] 23. Function of maintenance mode change [04] The machine monitor records the maintenance Following procedure allows changing the cur- information of the filters, oils, etc., which the rently set operating conditions of the mainte- operator can display and check by the follow- nance display function.
Page 329 30 Testing and adjusting SEN02304-00 Description of individual setting items (1): Default value: The maintenance time Number Items of the maintenance mode change set in the monitor (recommended by Return (End of change in the maintenance the manufacturer and cannot be mode) changed).
Page 330 SEN02304-00 30 Testing and adjusting 24. Function of phone number entry [05] Entry and setting phone number When the user code is displayed, following Following the method explained below, procedure allows entering or correcting the entry a phone number in the “Phone Num- phone numbers to be displayed alternately ber Entry”...
Page 331 30 Testing and adjusting SEN02304-00 25. Function of default [06] Language setting function Following machine monitor- or machine- Service Menu allows switching the lan- related settings are modifiable. Do necessary guage between Japanese and English. modifications as needed. Language used in the service menu Unit to be displayed in relation to the mon- itoring function Menu selection...
Page 332 SEN02304-00 30 Testing and adjusting 26. Function of adjustment [07] Function for Pump Absorption Torque adjustment The operator can adjust various items related The pump absorption torque can be to the machine with the machine monitor. adjusted within the range shown in the Menu selection table below.
Page 333 30 Testing and adjusting SEN02304-00 Move the cursor to the current to Move the cursor to the current to adjust with [ ] switch and [ ] switch adjust with [ ] switch and [ ] switch and depress [ ] switch.
Page 334 SEN02304-00 30 Testing and adjusting Check that the display is in the ordi- Function for option registration nary display mode. Use/Disuse of the options of the machine Set mode selector switch (1) of the can be set. main control box in the testing mode On the option setting menu screen, position.
Page 335 30 Testing and adjusting SEN02304-00 27. Function of cylinder cut out operation [08] The operator can perform the engine on cylin- der cut out operation with the machine monitor. “Cylinder cut out” operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders.
Page 336 SEN02304-00 30 Testing and adjusting Engine speed holding function [Reference]: Using the holding function effectively Pressing [E] switch while the engine The engine speed being displayed on the screen operation on cylinder cut out screen is through the holding function remains on it until the turned on holds the engine speed and its holding is cancelled.
Page 337 30 Testing and adjusting SEN02304-00 28. Function of no injection cranking [09] As the checkup is over, following screen No injection cranking of the engine is available appears. from the machine monitor. No injection cranking denotes stopping injec- tion of fuel from the injector even if the engine is run from the starting motor.
Page 338 SEN02304-00 30 Testing and adjusting a If the no injection cranking function is As the preparation for no injection crank- ing is completed, display of “Under Prepa- inadvertently selected while the r a t i o n ” i s r e p l a c e d w i t h “ A f t e r N o engine is running, “Engine Running”...
Page 339 30 Testing and adjusting SEN02304-00 29. Function for crusher clearance record [10] 30. Function for lock cylinder slip record [11] The machine monitor records the information The machine monitor records the information about the crusher clearance setting. about the past slip of the crusher lock cylinder The machine monitor records the informa- (service meter reading).
Page 340 SEN02304-00 30 Testing and adjusting Deletion of data ] + [1] o [2] o [3] (While pressing [ ], input numbers] BR380JG-1E0...
Page 342: Testing And Adjusting, Part 3
SEN02305-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting Testing and adjusting, Part 3 Check and adjustment of jaw crusher......................2 Check and adjustment of outlet clearance...................... 4 Adjusting tension of crusher drive V-belt....................... 37 Check and adjustment of primary conveyor....................
Page 343: Check And Adjustment Of Jaw Crusher
SEN02305-01 30 Testing and adjusting Check and adjustment of jaw Hang a warning tag on the horn switch of the control box, then lock the control box. crusher When entering the top of the feeder or the inside of the crusher to carry out inspec- tion and maintenance of the crusher, or replacement of consumable parts, always follow the procedure below when carrying...
Page 344 30 Testing and adjusting SEN02305-01 Press work equipment lock switch (1). When moving from the deck on the right side of the machine to the top of the feeder, put stand (2) of a height of approx. 300 mm on top of the deck, then go up to the feeder from stand (2).
Page 345: Check And Adjustment Of Outlet Clearance
SEN02305-01 30 Testing and adjusting Check and adjustment of outlet clearance Check of outlet clearance Outlet clearance A (opening end) means the dis- tance from the tip of the fixed jaw plate to the bot- tom of the movable tooth when the crusher outlet is fully open.
Page 346 30 Testing and adjusting SEN02305-01 Outlet clearance adjusting method Before starting operations, check that there is no one inside the crusher or in the sur- When the machine is used continuously, wear of rounding area. the addendum will cause the crusher outlet clear- When the machine is shipped from the fac- ance to become larger, and the size of the particle tory, the clearance is set to 50 mm (O.
Page 347 SEN02305-01 30 Testing and adjusting Adjusting clearance in A (automatic) mode Set clearance adjustment selector switch (3) to position (A) (automatic). Start the engine. Check that clearance adjustment monitor (D) Set fuel control dial (1) to the low idle (MIN) of the machine monitor is set to (A) (automatic) position.
Page 348 30 Testing and adjusting SEN02305-01 “|” lamp (C) goes out to show that the clear- After inputting the desired O.S.S. clear- ance, press input confirmation switch (6) ance adjustment is completed. to set the input value. Automatic adjustment is carried out with the following procedure.
Page 349 SEN02305-01 30 Testing and adjusting The swing jaw plate acts in the direction to Adjusting clearance in S (semi-automatic) open the crusher clearance. While the mode clearance is opening, machine monitor Measure the present crusher outlet clearance portion (G) flashes. to understand how much to increase or decrease the value to reach the target value for the clearance.
Page 350 30 Testing and adjusting SEN02305-01 Set mode selector switch (2) to INSPECTION Check that mode monitor (D) of the machine (c) position. The machine monitor switches to monitor has changed to S (semi-automatic) the normal inspection screen. mode, then input clearance value (A) for the amount to change the present clearance on the machine monitor as follows.
Page 351 SEN02305-01 30 Testing and adjusting Adjust the clearance. Adjusting clearance in M (manual) mode Use UP switch (4) or DOWN switch (5) to Measure the present crusher outlet clearance move the cursor on the screen display to to understand how much to increase or position (C).
Page 352 30 Testing and adjusting SEN02305-01 Set mode selector switch (2) to INSPECTION (c) position. The machine monitor switches to the normal inspection screen. a As the crusher is operated, the teeth become worn, so the value displayed on clearance dis- play monitor (A) gradually becomes different from the actual clearance.
Page 353 SEN02305-01 30 Testing and adjusting Check and adjustment of tooth plate wedge bolt Check that the spring set length is correct and adjust it if there is any problem. spring case, tension spring The spring set length is as follows. If there is play in the tooth plate, abnormal noise from around the crusher, knocking noise from the Fixed jaw plate wedge bolt spring...
Page 354 30 Testing and adjusting SEN02305-01 Swing jaw plate wedge bolt spring Tension spring A = 0 – 2 mm (when clearance at tip of teeth is set to maximum) As shown in the diagram below, face (a) (collar C = 258 – 260 mm face) does not extend to the outside from face (b) (plate surface), and the inset is within 2 mm.
Page 355 SEN02305-01 30 Testing and adjusting Check of wear on major wearing parts Jaw plate When checking the wear, stop the crusher, then stop the engine and check the wear. If the machine is used continuously with the crusher chamber excessively charged, premature partial wear will develop on the tips of jaw plates.
Page 356 30 Testing and adjusting SEN02305-01 Swing jaw plate wedge Cheek plate Carry out replacement when the remaining dimen- Replace when remaining dimension (A) at the bot- sion reaches approx. 15 mm (wear amount: 10 tom of the wedge is approx. 79 mm (wear amount mm) at the top, and approx.
Page 357 SEN02305-01 30 Testing and adjusting Toggle plate If distance (C) between the tip of the flange and the bottom of the toggle seat is 278 mm, remove the toggle plate and measure the amount of wear (A) of the toggle plate. For details of the amount of wear of the toggle seat, see “Toggle seat”.
Page 358 30 Testing and adjusting SEN02305-01 When wear develops on the side of toggle Liner plate plate (1) and as a result, the side comes in (Crusher feeder portion) contact with the tip of rod pin (2), replace the Liner plate (1) needs to be replaced with a new one toggle plate with a new one.
Page 359 SEN02305-01 30 Testing and adjusting Replacement of cheek plate Fit the tool supplied with the machine to the lift- Use an air gun or wire brush to remove the ing hole, then lift up vertically. If the load is at sand or soil clogging lifting hole (3) of top an angle, it may be difficult to remove.
Page 360 30 Testing and adjusting SEN02305-01 While lifting, hit the area around the cheek Insert new cheek plates in order from the plate with a medium-sized hammer. underside along the fixed jaw and a guide of (Hit the places marked q in the diagram.) the side frame.
Page 361 SEN02305-01 30 Testing and adjusting Reversal or replacement of fixed jaw plate This machine uses cover assembly (1) with springs built into the fixed jaw plate wedge portion and swing jaw plate wedge portion. If bolts (2) of the front face of the cover are removed during disassembly, there is dan- ger that the internal parts will fly out and cause injury.
Page 362 30 Testing and adjusting SEN02305-01 Remove the fixed jaw wedge bolt spring cover assembly as follows. Loosen locknut (4) and tighten until spring holder push bolt (5) contacts spring holder (6). Remove wedge bolt locknut (7), nut (8), Lift up the fixed jaw plate with a wire rope. and washer (9).
Page 363 SEN02305-01 30 Testing and adjusting Take measurements of the clearance on both sides of fixed jaw plate, and position the fixed jaw plate and the crusher frame so that both centers are aligned. If fixed jaw (13) is not in tight contact with the frame, insert wooden block (11) (or equivalent object) between fixed jaw (13) and swing jaw (12).
Page 364 30 Testing and adjusting SEN02305-01 Install the fixed jaw wedge, fixed jaw wedge bolt, and fixed jaw wedge bolt spring cover assembly. When the fixed jaw wedge is installed to the fixed jaw plate, the wedge may not sit well with the plate due to burrs remaining on the contact face of either parts.
Page 365 SEN02305-01 30 Testing and adjusting Install the fixed jaw wedge bolt spring cover assem- Check that spring holder (6) is being bly as follows. pushed into the correct position. Raise spring cover assembly (10) with (The width of (A) should be 0 – 2 mm.) wire and insert into the wedge bolt.
Page 366 30 Testing and adjusting SEN02305-01 Loosen spring holder push bolt (5) so that dimension (B) becomes 15 mm, then tighten locknut (4). Repeat the procedure in Step 3) to check that spring holder (6) is being pushed in to the correct position. If it is not the specified value, adjust again.
Page 367 SEN02305-01 30 Testing and adjusting Reversal or replacement of swing jaw plate Remove the swing jaw wedge bolt spring cover assembly (2 places), then remove 1 swing jaw This machine uses cover assembly (1) with wedge bolt on one side. After removing the springs built into the fixed jaw plate wedge swing jaw wedge spring cover assembly, fit the portion and swing jaw plate wedge portion.
Page 368 30 Testing and adjusting SEN02305-01 Loosen locknut (4) and tighten until spring holder push bolt (5) contacts spring holder (6). a To make it easier to fit lifting wire (A) to the Remove wedge bolt locknut (7), nut (8), and washer (9). swing jaw plate wedge, push the swing jaw plate wedge out approximately 30 mm.
Page 369 SEN02305-01 30 Testing and adjusting Fit swing jaw lifting hook (B) to the top surface of the swing jaw, then raise it. Swing jaw: 735 kg After removing the swing jaw plate, com- pletely remove soils, sand, etc. from the swing jaw plate fitting surfaces (swing jaw, each upper surface of swing jaw plate mount stopper and transverse stopper piece).
Page 370 30 Testing and adjusting SEN02305-01 Install the swing jaw wedge and swing jaw wedge bolt. When the swing jaw wedge is installed to the swing jaw plate, the wedge may not sit well with the plate due to burrs remaining on the contact face of either parts. In that case, remove the burrs before install- ing the wedge.
Page 371 SEN02305-01 30 Testing and adjusting Install the swing jaw wedge bolt spring cover Check that spring holder (6) is being assembly as follows. pushed into the correct position. Raise spring cover assembly (10) with (The width of (A) should be 0 – 2 mm.) wire and insert into the wedge bolt.
Page 372 30 Testing and adjusting SEN02305-01 Loosen spring holder push bolt (5) so that Wrap a nylon sling around toggle plate (1) and dimension (B) becomes 15 mm, then sling it. tighten locknut (4). Repeat the procedure in Step 3) to check that spring holder (6) is being pushed in to the correct position.
Page 373 SEN02305-01 30 Testing and adjusting If the tooth plates come into contact with each 10. Pass the wire through the hole in the bottom of other, stop the engine. the swing jaw, then use a chain block to pull the crusher case and the track frame and fix them in position.
Page 374 30 Testing and adjusting SEN02305-01 16. Take out the toggle plate. 20. Remove the nylon sling fitted to the toggle plate. Toggle plate: 144 kg 21. Install the tension spring and tighten it to the specified tightening length. Set tightening length (C) of the tension spring so that it is 258 –...
Page 375 SEN02305-01 30 Testing and adjusting Replacement of toggle seat Raise the toggle seat. Before replacing the toggle seat, follow the Toggle seat at swing jaw end: 44.5 kg items below without fail. After long use, the toggle seat becomes deformed, so it may get stuck to the fixed link or swing jaw.
Page 376 30 Testing and adjusting SEN02305-01 Replacement of crusher driving V-belt Turn the crusher V-belt adjustment turnbuckle (3) to reduce distance (L) between the yokes. Secure the crusher inspection hatch in the open position. Loosen the bolts of flywheel cover (1) at the side of the top step to release it, and at the same time, remove motor cover (2).
Page 377 SEN02305-01 30 Testing and adjusting Loosen the bolts of covers (6) at the top, rear, and bottom of the flywheel cover on the left. Remove the V-belts, starting from the outside, then remove them from the opening at the top of the crusher motor.
Page 378: Adjusting Tension Of Crusher Drive V-Belt
30 Testing and adjusting SEN02305-01 Adjusting tension of crusher drive V-belt If the V belt tension is not normal, the V belts will likely slip when the crusher starts or stops, and shorten the service life of the V belts drastically. Open the V-belt inspection cover, then adjust the V- belt tension as follows.
Page 379: Check And Adjustment Of Primary Conveyor
SEN02305-01 30 Testing and adjusting Check and adjustment of primary Close the V-belt inspection window. conveyor Start the engine and turn the fuel control dial to When inspecting and cleaning the primary the MAX position. conveyor and its surrounding, there is Next, start and stop the crusher and check that always the danger that you are caught in a there is no slipping sound from the V-belt.
Page 380 30 Testing and adjusting SEN02305-01 Check tension of conveyor belt Remove rubber cover (A) at the side of the machine. Place wooden block (B) on top of the conveyor between both sides (C) – (D) of the conveyor frame at cross-section A – A where the con- veyor frame bends.
Page 381 SEN02305-01 30 Testing and adjusting Adjustment of conveyor side rubber Adjustment of scraper If the conveyor side rubber has been worn out, cre- Driving pulley side ating a clearance between the rubber and belt, The default condition is as shown in the dia- loosen the adjustment bolt.
Page 382 30 Testing and adjusting SEN02305-01 Loosen bolts (2), then rotate the cleaner plate Rotate cleaner shaft (8) so that cleaner plate as shown in the diagram. (4) is at right angles. Raise the cleaner 5 mm. Check that cleaner tip (7) and the belt are at the 60°...
Page 383 SEN02305-01 30 Testing and adjusting Driven pulley side If the scraper rubber has been worn out, replace it by loosening the securing bolts. (It is in even contact with the belt across the width) BR380JG-1E0...
Page 384 30 Testing and adjusting SEN02305-01 Inspection of frame at head pulley portion If the frame was once deformed at the belt conveyor head pulley portion, or any of the parts was removed and installed in the past, carry out the following inspection and make adjustments or replace a parts, if nec- essary.
Page 385: Inspection And Maintenance Of Magnetic Separator
SEN02305-01 30 Testing and adjusting Inspection and maintenance of The discharging belt for this machine has the same structure as that for the conventional belt conveyor. magnetic separator Pay attention to the following points, when starting There is danger that the magnetic field may the day's work or daily inspection.
Page 386 30 Testing and adjusting SEN02305-01 Adjusting clearance from conveyor In case the belt tension is not appropriate; Adjust the belt tension in the same way as The clearance between the surface of the conveyor mentioned above. At that time, adjust the belt and the magnet when the machine is shipped belt so that it will have a clearance of 30 to from the factory is approx.
Page 387: Check And Adjustment Of Muck Discharge Conveyor
SEN02305-01 30 Testing and adjusting Check and adjustment of muck When the belt is deflected to the right, move the belt in the direction indicated with an arrow. discharge conveyor (1): Direction of travel of belt There is always the danger that you get caught in the revolving parts of the con- veyor, while inspecting or cleaning it.
Page 388 30 Testing and adjusting SEN02305-01 Check that the tail pulley and rollers turn smoothly or there is any part in the belt that is about to break The conveyor belt may be damaged or broken while in operation. In that case, replace the defec- tive belt with new one promptly.
Page 389: List Of Companies Which Handles Radio Controllers
SEN02305-01 30 Testing and adjusting List of companies which handles radio controllers Area Company name Address Yamada Bldg., Honjo 2-3-12, Matsumoto-shi, Nagano-ken Japan (Japan and Asia) Hetronic Japan Tel: 0263-38-7403 Fax: 0263-38-7404 Abalbert-Stifter-Sir. 2 D-84085 Langquaid, Germany Europe (all European countries) Hetronic Steuesysteme GmbH Tel: +49 9452-1890 Fax: +49 9452-189-20...
Page 390: Handling Voltage Circuit Of Engine Controller
30 Testing and adjusting SEN02305-01 Handling voltage circuit of engine controller Before disconnecting or connecting a connec- tor between the engine controller and engine, be sure to turn the starting switch OFF. If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting, do not start the engine.
Page 391: Procedure For Turning On Komtrax Terminal
SEN02305-01 30 Testing and adjusting Procedure for turning on KOMTRAX terminal When the machine is delivered, KOMTRAX ter- minal is installed: a When the machine is delivered, KOMTRAX terminal is installed (machine with the standard equipment), implement the following proce- dure.
Page 392 30 Testing and adjusting SEN02305-01 a As [Normal] is indicated, proceed to a If [Network error] were displayed, the next step. check the indication of [LED-C4] ref- a If [Abnormal] is indicated, repeat the erencing “KOMTRAX terminal lamp procedure from step 1). indications”.
Page 393 SEN02305-01 30 Testing and adjusting 13) Turn the starting switch OFF. Application for start of use a The application for start of use is allowed 14) Make sure that the 7-segment indicator lamp comes on normally in 10 seconds. only after the terminal station opening a As [Normal] is displayed, the station inspection has been successfully ended.
Page 394: Komtrax Terminal Lamp Indications
30 Testing and adjusting SEN02305-01 KOMTRAX terminal lamp indications LED for communication module LED for CPU 7-segment and dot for CPU LED-A1 (Power lamp) LED-C1 (R signal and ACC 12. 7-segment (Number of mails LED-A2 (Within communica- signal) not transmitted yet) tion range lamp) LED-C2 (Initial output state) 13.
Page 395 SEN02305-01 30 Testing and adjusting KOMTRAX system displays various information in the system as well as contents of information processing on the LED display unit located at the top of KOMTRAX terminal. Thus, when a failure on the system is sus- pected, implement the following checkups.
Page 396 30 Testing and adjusting SEN02305-01 Display contents of LED for CPU a Turn ON, START the starting switch or the engine prior to inspection of LED display. Name and function Display Contents of display Starting switch ACC signal: ON, Alternator R signal: ON Quick Starting switch ACC signal: ON, Alternator R signal: OFF State of starting switch...
Page 397: Preparation Work For Troubleshooting For Electrical System
SEN02305-01 30 Testing and adjusting Preparation work for Engine controller Open the engine hood. troubleshooting for electrical a The engine controller is mounted on system the engine. Insert or connect troubleshooting T-adapt- a When carrying out troubleshooting for an elec- ers in or to connectors CE01, CE02, and tric circuit related to the machine monitor, CE03 of engine controller (3).
Page 398 30 Testing and adjusting SEN02305-01 KOMTRAX terminal Insert or connect troubleshooting T-adapter in or to connector G01 of KOMTRAX terminal (4). a The connectors are fixed with screws. Loosen the screws before disconnecting them. a When returning the connectors to their original positions, fix them by tightening the screws with the specified torque.
Page 399 SEN02305-01 30 Testing and adjusting a Precautions for disconnecting connector Supply pump IMV solenoid (FUEL REGU- LATOR) The direction of the lock of the connector a Disconnection and connection of con- varies with the tightened position of the nector sensor and the lock may be in a direction The connector of the supply pump IMV in which it is difficult to reset (on the under- solenoid has a special locking mecha-...
Page 400 30 Testing and adjusting SEN02305-01 Engine coolant temperature sensor (COOL- ANT TEMP) a Disconnection and connection of con- nector The connector of the engine coolant tem- perature sensor has a special locking mechanism. Disconnect it according to steps (a) – (b) and connect it according to steps (c) –...
Page 401: Procedure For Testing Diodes
SEN02305-01 30 Testing and adjusting Procedure for testing diodes Note: In the case of a silicon diode, a value in the range from 460 to 600 is indi- a Test the assembled-type diode (8-pin) and the cated. single diode (2-pin) according to the following procedure.
Page 402 30 Testing and adjusting SEN02305-01 BR380JG-1E0...
Page 404: Troubleshooting
SEN02088-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Failure code table and fuse locations Failure code table ............................2 Fuse locations ..............................6 BR380JG-1E0...
Page 405: Failure Code Table
SEN02088-00 40 Troubleshooting Failure code table Failure Applicable User History Reference Failure contents code equipment code classification document No. 7RC1KB Short circuit conveyor ON switch — Electrical system 7RC2KA Disconnection in conveyor OFF switch — Electrical system 7RC5KB Short circuit in feeder ON switch —...
Page 406 40 Troubleshooting SEN02088-00 Failure Applicable User History Reference Failure contents code equipment code classification document No. 7RJAKB Short circuit in travel lock EPC solenoid valve — Electrical system 7RJAKY Short circuit in travel lock EPC solenoid valve — Electrical system 7RJMMW Lock cylinder slipping —...
Page 407 SEN02088-00 40 Troubleshooting Failure Applicable User History Reference Failure contents code equipment code classification document No. CA488 Charge temperature too high and torque derated Electrical system CA553 Common rail pressure sensor too high (1) Electrical system CA559 Supply pump no pressure Electrical system CA689 Abnormality in engine Ne speed sensor...
Page 408: Fuse Locations
SEN02088-00 40 Troubleshooting Fuse locations Connection table of fuse box and fusible links a This connection table indicates the devices to which the power of the fuse box and fusible links is sup- plied. (A switched power supply is a device which supplies power while the stating switch is in the ON position and a constant power supply is a device which supplies power while the starting switch is in the OFF and ON positions).
Page 409 40 Troubleshooting SEN02088-00 Capacity Type of power source Fuse No. Destination of power of fuse Mode select switch Travel alarm relay Travel alarm Conveyor up solenoid valve Conveyor down solenoid valve Power source for accessory input (conveyor up/down switch) Conveyor/muck discharge conveyor select solenoid valve 2nd conveyor solenoid valve Vibrator screen solenoid valve Sprinkler relay...
Page 410 SEN02088-00 40 Troubleshooting Fusible link Fusible link Connector Capacity Type of power source Destination of power of fusible link Constant power source Fuse No.1 – No.5 Switched power source Fuse No.6 – No.15 BR380JG-1E0...
Page 412 SEN02089-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting General information on troubleshooting Points to remember when troubleshooting ..................... 2 Sequence of events in troubleshooting......................3 Checks before troubleshooting ........................4 Classification and procedures of troubleshooting ................... 6 Contents of troubleshooting table .........................
Page 413: Points To Remember When Troubleshooting
SEN02089-01 40 Troubleshooting Points to remember when troubleshooting Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are securely fitted. When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near.
Page 414: Sequence Of Events In Troubleshooting
40 Troubleshooting SEN02089-01 Sequence of events in troubleshooting BR380JG-1E0...
Page 415: Checks Before Troubleshooting
SEN02089-01 40 Troubleshooting Checks before troubleshooting 1. Chassis Judgement Item Action Value 1. Check fuel level, type of fuel — Add fuel 2. Check for impurities in fuel — Clean, drain 3. Check hydraulic oil level Between H – L Add oil 4.
Page 416 40 Troubleshooting SEN02089-01 2. Crusher Judgment Item Action value 1. Wear of fixed jaw Reverse or replace 2. Wear of swing jaw 3. Wear of cheek plate Wear limit 4. Wear of protector *See Testing and adjusting. 5. Wear of movable tooth wedge Replace 6.
Page 417: Classification And Procedures Of Troubleshooting
SEN02089-01 40 Troubleshooting Classification and procedures of troubleshooting Classification for troubleshooting Type Contents Display of code Troubleshooting by failure code E mode Troubleshooting for electrical system H mode Troubleshooting for hydraulic and mechanical system S mode Troubleshooting for engine Procedure for troubleshooting If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No.
Page 418 40 Troubleshooting SEN02089-01 Phenomena considered to be failures and troubleshooting Nos. Troubleshooting Phenomena considered to be failures Indication E-mode H-mode S-mode of code Phenomena related to user code, error code, or failure code User code is displayed on machine monitor Accord- When failure history is checked, error code is displayed in electri- ing to...
Page 419 SEN02089-01 40 Troubleshooting (Rev. 2006.11) Troubleshooting Phenomena considered to be failures Indication E-mode H-mode S-mode of code Phenomena related to work equipment 31 Conveyor does not operate 32 Speed or power of conveyor is low 33 Crusher does not operate 34 Speed or power of crusher is low 35 Feeder does not operate H-10...
Page 420 40 Troubleshooting SEN02089-01 Troubleshooting Phenomena considered to be failures Indication E-mode H-mode S-mode of code 64 Hydraulic oil temperature gauge does not display normally E-13 65 Travel, work, and inspection modes do not change E-14 66 Crusher clearance adjustment mode does not change E-15 67 When switches on monitor are operated, nothing is displayed E-21...
Page 421: Contents Of Troubleshooting Table
SEN02089-01 40 Troubleshooting Contents of troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. User code Failure code Names of the failure symptoms displayed in the failure history on the Machine Machine Trouble...
Page 422 40 Troubleshooting SEN02089-01 Circuit diagram related This drawing is a part of the electric circuit diagram related to trouble- shooting. • Connector No.: Indicates (Model - Number of pins) and (Color). • “Connector No. and pin No.“ from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness.
Page 423: Wiring Table For Connector Pin Numbers
SEN02089-01 40 Troubleshooting Wiring table for connector pin numbers (Rev. 2006.11) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing. BR380JG-1E0...
Page 424 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 425 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 426 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 427 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 428 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 429 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 430 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 431 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 432 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 433 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 434 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 435 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 436 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 437 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 438 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 439 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 440 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 441 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 442 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 443 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 444 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 445 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 446 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 447 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 448 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 449 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 450 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 451 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 452 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 453 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 454 40 Troubleshooting SEN02089-01 BR380JG-1E0...
Page 455 SEN02089-01 40 Troubleshooting BR380JG-1E0...
Page 456: T-Adapter Box And T-Adapter Table
40 Troubleshooting SEN02089-01 T-adapter box and T-adapter table (Rev. 2006.11) a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly. T-adapter kit Identification Part No. Part name symbol 799-601-2600 T-box (for ECONO)
Page 457 SEN02089-01 40 Troubleshooting T-adapter kit Identification Part No. Part name symbol q q q 799-601-7120 Adapter for M q q q 799-601-7130 Adapter for M 799-601-7340 Adapter for M q q q 799-601-7140 Adapter for S q q q 799-601-7150 Adapter for S (White) S10P q q q 799-601-7160 Adapter for S (Blue)
Page 458 40 Troubleshooting SEN02089-01 T-adapter kit Identification Part No. Part name symbol 799-601-9320 T-box (for DT/HD) 799-601-9330 Case 799-601-9340 Case 799-601-9350 Adapter for DRC DRC-40 799-601-9360 Adapter for DRC DRC-24 799-601-9410* Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Socket for engine (CRI-T2) 799-601-9430* Socket for engine (CRI-T3) PCV...
Page 460: Troubleshooting By Failure Code, Part 1
SEN02090-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting by failure code, Part 1 Failure code [7RC1KB] Short circuit conveyor ON switch ................4 Failure code [7RC2KA] Disconnection in conveyor OFF switch ..............6 Failure code [7RC5KB] Short circuit in feeder ON switch................
Page 461 SEN02090-00 40 Troubleshooting Failure code [7RESKB] Short circuit in one-touch start switch ..............36 Failure code [7RETKA] Disconnection in one-touch stop switch ..............38 Failure code [7RF2KA] Disconnection in crusher forward EPC valve............40 Failure code [7RF2KB] Short circuit in crusher forward EPC valve .............. 41 Failure code [7RF2KY] Short circuit in crusher forward EPC valve ..............
Page 462: Failure Code [7Rc1Kb] Short Circuit Conveyor On Switch
SEN02090-00 40 Troubleshooting Failure code [7RC1KB] Short circuit conveyor ON switch User code Failure code Short circuit conveyor ON switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RC1KB Contents of • Input signal circuit for the conveyor ON switch is closed (connected to ground circuit) within 1 sec- trouble ond after the engine starting switch ON.
Page 463 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 464: Failure Code [7Rc2Ka] Disconnection In Conveyor Off Switch
SEN02090-00 40 Troubleshooting Failure code [7RC2KA] Disconnection in conveyor OFF switch User code Failure code Disconnection in conveyor OFF switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RC2KA Contents of • Input signal circuit for the conveyor OFF switch is opened (disconnected from ground circuit) within trouble 1 second after the engine starting switch ON.
Page 465 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 466: Failure Code [7Rc5Kb] Short Circuit In Feeder On Switch
SEN02090-00 40 Troubleshooting Failure code [7RC5KB] Short circuit in feeder ON switch User code Failure code Short circuit in feeder ON switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RC5KB Contents of • Input signal circuit for the feeder ON switch is closed (connected to ground circuit) within 1 second trouble after the engine starting switch ON.
Page 467 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 468: Failure Code [7Rd2Kb] Short Circuit In Conveyor Reverse Relay
SEN02090-00 40 Troubleshooting Failure code [7RD2KB] Short circuit in conveyor reverse relay User code Failure code Short circuit in conveyor reverse relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RD2KB Contents of • Abnormal voltage is detected when output to the discharge conveyor reverse relay is ON. trouble •...
Page 469 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 470: Failure Code [7Rd2Kz] Disconnection Or Short Circuit In Conveyor Reverse Relay
SEN02090-00 40 Troubleshooting Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay User code Failure code Disconnection or short circuit in conveyor reverse relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RD2KZ Contents of •...
Page 471 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 472: Failure Code [7Re1Kb] Short Circuit In Crusher On Switch
SEN02090-00 40 Troubleshooting Failure code [7RE1KB] Short circuit in crusher ON switch User code Failure code Short circuit in crusher ON switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE1KB Contents of • Input signal circuit for the crusher ON switch is closed (connected to ground circuit) within 1 second trouble after the engine starting switch ON.
Page 473 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 474: Failure Code [7Re2Ka] Disconnection In Crusher Off Switch
SEN02090-00 40 Troubleshooting Failure code [7RE2KA] Disconnection in crusher OFF switch User code Failure code Disconnection in crusher OFF switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE2KA Contents of • Input signal circuit for the crusher OFF switch is opened (disconnected from ground circuit) within 1 trouble second after the engine starting switch ON.
Page 475 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 476: Failure Code [7Re6Kb] Short Circuit In Muck Discharge Conveyor On Switch
SEN02090-00 40 Troubleshooting Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch User code Failure code Short circuit in muck discharge conveyor ON switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE6KB Contents of •...
Page 477 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 478: Failure Code [7Re7Ka] Disconnection In Muck Discharge Conveyor Off Switch
SEN02090-00 40 Troubleshooting Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch User code Failure code Disconnection in muck discharge conveyor OFF switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE7KA Contents of • Input signal circuit for the muck discharge conveyor OFF switch is opened (disconnected to ground trouble circuit) within 1 second after the engine starting switch ON.
Page 479 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 480: Failure Code [7Re8Kb] Short Circuit In Magnetic Separator On Switch
SEN02090-00 40 Troubleshooting Failure code [7RE8KB] Short circuit in magnetic separator ON switch User code Failure code Short circuit in magnetic separator ON switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE8KB Contents of • The magnetic separator ON switch input signal circuit is closed (connected to the chassis ground) in trouble 1 second after the engine starting switch is turned ON.
Page 481 40 Troubleshooting SEN02090-00 Circuit diagram related to magnetic separator ON switch BR380JG-1E0...
Page 482: Failure Code [7Re9Ka] Disconnection In Magnetic Separator Off Switch
SEN02090-00 40 Troubleshooting Failure code [7RE9KA] Disconnection in magnetic separator OFF switch User code Failure code Disconnection in magnetic separator OFF switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RE9KA Contents of • The magnetic separator OFF switch input signal circuit is opened (disconnected from the chassis trouble ground) in 1 second after the engine starting switch is turned ON.
Page 483 40 Troubleshooting SEN02090-00 Circuit diagram related to magnetic separator OFF switch BR380JG-1E0...
Page 484: Failure Code [7Reakb] Short Circuit In Accessory Input Circuit
SEN02090-00 40 Troubleshooting Failure code [7REAKB] Short circuit in accessory input circuit User code Failure code Short circuit in accessory input circuit Trouble (Work equipment and pump controller (work equipment control) system) — 7REAKB Contents of • Input signal circuit 1 for the accessory is closed (connected to power supply circuit) within 1 second trouble after the engine starting switch ON.
Page 485 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 486: Failure Code [7Redma] Abnormality In Primary Conveyor Pressure Sensor
SEN02090-00 40 Troubleshooting Failure code [7REDMA] Abnormality in primary conveyor pressure sensor User code Failure code Abnormality in primary conveyor pressure sensor Trouble (Work equipment and pump controller (work equipment control) system) — 7REDMA Contents of • Signal voltage from the primary conveyor pressure sensor is below 0.3 V or above 4.42 V. trouble Action of •...
Page 487 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 488: Failure Code [7Reema] Abnormality In Muck Conveyor Pressure Sensor
SEN02090-00 40 Troubleshooting Failure code [7REEMA] Abnormality in muck conveyor pressure sensor User code Failure code Abnormality in muck conveyor pressure sensor Trouble (Work equipment and pump controller (work equipment control) system) — 7REEMA Contents of • Signal voltage from the muck discharge conveyor pressure sensor is below 0.3 V or above 4.42 V. trouble Action of •...
Page 489 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 490: Failure Code [7Renkz] Abnormality In Clearance Potentiometer
SEN02090-00 40 Troubleshooting Failure code [7RENKZ] Abnormality in clearance potentiometer User code Failure code Abnormality in clearance potentiometer Trouble (Work equipment and pump controller (work equipment control) system) — 7RENKZ Contents of • Signal voltage from the clearance detection potentiometer is below 0.23 V or above 4.77 V. trouble •...
Page 491 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 492: Failure Code [7Repka] Disconnection In Feeder Off Switch
SEN02090-00 40 Troubleshooting Failure code [7REPKA] Disconnection in feeder OFF switch User code Failure code Disconnection in feeder OFF switch Trouble (Work equipment and pump controller (work equipment control) system) — 7REPKA Contents of • Input signal circuit for the grizzly feeder OFF switch is opened (disconnected from ground circuit) trouble within 1 second after the engine starting switch ON.
Page 493 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 494: Failure Code [7Reskb] Short Circuit In One-Touch Start Switch
SEN02090-00 40 Troubleshooting Failure code [7RESKB] Short circuit in one-touch start switch User code Failure code Short circuit in one-touch start switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RESKB Contents of • Input signal circuit for the one-touch start switch or work equipment start switch is closed (connected trouble to ground circuit) within 1 second after the starting switch ON.
Page 495 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 496: Failure Code [7Retka] Disconnection In One-Touch Stop Switch
SEN02090-00 40 Troubleshooting Failure code [7RETKA] Disconnection in one-touch stop switch User code Failure code Disconnection in one-touch stop switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RETKA Contents of • Input signal circuit for the one-touch stop switch or work equipment stop switch is opened (discon- trouble nected from ground circuit) within 1 second after the engine starting switch ON.
Page 497 40 Troubleshooting SEN02090-00 Related electrical circuit diagram BR380JG-1E0...
Page 498: Failure Code [7Rf2Ka] Disconnection In Crusher Forward Epc Valve
SEN02090-00 40 Troubleshooting Failure code [7RF2KA] Disconnection in crusher forward EPC valve User code Failure code Disconnection in crusher forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF2KA Contents of • Open circuit is detected when EPC valve solenoid for crusher forward rotation is driven. trouble •...
Page 499: Failure Code [7Rf2Kb] Short Circuit In Crusher Forward Epc Valve
40 Troubleshooting SEN02090-00 Failure code [7RF2KB] Short circuit in crusher forward EPC valve User code Failure code Short circuit in crusher forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF2KB Contents of • Ground short circuit is detected when EPC valve solenoid for crusher forward rotation is driven. trouble •...
Page 500: Failure Code [7Rf2Ky] Short Circuit In Crusher Forward Epc Valve
SEN02090-00 40 Troubleshooting Failure code [7RF2KY] Short circuit in crusher forward EPC valve User code Failure code Short circuit in crusher forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF2KY Contents of • Hot short circuit (contact with 24 V circuit) is detected when EPC valve solenoid for crusher forward trouble rotation is not driven.
Page 501: Failure Code [7Rf3Ka] Disconnection In Crusher Reverse Epc Valve
40 Troubleshooting SEN02090-00 Failure code [7RF3KA] Disconnection in crusher reverse EPC valve User code Failure code Disconnection in crusher reverse EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF3KA Contents of • Open circuit is detected when EPC valve solenoid for crusher reverse rotation is driven. trouble •...
Page 502: Failure Code [7Rf3Kb] Short Circuit In Crusher Reverse Epc Valve
SEN02090-00 40 Troubleshooting Failure code [7RF3KB] Short circuit in crusher reverse EPC valve User code Failure code Short circuit in crusher reverse EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF3KB Contents of • Ground short circuit is detected when EPC valve solenoid for crusher reverse rotation is driven. trouble •...
Page 503: Failure Code [7Rf3Ky] Short Circuit In Crusher Reverse Epc Valve
40 Troubleshooting SEN02090-00 Failure code [7RF3KY] Short circuit in crusher reverse EPC valve User code Failure code Short circuit in crusher reverse EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF3KY Contents of • Hot short circuit is detected when EPC valve solenoid for crusher reverse rotation is not driven. trouble Action of •...
Page 504: Failure Code [7Rf4Ka] Disconnection In Feeder Forward Epc Valve
SEN02090-00 40 Troubleshooting Failure code [7RF4KA] Disconnection in feeder forward EPC valve User code Failure code Disconnection in feeder forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF4KA Contents of • Open circuit is detected when the EPC valve solenoid for feeder forward rotation is driven. trouble •...
Page 505: Failure Code [7Rf4Kb] Short Circuit In Feeder Forward Epc Valve
40 Troubleshooting SEN02090-00 Failure code [7RF4KB] Short circuit in feeder forward EPC valve User code Failure code Short circuit in feeder forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF4KB Contents of • Ground short circuit is detected when EPC valve solenoid for feeder forward rotation is driven. trouble •...
Page 506: Failure Code [7Rf4Ky] Short Circuit In Feeder Forward Epc Valve
SEN02090-00 40 Troubleshooting Failure code [7RF4KY] Short circuit in feeder forward EPC valve User code Failure code Short circuit in feeder forward EPC valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RF4KY Contents of • When feeder forward EPC valve solenoid is not driven, hot short (contact with 24 V circuit) is trouble detected.
Page 508: Troubleshooting By Failure Code, Part 2
SEN02091-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting by failure code, Part 2 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 ............
Page 509 SEN02091-00 40 Troubleshooting 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 ............
Page 510: Failure Code [7Rfaky] Short Circuit In Engine Stop Relay
SEN02091-00 40 Troubleshooting Failure code [7RFAKY] Short circuit in engine stop relay User code Failure code Short circuit in engine stop relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFAKY Contents of • When the engine stop relay circuit was driven, hot short (contact with 24 V circuit) was detected. trouble •...
Page 511 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 512: Failure Code [7Rfakz] Disconnection Or Short Circuit In Engine Stop Relay
SEN02091-00 40 Troubleshooting Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay User code Failure code Disconnection or short circuit in engine stop relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFAKZ Contents of •...
Page 513 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 514: Failure Code [7Rfbkb] Short Circuit In Muck Conveyor Solenoid
SEN02091-00 40 Troubleshooting Failure code [7RFBKB] Short circuit in muck conveyor solenoid User code Failure code Short circuit in muck conveyor solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFBKB Contents of • When the muck discharge conveyor solenoid was driven, ground short circuit was detected. trouble •...
Page 515: Failure Code [7Rfbkz] Disconnection Or Short Circuit In Muck Conveyor Solenoid
40 Troubleshooting SEN02091-00 Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid User code Failure code Disconnection or short circuit in muck conveyor solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFBKZ Contents of •...
Page 516: Failure Code [7Rfcka] Disconnection In Magnetic Separator Solenoid
SEN02091-00 40 Troubleshooting Failure code [7RFCKA] Disconnection in magnetic separator solenoid User code Failure code Disconnection in magnetic separator solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFCKA Contents of • When the magnetic separator solenoid is driven, disconnection of the circuit is detected. trouble •...
Page 517: Failure Code [7Rfckb] Short Circuit In Magnetic Separator Solenoid
40 Troubleshooting SEN02091-00 Failure code [7RFCKB] Short circuit in magnetic separator solenoid User code Failure code Short circuit in magnetic separator solenoid Trouble (Work equipment and pump (work equipment control) controller system) — 7RFCKB Contents of • When the magnetic separator solenoid is driven, ground short circuit is detected. trouble •...
Page 518: Failure Code [7Rfcky] Short Circuit In Magnetic Separator Solenoid
SEN02091-00 40 Troubleshooting Failure code [7RFCKY] Short circuit in magnetic separator solenoid User code Failure code Short circuit in magnetic separator solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFCKY Contents of • When magnetic separator solenoid is not driven, hot short of the circuit (contact with 24 V circuit) is trouble detected.
Page 519: Failure Code [7Rfhkb] Short Circuit In Conveyor Forward Relay
SEN02091-00 40 Troubleshooting Failure code [7RFHKB] Short circuit in conveyor forward relay User code Failure code Short circuit in conveyor forward relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFHKB Contents of • When the conveyor forward rotation relay circuit is driven, ground short circuit is detected. trouble •...
Page 520 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 521: Failure Code [7Rfhky] Short Circuit In Conveyor Forward Relay
SEN02091-00 40 Troubleshooting Failure code [7RFHKY] Short circuit in conveyor forward relay User code Failure code Short circuit in conveyor forward relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFHKY Contents of • When the conveyor forward relay is not driven, hot short of the circuit (contact with 24 V circuit) is trouble detected.
Page 522 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 523: Failure Code [7Rfkkb] Short Circuit In Lock Cylinder Pull Relay
SEN02091-00 40 Troubleshooting Failure code [7RFKKB] Short circuit in lock cylinder pull relay User code Failure code Short circuit in lock cylinder pull relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFKKB Contents of • When the lock cylinder pull relay is driven, ground short circuit is detected. trouble •...
Page 524 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 525: Failure Code [7Rfkky] Short Circuit In Lock Cylinder Pull Relay
SEN02091-00 40 Troubleshooting Failure code [7RFKKY] Short circuit in lock cylinder pull relay User code Failure code Short circuit in lock cylinder pull relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFKKY Contents of • When the lock cylinder pull relay is not driven, hot short circuit (contact with 24 V circuit) is detected. trouble Action of •...
Page 526 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 527: Failure Code [7Rflka] Disconnection In Accessory Epc Solenoid
SEN02091-00 40 Troubleshooting Failure code [7RFLKA] Disconnection in accessory EPC solenoid User code Failure code Disconnection in accessory EPC solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFLKA Contents of • When the accessory drive EPC valve circuit is driven, disconnection of the circuit is detected. trouble •...
Page 528: Failure Code [7Rflkb] Short Circuit In Accessory Epc Solenoid
40 Troubleshooting SEN02091-00 Failure code [7RFLKB] Short circuit in accessory EPC solenoid User code Failure code Short circuit in accessory EPC solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFLKB Contents of • When the accessory drive EPC valve is driven, ground short circuit is detected. trouble •...
Page 529: Failure Code [7Rflky] Short Circuit In Accessory Epc Solenoid
SEN02091-00 40 Troubleshooting Failure code [7RFLKY] Short circuit in accessory EPC solenoid User code Failure code Short circuit in accessory EPC solenoid Trouble (Work equipment and pump controller (work equipment control) system) — 7RFLKY Contents of • When the accessory drive EPC valve circuit is not driven, hot short (contact with 24 V circuit) is trouble detected.
Page 530: Failure Code [7Rfmky] Short Circuit In Abnormal Pressure Relay
SEN02091-00 40 Troubleshooting Failure code [7RFMKY] Short circuit in abnormal pressure relay User code Failure code Short circuit in abnormal pressure relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFMKY Contents of • When the abnormal pressure recovery relay circuit is driven, hot short (contact with 24 V circuit) is trouble detected.
Page 531 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 532: Failure Code [7Rfmkz] Disconnection Or Short Circuit In Abnormal Pressure Relay
SEN02091-00 40 Troubleshooting Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay User code Failure code Disconnection or short circuit in abnormal pressure relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFMKZ Contents of •...
Page 533 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 534: Failure Code [7Rfnka] Disconnection In Lock Cylinder Unlock Solenoid Valve
SEN02091-00 40 Troubleshooting Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve User code Failure code Disconnection in lock cylinder unlock solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RFNKA Contents of • When the lock cylinder unlock solenoid circuit is driven, disconnection of the circuit is detected. trouble •...
Page 535: Failure Code [7Rfnkb] Short Circuit In Lock Cylinder Unlock Solenoid Valve
40 Troubleshooting SEN02091-00 Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve User code Failure code Short circuit in lock cylinder unlock solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RFNKB Contents of •...
Page 536: Failure Code [7Rfnky] Short Circuit In Lock Cylinder Unlock Solenoid Valve
SEN02091-00 40 Troubleshooting Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve User code Failure code Short circuit in lock cylinder unlock solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RFNKY Contents of •...
Page 537: Failure Code [7Rfpkb] Short Circuit In Lock Cylinder Push Relay
SEN02091-00 40 Troubleshooting Failure code [7RFPKB] Short circuit in lock cylinder push relay User code Failure code Short circuit in lock cylinder push relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFPKB Contents of • When the lock cylinder push relay circuit is driven, ground short circuit is detected. trouble •...
Page 538 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 539: Failure Code [7Rfpky] Short Circuit In Lock Cylinder Push Relay
SEN02091-00 40 Troubleshooting Failure code [7RFPKY] Short circuit in lock cylinder push relay User code Failure code Short circuit in lock cylinder push relay Trouble (Work equipment and pump controller (work equipment control) system) — 7RFPKY Contents of • When the output to the lock cylinder push relay circuit was OFF, an abnormal voltage was detected. trouble Action of •...
Page 540 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 541: Failure Code [7Rgama] Abnormality In 2Nd Conveyor Pressure Sensor
SEN02091-00 40 Troubleshooting Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor User code Failure code Abnormality in 2nd conveyor pressure sensor Trouble (Work equipment and pump controller (work equipment control) system) — 7RGAMA Contents of • Signal voltage from the secondary conveyor pressure sensor is below 0.3 V or above 4.42 V. trouble •...
Page 542 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 543: Failure Code [7Rjaka] Disconnection In Travel Lock Epc Solenoid Valve
SEN02091-00 40 Troubleshooting Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve User code Failure code Disconnection in travel lock EPC solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RJAKA Contents of • When the travel lock EPC valve solenoid is driven, disconnection of the circuit is detected. trouble •...
Page 544 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 545: Failure Code [7Rjakb] Short Circuit In Travel Lock Epc Solenoid Valve
SEN02091-00 40 Troubleshooting Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve User code Failure code Short circuit in travel lock EPC solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RJAKB Contents of •...
Page 546 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 547: Failure Code [7Rjaky] Short Circuit In Travel Lock Epc Solenoid Valve
SEN02091-00 40 Troubleshooting Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve User code Failure code Short circuit in travel lock EPC solenoid valve Trouble (Work equipment and pump controller (work equipment control) system) — 7RJAKY Contents of •...
Page 548: Failure Code [7Rjmmw] Lock Cylinder Slipping
40 Troubleshooting SEN02091-00 Failure code [7RJMMW] Lock cylinder slipping User code Failure code Lock cylinder slipping Trouble (Work equipment and pump controller (work equipment control) system) — 7RJMMW • Judges that the lock cylinder slips if the gap in the crusher is increased for more than the specified Contents of value during the crusher operation, compared with the gap amount when the switch is turned from trouble...
Page 549: Failure Code [7Rjnma] Abnormality In Vibratory Screen Pressure Sensor
SEN02091-00 40 Troubleshooting Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor User code Failure code Abnormality in vibratory screen pressure sensor Trouble (Work equipment and pump controller (work equipment control) system) — 7RJNMA Contents of • Signal voltage from the vibratory screen pressure sensor is below 0.3 V or above 4.42 V. trouble Action of •...
Page 550 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 551: Failure Code [7Rjpkb] Short Circuit In Radio Control Work-Mode Switch
SEN02091-00 40 Troubleshooting Failure code [7RJPKB] Short circuit in radio control work-mode switch User code Failure code Short circuit in radio control work-mode switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RJPKB Contents of • Input signal circuit for the radio controller mode selector switch is closed (connected to ground cir- trouble cuit) within 1 second after the engine starting switch ON.
Page 552: Failure Code [7Rjqkb] Short Circuit In Radio Control Travel-Mode Switch
40 Troubleshooting SEN02091-00 Failure code [7RJQKB] Short circuit in radio control travel-mode switch User code Failure code Short circuit in radio control travel-mode switch Trouble (Work equipment and pump controller (work equipment control) system) — 7RJQKB Contents of • Input signal circuit for the radio controller travel selector switch is closed (connected to ground cir- trouble cuit) within 1 second after the engine starting switch ON.
Page 553: Failure Code [7Rjrkb] Short Circuit On Travel Signal
SEN02091-00 40 Troubleshooting Failure code [7RJRKB] Short circuit on travel signal User code Failure code Short circuit on travel signal Trouble (Work equipment and pump controller (work equipment control) system) — 7RJRKB Contents of • Travel signal circuit is closed (connected to ground circuit) within 1 second after the engine starting trouble switch ON.
Page 554 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 555: Failure Code [7Rjsma] Abnormality In Magnetic Separator Pressure Sensor
SEN02091-00 40 Troubleshooting Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor User code Failure code Abnormality in magnetic separator pressure sensor Trouble (Work equipment and pump controller (work equipment control) system) — 7RJSMA Contents of • Signal voltage from the magnetic separator pressure sensor is below 0.3 V or above 4.42 V. trouble Action of •...
Page 556 40 Troubleshooting SEN02091-00 Related electrical circuit diagram BR380JG-1E0...
Page 557: Failure Code [Aa10Nx] Air Cleaner Clogging
SEN02091-00 40 Troubleshooting Failure code [AA10NX] Air cleaner Clogging User code Failure code Air cleaner Clogging Trouble (Machine monitor system) — AA10NX Contents of • While the engine is running, the signal circuit of the air cleaner clogging switch is opened (discon- trouble nected from the chassis ground).
Page 558 40 Troubleshooting SEN02091-00 Circuit diagram related to air cleaner clogging BR380JG-1E0...
Page 559: Failure Code [Ab00Ke] Charge Voltage Too Low
SEN02091-00 40 Troubleshooting Failure code [AB00KE] Charge voltage too low User code Failure code Charge voltage too low Trouble (Machine monitor system) — AB00KE Contents of • While the engine is running, the generation signal is not input from the alternator. trouble Action of •...
Page 560 40 Troubleshooting SEN02091-00 Circuit diagram related to charge voltage BR380JG-1E0...
Page 562: Troubleshooting By Failure Code, Part 3
SEN02092-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting by failure code, Part 3 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 ..................
Page 563 SEN02092-00 40 Troubleshooting 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 ......................
Page 564: Failure Code [B@Bazg] Engine Oil Pressure Too Low
SEN02092-00 40 Troubleshooting Failure code [B@BAZG] Engine oil pressure too low User code Failure code Engine oil pressure too low Trouble (Engine controller system) — B@BAZG Contents of • Engine oil pressure drops while engine is running. trouble • Limits output for travel (Limits injection rate and engine speed) Action of •...
Page 565 40 Troubleshooting SEN02092-00 Circuit diagram related to engine oil pressure of machine monitor BR380JG-1E0...
Page 566: Failure Code [B@Bazk] Engine Oil Level Reduction
SEN02092-00 40 Troubleshooting Failure code [ B@BAZK] Engine oil level reduction User code Failure code Engine oil level reduction Trouble (Machine monitor system) — B@BAZK Contents of • While the engine is stopped (with the starting switch in the ON position), the signal circuit of the trouble engine oil level switch is opened (disconnected from the chassis ground).
Page 567: Failure Code [B@Bcns] Radiator Coolant Overheat
40 Troubleshooting SEN02092-00 Failure code [B@BCNS] Radiator coolant overheat User code Failure code Radiator coolant overheat Trouble (Engine controller system) — B@BCNS Contents of • Engine coolant overheats while engine is running. trouble • Limits output for travel (Limits injection rate and engine speed) Action of •...
Page 568: Failure Code [B@Bczk] Radiator Coolant Level Reduction
SEN02092-00 40 Troubleshooting Failure code [B@BCZK] Radiator coolant level reduction User code Failure code Radiator coolant level reduction Trouble (Machine monitor system) — B@BCZK Contents of • While the engine is running, the signal circuit of the radiator coolant level switch is opened (discon- trouble nected from the chassis ground).
Page 569 40 Troubleshooting SEN02092-00 Circuit diagram related to radiator coolant level BR380JG-1E0...
Page 570: Failure Code [B@Hans] Hydraulic Oil Overheat
SEN02092-00 40 Troubleshooting Failure code [B@HANS] Hydraulic oil overheat User code Failure code Hydraulic oil overheat Trouble (Machine monitor system) — B@HANS Contents of • While engine was running, signal circuit of hydraulic oil temperature sensor detected overheating of trouble hydraulic oil (above about 102°C).
Page 571: Failure Code [Ca115] Abnormality In Engine Ne And Bkup Speed Sensors
40 Troubleshooting SEN02092-00 Failure code [CA115] Abnormality in engine NE and Bkup speed sensors User code Failure code Abnormality in engine NE and Bkup speed sensors Trouble (Engine controller system) CA115 Contents of • Both signals of engine Ne speed sensor and engine Bkup speed sensor are abnormal. trouble Action of •...
Page 572: Failure Code [Ca122] Charge Pressure Sensor Too High
SEN02092-00 40 Troubleshooting Failure code [CA122] Charge pressure sensor too high User code Failure code Charge pressure sensor too high Trouble (Engine controller system) CA122 Contents of • Pressure signal circuit of boost pressure/temperature sensor detected high voltage. trouble Action of •...
Page 573 40 Troubleshooting SEN02092-00 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) BR380JG-1E0...
Page 574: Failure Code [Ca123] Charge Pressure Sensor Too Low
SEN02092-00 40 Troubleshooting Failure code [CA123] Charge pressure sensor too low User code Failure code Charge pressure sensor too low Trouble (Engine controller system) CA123 Contents of • Pressure signal circuit of boost pressure/temperature sensor detected low voltage. trouble Action of •...
Page 575 40 Troubleshooting SEN02092-00 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) BR380JG-1E0...
Page 576: Failure Code [Ca131] Throttle Sensor Too High
SEN02092-00 40 Troubleshooting Failure code [CA131] Throttle sensor too high User code Failure code Throttle sensor too high Trouble (Engine controller system) CA131 Contents of • Signal circuit of fuel control dial detected high voltage. trouble • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just Action of before detection of trouble and continues operation.
Page 577 40 Troubleshooting SEN02092-00 Circuit diagram related to fuel control dial BR380JG-1E0...
Page 578: Failure Code [Ca132] Throttle Sensor Too Low
SEN02092-00 40 Troubleshooting Failure code [CA132] Throttle sensor too low User code Failure code Throttle sensor too low Trouble (Engine controller system) CA132 Contents of • Signal circuit of fuel control dial detected low voltage. trouble • If trouble occurs while starting switch is in ON position, controller fixes voltage value to level just Action of before detection of trouble and continues operation.
Page 579 40 Troubleshooting SEN02092-00 Circuit diagram related to fuel control dial BR380JG-1E0...
Page 580: Failure Code [Ca144] Coolant Temperature Sensor Too High
SEN02092-00 40 Troubleshooting Failure code [CA144] Coolant temperature sensor too high User code Failure code Coolant temperature sensor too high Trouble (Engine controller system) CA144 Contents of • Signal circuit of coolant temperature sensor detected high voltage. trouble Action of •...
Page 581 40 Troubleshooting SEN02092-00 Circuit diagram related to coolant temperature sensor BR380JG-1E0...
Page 582: Failure Code [Ca145] Coolant Temperature Sensor Too Low
SEN02092-00 40 Troubleshooting Failure code [CA145] Coolant temperature sensor too low User code Failure code Coolant temperature sensor too low Trouble (Engine controller system) CA145 Contents of • Signal circuit of coolant temperature sensor detected low voltage. trouble Action of •...
Page 583 40 Troubleshooting SEN02092-00 Circuit diagram related to coolant temperature sensor BR380JG-1E0...
Page 584: Failure Code [Ca153] Charge Temperature Sensor Too High
SEN02092-00 40 Troubleshooting Failure code [CA153] Charge temperature sensor too high User code Failure code Charge temperature sensor too high Trouble (Engine controller system) CA153 Contents of • Temperature signal circuit of boost pressure/temperature sensor detected high voltage. trouble Action of •...
Page 585 40 Troubleshooting SEN02092-00 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) BR380JG-1E0...
Page 586: Failure Code [Ca154] Charge Temperature Sensor Too Low
SEN02092-00 40 Troubleshooting Failure code [CA154] Charge temperature sensor too low User code Failure code Charge temperature sensor too low Trouble (Engine controller system) CA154 Contents of • Temperature signal circuit of boost pressure/temperature sensor detected low voltage. trouble Action of •...
Page 587 40 Troubleshooting SEN02092-00 Circuit diagram related to boost pressure/temperature sensor (Combination sensor) BR380JG-1E0...
Page 588: Failure Code [Ca155] Charge Temperature Too High And Engine Speed Derated
SEN02092-00 40 Troubleshooting Failure code [CA155] Charge temperature too high and engine speed derated User code Failure code Charge temperature too high and engine speed derated Trouble (Engine controller system) CA155 Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature trouble limit.
Page 589: Failure Code [Ca187] Sensor Power Source 2 Too Low
SEN02092-00 40 Troubleshooting Failure code [CA187] Sensor power source 2 too low User code Failure code Sensor power source 2 too low Trouble (Engine controller system) CA187 Contents of • Low voltage was detected in sensor power supply 2 circuit. trouble •...
Page 590 40 Troubleshooting SEN02092-00 Circuit diagram related to sensor power supply 2 BR380JG-1E0...
Page 591: Failure Code [Ca221] Ambient Pressure Sensor Too High
SEN02092-00 40 Troubleshooting Failure code [CA221] Ambient pressure sensor too high User code Failure code Ambient pressure sensor too high Trouble (Engine controller system) CA221 Contents of • High voltage was detected in signal circuit of ambient pressure sensor. trouble Action of •...
Page 592 40 Troubleshooting SEN02092-00 Circuit diagram related to ambient pressure sensor BR380JG-1E0...
Page 593: Failure Code [Ca222] Ambient Pressure Sensor Too Low
SEN02092-00 40 Troubleshooting Failure code [CA222] Ambient pressure sensor too low User code Failure code Ambient pressure sensor too low Trouble (Engine controller system) CA222 Contents of • Low voltage was detected in signal circuit of ambient pressure sensor. trouble Action of •...
Page 594 40 Troubleshooting SEN02092-00 Circuit diagram related to ambient pressure sensor BR380JG-1E0...
Page 595: Failure Code [Ca227] Sensor Power Source 2 Too High
SEN02092-00 40 Troubleshooting Failure code [CA227] Sensor power source 2 too high User code Failure code Sensor power source 2 too high Trouble (Engine controller system) CA227 Contents of • High voltage was detected in sensor power supply 2 circuit. trouble •...
Page 596: Failure Code [Ca234] Engine Overspeed
40 Troubleshooting SEN02092-00 Failure code [CA234] Engine overspeed User code Failure code Engine overspeed Trouble (Engine controller system) — CA234 Contents of • Engine speed exceeded control upper speed limit. trouble Action of • Stops injection until engine speed lowers to normal level. controller Problem that appears on...
Page 597: Failure Code [Ca238] Abnormal Power Source For Ne Speed Sensor
SEN02092-00 40 Troubleshooting Failure code [CA238] Abnormal power source for Ne speed sensor User code Failure code Abnormal power source for Ne speed sensor Trouble (Engine controller system) CA238 Contents of • Low voltage was detected in power supply circuit of engine Ne speed sensor. trouble Action of •...
Page 598: Failure Code [Ca271] Short Circuit In Fuel Pump Actuator
40 Troubleshooting SEN02092-00 Failure code [CA271] Short circuit in fuel pump actuator User code Failure code Short circuit in fuel pump actuator Trouble (Engine controller system) CA271 Contents of • Short circuit was detected in drive circuit of supply pump actuator. trouble Action of •...
Page 599: Failure Code [Ca272] Disconnection In Fuel Pump Actuator
SEN02092-00 40 Troubleshooting Failure code [CA272] Disconnection in fuel pump actuator User code Failure code Disconnection in fuel pump actuator Trouble (Engine controller system) CA272 Contents of • Opening was detected in drive circuit of supply pump actuator. trouble Action of •...
Page 600: Failure Code [Ca322] Disconnection Or Short Circuit In Injector No.1
SEN02092-00 40 Troubleshooting Failure code [CA322] Disconnection or short circuit in injector No.1 User code Failure code Disconnection or short circuit in injector No.1 Trouble (Engine controller system) CA322 Contents of • Opening or short circuit was detected in drive circuit of No. 1 injector. trouble Action of •...
Page 601 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 1 injector BR380JG-1E0...
Page 602: Failure Code [Ca323] Disconnection Or Short Circuit In Injector No.5
SEN02092-00 40 Troubleshooting Failure code [CA323] Disconnection or short circuit in injector No.5 User code Failure code Disconnection or short circuit in injector No.5 Trouble (Engine controller system) CA323 Contents of • Opening or short circuit was detected in drive circuit of No. 5 injector. trouble Action of •...
Page 603 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 5 injector BR380JG-1E0...
Page 604: Failure Code [Ca324] Disconnection Or Short Circuit In Injector No.3
SEN02092-00 40 Troubleshooting Failure code [CA324] Disconnection or short circuit in injector No.3 User code Failure code Disconnection or short circuit in injector No.3 Trouble (Engine controller system) CA324 Contents of • Opening or short circuit was detected in drive circuit of No. 3 injector. trouble Action of •...
Page 605 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 3 injector BR380JG-1E0...
Page 606: Failure Code [Ca325] Disconnection Or Short Circuit In Injector No.6
SEN02092-00 40 Troubleshooting Failure code [CA325] Disconnection or short circuit in injector No.6 User code Failure code Disconnection or short circuit in injector No.6 Trouble (Engine controller system) CA325 Contents of • Opening or short circuit was detected in drive circuit of No. 6 injector. trouble Action of •...
Page 607 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 6 injector BR380JG-1E0...
Page 608: Failure Code [Ca331] Disconnection Or Short Circuit In Injector No.2
SEN02092-00 40 Troubleshooting Failure code [CA331] Disconnection or short circuit in injector No.2 User code Failure code Disconnection or short circuit in injector No.2 Trouble (Engine controller system) CA331 Contents of • Opening or short circuit was detected in drive circuit of No. 2 injector. trouble Action of •...
Page 609 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 2 injector BR380JG-1E0...
Page 610: Failure Code [Ca332] Disconnection Or Short Circuit In Injector No.4
SEN02092-00 40 Troubleshooting Failure code [CA332] Disconnection or short circuit in injector No.4 User code Failure code Disconnection or short circuit in injector No.4 Trouble (Engine controller system) CA332 Contents of • Opening or short circuit was detected in drive circuit of No. 4 injector. trouble Action of •...
Page 611 40 Troubleshooting SEN02092-00 Circuit diagram related to No. 4 injector BR380JG-1E0...
Page 613: Troubleshooting By Failure Code, Part 4
SEN02093-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting by failure code, Part 4 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..................
Page 614 SEN02093-00 40 Troubleshooting Failure code [CA731] Abnormal phase in engine Bkup speed sensor............30 Failure code [CA757] Loss of all engine controller data................32 Failure code [CA778] Abnormality in engine Bkup speed sensor ..............34 Failure code [CA1633] CAN communication error (engine controller) ............36 Failure code [CA2185] Throttle pedal sensor power source too high ............
Page 615: Failure Code [Ca342] Abnormality In Engine Controller Data Consistency
40 Troubleshooting SEN02093-00 Failure code [CA342] Abnormality in engine controller data consistency User code Failure code Abnormality in engine controller data consistency Trouble (Engine controller system) CA342 Contents of • Incompatibility of data occurred in engine controller. trouble Action of •...
Page 616: Failure Code [Ca351] Abnormality In Injector Drive Circuit
SEN02093-00 40 Troubleshooting Failure code [CA351] Abnormality in injector drive circuit User code Failure code Abnormality in injector drive circuit Trouble (Engine controller system) CA351 Contents of • There is error in drive power circuit of injector. trouble Action of •...
Page 617 40 Troubleshooting SEN02093-00 Circuit diagram related to engine controller BR380JG-1E0...
Page 618: Failure Code [Ca352] Sensor Power Source 1 Too Low
SEN02093-00 40 Troubleshooting Failure code [CA352] Sensor power source 1 too low User code Failure code Sensor power source 1 too low Trouble (Engine controller system) CA352 Contents of • Low voltage was detected in sensor power supply 1 circuit. trouble Action of •...
Page 619 40 Troubleshooting SEN02093-00 Circuit diagram related to sensor power supply 1 BR380JG-1E0...
Page 620: Failure Code [Ca386] Sensor Power Source 1 Too High
SEN02093-00 40 Troubleshooting Failure code [CA386] Sensor power source 1 too high User code Failure code Sensor power source 1 too high Trouble (Engine controller system) CA386 Contents of • High voltage was detected in sensor power supply 1 circuit. trouble Action of •...
Page 621: Failure Code [Ca428] Water Detection Sensor Too High
SEN02093-00 40 Troubleshooting Failure code [CA428] Water detection sensor too high User code Failure code Water detection sensor too high Trouble (Engine controller system) CA428 Contents of • High voltage was detected in signal circuit of water-in-fuel sensor. trouble Action of •...
Page 622 40 Troubleshooting SEN02093-00 Circuit diagram related to water-in-fuel sensor BR380JG-1E0...
Page 623: Failure Code [Ca429] Water Detection Sensor Too Low
SEN02093-00 40 Troubleshooting Failure code [CA429] Water detection sensor too low User code Failure code Water detection sensor too low Trouble (Engine controller system) CA429 Contents of • Low voltage was detected in signal circuit of water-in-fuel sensor. trouble Action of •...
Page 624 40 Troubleshooting SEN02093-00 Circuit diagram related to water-in-fuel sensor BR380JG-1E0...
Page 625: Failure Code [Ca435] Abnormality In Engine Oil Pressure Switch
SEN02093-00 40 Troubleshooting Failure code [CA435] Abnormality in engine oil pressure switch User code Failure code Abnormality in engine oil pressure switch Trouble (Engine controller system) CA435 Contents of • There is error in signal circuit of engine oil pressure switch. trouble Action of •...
Page 626: Failure Code [Ca441] Power Source Voltage Too Low
SEN02093-00 40 Troubleshooting Failure code [CA441] Power source voltage too low User code Failure code Power source voltage too low Trouble (Engine controller system) CA441 Contents of • There is low voltage in controller power supply circuit. trouble Action of •...
Page 627 40 Troubleshooting SEN02093-00 Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between fuse No. 3 – machine wiring harness – engine controller may be defective. Check them directly. Defective wiring • Looseness of connector, breakage of lock, or breakage of seal harness connector •...
Page 628: Failure Code [Ca442] Power Source Voltage Too High
SEN02093-00 40 Troubleshooting Failure code [CA442] Power source voltage too high User code Failure code Power source voltage too high Trouble (Engine controller system) CA442 Contents of • There is high voltage (36 V or higher) in controller power supply circuit. trouble Action of •...
Page 629 40 Troubleshooting SEN02093-00 Circuit diagram related to engine controller power supply BR380JG-1E0...
Page 630: Failure Code [Ca449] Common Rail Pressure Sensor Too High (2)
SEN02093-00 40 Troubleshooting Failure code [CA449] Common rail pressure sensor too high (2) User code Failure code Common rail pressure sensor too high (2) Trouble (Engine controller system) CA449 Contents of • There is high pressure error in common rail circuit. trouble Action of •...
Page 631: Failure Code [Ca451] Common Rail Pressure Sensor Too High
SEN02093-00 40 Troubleshooting Failure code [CA451] Common rail pressure sensor too high User code Failure code Common rail pressure sensor too high Trouble (Engine controller system) CA451 Contents of • There is high voltage in signal circuit of common rail pressure sensor. trouble Action of •...
Page 632 40 Troubleshooting SEN02093-00 Circuit diagram related to common rail pressure sensor BR380JG-1E0...
Page 633: Failure Code [Ca452] Common Rail Pressure Sensor Too Low
SEN02093-00 40 Troubleshooting Failure code [CA452] Common rail pressure sensor too low User code Failure code Common rail pressure sensor too low Trouble (Engine controller system) CA452 Contents of • There is low voltage in signal circuit of common rail pressure sensor. trouble Action of •...
Page 634 40 Troubleshooting SEN02093-00 Circuit diagram related to common rail pressure sensor BR380JG-1E0...
Page 635: Failure Code [Ca488] Charge Temperature Too High And Torque Derated
SEN02093-00 40 Troubleshooting Failure code [CA488] Charge temperature too high and torque derated User code Failure code Charge temperature too high and torque derated Trouble (Engine controller system) CA488 Contents of • Temperature signal of boost pressure/temperature sensor exceeded control upper temperature trouble limit.
Page 636: Failure Code [Ca559] Supply Pump No Pressure
40 Troubleshooting SEN02093-00 Failure code [CA559] Supply pump no pressure User code Failure code Supply pump no pressure Trouble (Engine controller system) CA559 Contents of • There is low pressure error in common rail circuit. trouble Action of • None in particular. controller Problem that •...
Page 637: Failure Code [Ca689] Abnormality In Engine Ne Speed Sensor
SEN02093-00 40 Troubleshooting Failure code [CA689] Abnormality in engine Ne speed sensor User code Failure code Abnormality in engine Ne speed sensor Trouble (Engine controller system) CA689 Contents of • There is error in signal from engine Ne speed sensor. trouble Action of •...
Page 638 40 Troubleshooting SEN02093-00 Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between engine Ne speed sensor – engine wiring har- ness – engine controller may be defective. Check them directly. Defective wiring • Looseness of connector, breakage of lock, or breakage of seal Possible harness connector •...
Page 639: Failure Code [Ca731] Abnormal Phase In Engine Bkup Speed Sensor
SEN02093-00 40 Troubleshooting Failure code [CA731] Abnormal phase in engine Bkup speed sensor User code Failure code Abnormal phase in engine Bkup speed sensor Trouble (Engine controller system) CA731 Contents of • Phase error was detected in signals from engine Ne speed sensor and engine Bkup speed sensor trouble Action of •...
Page 640: Failure Code [Ca757] Loss Of All Engine Controller Data
SEN02093-00 40 Troubleshooting Failure code [CA757] Loss of all engine controller data User code Failure code Loss of all engine controller data Trouble (Engine controller system) CA757 Contents of • All data in engine controller are lost. trouble Action of •...
Page 641 40 Troubleshooting SEN02093-00 Circuit diagram related to engine controller power supply BR380JG-1E0...
Page 642: Failure Code [Ca778] Abnormality In Engine Bkup Speed Sensor
SEN02093-00 40 Troubleshooting Failure code [CA778] Abnormality in engine Bkup speed sensor User code Failure code Abnormality in engine Bkup speed sensor Trouble (Engine controller system) CA778 Contents of • There is error in signal from engine Bkup speed sensor. trouble Action of •...
Page 643 40 Troubleshooting SEN02093-00 Cause Standard value in normal state/Remarks on troubleshooting Connecting parts between engine Bkup speed sensor – engine wiring har- ness – engine controller may be defective. Check them directly. Defective wiring • Looseness of connector, breakage of lock, or breakage of seal Possible harness connector •...
Page 644: Failure Code [Ca1633] Can Communication Error (Engine Controller)
SEN02093-00 40 Troubleshooting Failure code [CA1633] CAN communication error (engine controller) User code Failure code CAN communication error (engine controller) Trouble (Engine controller system) CA1633 Contents of • Engine controller detected communication error in CAN communication circuit between pump con- trouble troller and machine monitor.
Page 645 40 Troubleshooting SEN02093-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine starting switch OFF, then carry out troubleshooting Defective CAN termi- Possible without turning engine starting switch ON. nal resistance (Inter- causes and nal short circuit or K02 (male), P03 (male) Resistance standard value...
Page 646: Failure Code [Ca2185] Throttle Pedal Sensor Power Source Too High
SEN02093-00 40 Troubleshooting Failure code [CA2185] Throttle pedal sensor power source too high User code Failure code Throttle pedal sensor power source too high Trouble (Engine controller system) CA2185 Contents of • High voltage (5.25 V or higher) was detected in throttle sensor power supply circuit. trouble •...
Page 647: Failure Code [Ca2186] Throttle Pedal Sensor Power Source Too Low
40 Troubleshooting SEN02093-00 Failure code [CA2186] Throttle pedal sensor power source too low User code Failure code Throttle pedal sensor power source too low Trouble (Engine controller system) CA2186 Contents of • Low voltage was detected in throttle sensor power supply circuit. trouble •...
Page 648: Failure Code [Ca2249] Supply Pump No Pressure (2)
SEN02093-00 40 Troubleshooting Failure code [CA2249] Supply pump no pressure (2) User code Failure code Supply pump no pressure (2) Trouble (Engine controller system) CA2249 Contents of • There is low pressure error in common rail circuit. trouble Action of •...
Page 649: Failure Code [Ca2311] Abnormal Resistance In Pump Regulator Valve
SEN02093-00 40 Troubleshooting Failure code [CA2311] Abnormal resistance in pump regulator valve User code Failure code Abnormal resistance in pump regulator valve Trouble (Engine controller system) CA2311 Contents of • Resistance of supply pump actuator circuit is abnormally high or low. trouble Action of •...
Page 650 40 Troubleshooting SEN02093-00 Circuit diagram related to supply pump actuator (metering unit) BR380JG-1E0...
Page 651: Failure Code [Ca2555] Disconnection In Air Intake Heater Relay
SEN02093-00 40 Troubleshooting Failure code [CA2555] Disconnection in air intake heater relay User code Failure code Disconnection in air intake heater relay Trouble (Engine controller system) CA2555 Contents of • Disconnection was detected in drive circuit of intake air heater relay. trouble Action of •...
Page 652 40 Troubleshooting SEN02093-00 Related electrical circuit diagram BR380JG-1E0...
Page 653: Failure Code [Ca2556] Short Circuit In Air Intake Heater Relay
SEN02093-00 40 Troubleshooting Failure code [CA2556] Short circuit in air intake heater relay User code Failure code Short circuit in air intake heater relay Trouble (Engine controller system) CA2556 Contents of • Short circuit was detected in drive circuit of intake air heater relay. trouble Action of •...
Page 654 40 Troubleshooting SEN02093-00 Related electrical circuit diagram BR380JG-1E0...
Page 656: Troubleshooting By Failure Code, Part 5
SEN02094-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting by failure code, Part 5 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 .................
Page 657 SEN02094-00 40 Troubleshooting 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 BR380JG-1E0...
Page 658: Failure Code [D162Ky] Short Circuit In Horn Relay
SEN02094-00 40 Troubleshooting Failure code [D162KY] Short circuit in horn relay User code Failure code Short circuit in horn relay Trouble (Work equipment and pump controller (work equipment control) system) — D162KY Contents of • When the horn relay drive circuit is driven, hot short of the circuit (contact with 24 V circuit) is trouble detected.
Page 659 40 Troubleshooting SEN02094-00 Circuit diagram related to horn relay BR380JG-1E0...
Page 660: Failure Code [D162Kz] Disconnection Or Short Circuit In Horn Relay
SEN02094-00 40 Troubleshooting Failure code [D162KZ] Disconnection or short circuit in horn relay User code Failure code Disconnection or short circuit in horn relay Trouble (Work equipment and pump controller (work equipment control) system) — D162KZ Contents of • When the horn relay drive circuit is driven, disconnection or ground short circuit is detected. trouble •...
Page 661 40 Troubleshooting SEN02094-00 Related electrical circuit diagrams BR380JG-1E0...
Page 662: Failure Code [Da22Kk] Solenoid Power Source Too Low
SEN02094-00 40 Troubleshooting Failure code [DA22KK] Solenoid power source too low User code Failure code Solenoid power source too low Trouble (Work equipment and pump controller (pump control) system) DA22KK Contents of • Solenoid power supply voltage of controller is below 20 V. trouble •...
Page 663 40 Troubleshooting SEN02094-00 Circuit diagram related to pump controller power supply BR380JG-1E0...
Page 664: Failure Code [Da25Kp] Abnormality In Pressure Sensor Power Source
SEN02094-00 40 Troubleshooting Failure code [DA25KP] Abnormality in pressure sensor power source User code Failure code Abnormality in pressure sensor power source Trouble (Work equipment and pump controller (pump control) system) — DA25KP Contents of • Voltage from the pressure sensor power supply circuit reads under 2.0 V or above 5.3 V. trouble Action of •...
Page 665 40 Troubleshooting SEN02094-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine starting switch OFF, then turn engine starting switch ON and carry out troubleshooting Wiring harness between C01 (female) (22) – J03 – S01 (female) (3) and chassis ground Voltage Max.
Page 666 SEN02094-00 40 Troubleshooting Related electrical circuit diagram BR380JG-1E0...
Page 667: Failure Code [Da2Rmc] Can Communication Error (Work Equipment And Pump Controller)
SEN02094-00 40 Troubleshooting Failure code [DA2RMC] CAN communication error (work equipment and pump controller) User code Failure code CAN communication error (work equipment and pump controller) Trouble (Work equipment and pump controller system) DA2RMC Contents of • Work equipment and pump controller detects communication error in CAN communication circuit trouble between engine controller and machine monitor.
Page 668 40 Troubleshooting SEN02094-00 Related electrical circuit diagram BR380JG-1E0...
Page 669: Failure Code [Da2Skq] Abnormality In Model Code Input
SEN02094-00 40 Troubleshooting Failure code [DA2SKQ] Abnormality in model code input User code Failure code Abnormality in model code input Trouble (Work equipment and pump controller (pump control) system) — DA2SKQ Contents of • Model code signal for other model than registered in the controller is input. trouble •...
Page 670 40 Troubleshooting SEN02094-00 Related electrical circuit diagram BR380JG-1E0...
Page 671 SEN02094-00 40 Troubleshooting Failure code [DAFRMC] CAN communication error (monitor controller)1 User code Failure code CAN communication error (monitor controller) Trouble (Machine monitor system) DAFRMC Contents of • Machine monitor detects communication error in CAN communication circuit between work equip- trouble ment and pump controller and engine controller.
Page 672 40 Troubleshooting SEN02094-00 Related electrical circuit diagram BR380JG-1E0...
Page 673: Failure Code [Dda6Ka] Disconnection In Engine Stop Switch
SEN02094-00 40 Troubleshooting Failure code [DDA6KA] Disconnection in engine stop switch User code Failure code Disconnection in engine stop switch Trouble (Work equipment and pump controller (work equipment control) system) — DDA6KA Contents of • The engine stop switch input signal circuit is opened (disconnected from the terminal ACC) in 1 sec- trouble ond after the engine starting switch is turned ON.
Page 674 40 Troubleshooting SEN02094-00 Circuit diagram related to engine stop switch BR380JG-1E0...
Page 675: Failure Code [Dgh2Kb] Short Circuit In Hydraulic Oil Temperature Sensor
SEN02094-00 40 Troubleshooting Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor1 User code Failure code Short circuit in hydraulic oil temperature sensor Trouble (Machine monitor system) — DGH2KB Contents of • Ground fault was detected in hydraulic oil temperature sensor circuit. trouble Action of •...
Page 676: Failure Code [Dhpama] Abnormality In F Pump Pressure Sensor
SEN02094-00 40 Troubleshooting Failure code [DHPAMA] Abnormality in F pump pressure sensor User code Failure code Abnormality in F pump pressure sensor Trouble (Work equipment and pump controller (pump control) system) — DHPAMA Contents of • Signal voltage of F pump pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 677 40 Troubleshooting SEN02094-00 Circuit diagram related to F pump pressure sensor BR380JG-1E0...
Page 678: Failure Code [Dhpbma] Abnormality In R Pump Pressure Sensor
SEN02094-00 40 Troubleshooting Failure code [DHPBMA] Abnormality in R pump pressure sensor User code Failure code Abnormality in R pump pressure sensor Trouble (Work equipment and pump controller (pump control) system) — DHPBMA Contents of • Signal voltage of R pump pressure sensor circuit is below 0.3 V or above 4.5 V. trouble Action of •...
Page 679 40 Troubleshooting SEN02094-00 Circuit diagram related to R pump pressure sensor BR380JG-1E0...
Page 680: Failure Code [Dub0Ky] Short Circuit In Beacon Solid State Relay
SEN02094-00 40 Troubleshooting Failure code [DUB0KY] Short circuit in beacon solid state relay User code Failure code Short circuit in beacon solid state relay Trouble (Work equipment and pump controller (work equipment control) system) — DUB0KY Contents of • When the rotary lamp relay is driven, hot short circuit (contact with 24 V circuit) is detected. trouble Action of •...
Page 681 40 Troubleshooting SEN02094-00 Related electrical circuit diagram BR380JG-1E0...
Page 682: Failure Code [Dub0Kz] Disconnection Or Short Circuit In Beacon Solid State Relay
SEN02094-00 40 Troubleshooting Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay User code Failure code Disconnection or short circuit in beacon solid state relay Trouble (Work equipment and pump controller (work equipment control) system) — DUB0KZ Contents of •...
Page 683 40 Troubleshooting SEN02094-00 Related electrical circuit diagram BR380JG-1E0...
Page 684: Failure Code [Dxa0Ka] Disconnection In Pc-Epc Solenoid
SEN02094-00 40 Troubleshooting Failure code [DXA0KA] Disconnection in PC-EPC Solenoid User code Failure code Disconnection in PC-EPC Solenoid Trouble (Work equipment and pump controller (pump control) system) DXA0KA Contents of • When the PC-EPC solenoid is driven, disconnection of the circuit is detected. trouble Action of •...
Page 685: Failure Code [Dxa0Kb] Short Circuit In Pc-Epc Solenoid
40 Troubleshooting SEN02094-00 Failure code [DXA0KB] Short circuit in PC-EPC Solenoid User code Failure code Short circuit in PC-EPC Solenoid Trouble (Work equipment and pump controller (pump control) system) DXA0KB Contents of • When the PC-EPC solenoid is driven, ground short circuit is detected. trouble Action of •...
Page 686: Failure Code [Dxa0Ky] Short Circuit In Pc-Epc Solenoid
SEN02094-00 40 Troubleshooting Failure code [DXA0KY] Short circuit in PC-EPC Solenoid User code Failure code Short circuit in PC-EPC Solenoid Trouble (Work equipment and pump controller (pump control) system) DXA0KY Contents of • When the PC-EPC solenoid circuit is not driven, hot short (contact with 24 V circuit) is detected. trouble Action of •...
Page 687: Failure Code [Dxe0Ka] Disconnection In Ls-Epc Solenoid
40 Troubleshooting SEN02094-00 Failure code [DXE0KA] Disconnection in LS-EPC solenoid User code Failure code Disconnection in LS-EPC solenoid Trouble (Work equipment and pump controller (pump control) system) — DXE0KA Contents of • When the LS-EPC solenoid is driven, disconnection of the circuit is detected. trouble Action of •...
Page 688: Failure Code [Dxe0Kb] Short Circuit In Ls-Epc Solenoid
SEN02094-00 40 Troubleshooting Failure code [DXE0KB] Short circuit in LS-EPC solenoid User code Failure code Short circuit in LS-EPC solenoid Trouble (Work equipment and pump controller (pump control) system) — DXE0KB Contents of • When the LS-EPC solenoid is driven, short circuit is detected. trouble •...
Page 689: Failure Code [Dxe0Ky] Short Circuit In Ls-Epc Solenoid
40 Troubleshooting SEN02094-00 Failure code [DXE0KY] Short circuit in LS-EPC solenoid User code Failure code Short circuit in LS-EPC solenoid Trouble (Work equipment and pump controller (pump control) system) — DXE0KY Contents of • When the output to the LS-EPC solenoid circuit is OFF, abnormal voltage is detected. trouble Action of •...
Page 691 SEN02095-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting of electrical system (E-mode) 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 E-3 The automatic warm-up function does not work..................
Page 692 SEN02095-00 40 Troubleshooting 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..................
Page 693: Information In Troubleshooting Table
40 Troubleshooting SEN02095-00 Information in troubleshooting table a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully. Trouble Trouble which occurred in the machine Related Information related to detected trouble or troubleshooting information Cause Standard value in normal state/Remarks on troubleshooting...
Page 694: Engine Does Not Start (Engine Does Not Turn)
SEN02095-00 40 Troubleshooting E-1 Engine does not start (Engine does not turn) Trouble • Engine does not start (Engine does not turn). Related • Engine starting circuit has following 2 start lock mechanisms. information 1) Start lock with password of machine monitor Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without...
Page 695 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Defective battery relay (Disconnection or Battery relay Starting switch Voltage defective tightening of Between battery relay terminal) terminal M and chassis 20 –...
Page 696 SEN02095-00 40 Troubleshooting Electrical circuit diagram related to engine preheating, starting, stopping and charging BR380JG-1E0...
Page 697: The Engine Stops While It Is Running
SEN02095-00 40 Troubleshooting E-2 The engine stops while it is running Trouble • The engine stops while it is running. • When the engine stop switch (or radio controller all stop switch) is operated, the machine monitor Related displays “Engine stopped” for about 10 seconds. information •...
Page 698 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to engine preheating, starting, stopping and charging BR380JG-1E0...
Page 699: The Automatic Warm-Up Function Does Not Work
SEN02095-00 40 Troubleshooting E-3 The automatic warm-up function does not work. Trouble • The automatic warm-up function does not work. • When the engine coolant temperature is below 30°C, the automatic warm-up device raise the engine speed to 1,200 rpm. Related •...
Page 700: Preheater Does Not Operate
SEN02095-00 40 Troubleshooting E-4 Preheater does not operate Trouble (1) When starting switch is turned to HEAT position, preheating monitor does not light up or flash. • Preheater monitor lights up when starting switch is turned to HEAT and starts flashing about 30 sec- onds after to notify completion of preheating (It stops flashing about 10 seconds after).
Page 701 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to engine preheating, starting, stopping and charging BR380JG-1E0...
Page 702: The Whole Work Equipment Stops Suddenly
SEN02095-00 40 Troubleshooting E-5 The whole work equipment stops suddenly Trouble • The whole work equipment stops suddenly. • The work equipment stops suddenly while no switches are operated in the following cases; (1) The work equipment is overloaded. (2) Engine has abnormality. In these cases, the horn sounds. Related •...
Page 703 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without Disconnection in wiring turning starting switch ON. harness (Disconnec- Wiring harness between B28 (10) – B13 (female) Resistance Max. 1 z tion in wiring harness or defective contact in Wiring harness between B13 (female) (3) –...
Page 704: The Red Mark Of Emergency Stop Is Indicated Just After The Engine Is Started
SEN02095-00 40 Troubleshooting E-6 The red mark of emergency stop is indicated just after the engine is started • The red mark of emergency stop is indicated just after the starting switch is turned ON. Trouble • In this case, the work equipment cannot be started. Related •...
Page 705 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between B28 (6) – A06 (6) – Resistance Max. 1 z B92D (1) – B91D (1) – A36 (female) (6) Wiring harness between A36 (female) (5) –...
Page 706 SEN02095-00 40 Troubleshooting Electrical circuit diagram related to engine emergency stop BR380JG-1E0...
Page 707: The Machine Monitor Does Not Display Any Item
SEN02095-00 40 Troubleshooting E-7 The machine monitor does not display any item Trouble • When the starting switch is turned ON, the machine monitor does not display any item Related — information Cause Standard value in normal state/Remarks on troubleshooting 1 Defective fuse No.
Page 708 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to machine monitor power supply system BR380JG-1E0...
Page 709: Some Items Are Not Displayed On The Machine Monitor
SEN02095-00 40 Troubleshooting E-8 Some items are not displayed on the machine monitor Trouble • When the starting switch is turned ON, some items are not displayed on the machine monitor. Related — information Cause Standard value in normal state/Remarks on troubleshooting Possible causes and Troubleshooting cannot be carried out since the defect is in the machine...
Page 710: Fuel Level Monitor Was Lighted In Red While Engine Running
40 Troubleshooting SEN02095-00 E-10 Fuel level monitor was lighted in red while engine running Trouble • Fuel level monitor was lighted in red while the engine running • If fuel level gauge on the machine monitor indicates red range, fuel level monitor turns red. Related •...
Page 711: Engine Coolant Temperature Gauge Does Not Indicate Normally
SEN02095-00 40 Troubleshooting E-11 Engine coolant temperature gauge does not indicate normally • While engine coolant temperature is rising normally, temperature gauge does not rise from white Trouble range (C). • While engine coolant temperature is stabilized normally, temperature gauge rises to red range (H). •...
Page 712 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to engine coolant temperature sensor BR380JG-1E0...
Page 713: The Fuel Level Gauge Does Not Display Normally
SEN02095-00 40 Troubleshooting E-12 The fuel level gauge does not display normally. • After fuel is added, the fuel level gauge does not rise from the red range (E). Trouble • After the fuel level lowers, the fuel level gauge does not lower from the green range (F). Relative •...
Page 714: The Hydraulic Oil Temperature Gauge Does Not Display Normally
40 Troubleshooting SEN02095-00 E-13 The hydraulic oil temperature gauge does not display normally • While the hydraulic oil temperature rises normally, the temperature gauge does not rise from the white range (C). Trouble • While the hydraulic oil temperature is stabled normally, the temperature gauge rises to the red range (H).
Page 715: The Travel, Work, And Inspection Modes Do Not Change
SEN02095-00 40 Troubleshooting E-14 The travel, work, and inspection modes do not change. Trouble • When the mode selector switch is changed, the current mode does not change. • The mode selector switches (Mode selector work switch of switch input 2 and mode selector travel switch) can be checked in the monitoring function of the machine monitor.
Page 716 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then turn starting switch ON and carry out troubleshooting. Position of selector C01 (female) Voltage switch Between (5) – Max. 1 V chassis ground Inspection Possible Between (11) –...
Page 717: The Crusher Clearance Adjustment Mode Does Not Change
SEN02095-00 40 Troubleshooting E-15 The crusher clearance adjustment mode does not change Trouble • When the clearance adjustment selector switch is changed, the current mode does not change. • Clearance adjustment selector switch (The clearance selector (full auto) or clearance selector (auto) of switch input 5 can be checked with the machine monitoring function (See Table below) Clearance adjustment selector Clearance adjustment selector...
Page 718 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to crusher clearance adjustment mode selector switch BR380JG-1E0...
Page 719: The Crusher Rotation Direction Does Not Change
SEN02095-00 40 Troubleshooting E-16 The crusher rotation direction does not change Trouble • The crusher rotation direction does not change. • The signals of the crusher forward-reverse selector switch can be checked in the monitoring func- Relative tion of machine monitor. (Code 25002: Crusher rotation direction selector switch (ON = reverse)) information •...
Page 720: Machine Does Not Travel
SEN02095-00 40 Troubleshooting E-17 Machine does not travel Trouble • Machine does not travel • Travel operation may be interlocked by (1) Mode selector switch or (2) conveyor height, rendering the machine unable to travel. For the machine equipped with the radio controller, radio controller switch can select the method for machine to travel by travel lever or by radio controller.
Page 721 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to travel system (When the radio controller (OPT) is not equipped, directly connect A08 (marked a).) BR380JG-1E0...
Page 722: Travel Cannot Be Controlled By Radio Control
SEN02095-00 40 Troubleshooting E-18 Travel cannot be controlled by radio control Trouble • Travel cannot be controlled by radio control. • Radio control system is an optional specification. • (1) Start the engine and turn the radio control selector switch to the remote control position, (2) Turn the power switch of the radio control transmitter ON, and (3) Check that the radio wave from the radio control transmitter is received by the receiver (The antenna of the receiver is built in).
Page 723 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between A33 (female) (3) – A45 – Resistance Max. 1 z A32 (female) (1) Wiring harness between A33 (female) (3) –...
Page 724 SEN02095-00 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Wiring harness between A33 (female) (7) – A45 Disconnection in wiring Resistance Max. 1 z (5) – D10 (female) (4) harness (Disconnection in wir- Wiring harness between S23 (female) (2) – A02 Resistance Max.
Page 725 40 Troubleshooting SEN02095-00 Electrical circuit diagram related to travel system (When the radio controller (OPT) is not equipped, directly connect A08 (marked a).) BR380JG-1E0...
Page 726: The Feeder Cannot Be Turned On And Off By Radio Control
SEN02095-00 40 Troubleshooting E-19 The feeder cannot be turned ON and OFF by radio control Trouble • The feeder cannot be turned ON and OFF by radio control. • Radio control system is an optional specification. • (1) Start the engine and turn the radio control selector switch to the remote control position, (2) Turn the power switch of the radio control transmitter ON, and (3) Check that the radio wave from the radio control transmitter is received by the receiver (The antenna of the receiver is built in).
Page 727 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between A33 (female) (3) – A45 – Resistance Max. 1 z A32 (female) (1) Wiring harness between A33 (female) (3) –...
Page 728 SEN02095-00 40 Troubleshooting Electrical circuit diagram related to radio control system BR380JG-1E0...
Page 729: One-Touch Start, Stop Switch Cannot Be Operated By Radio Control
SEN02095-00 40 Troubleshooting E-20 One-touch start, stop switch cannot be operated by radio control1 Trouble • The crusher cannot be turned ON and OFF by radio control. • Radio control system is an optional specification. • (1) Start the engine and turn the radio control selector switch to the remote control position, (2) Turn the power switch of the radio control transmitter ON, (3) Check that the radio wave from the radio control transmitter is received by the receiver (The antenna of the receiver is built in).
Page 730 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON. Wiring harness between A33 (female) (3) – A45 – Resistance Max. 1 z A32 (female) (1) Wiring harness between A33 (female) (3) –...
Page 731 SEN02095-00 40 Troubleshooting Electrical circuit diagram related to radio control system BR380JG-1E0...
Page 732: The Monitor Switches Do Not Work
40 Troubleshooting SEN02095-00 E-21 The monitor switches do not work • When the maintenance switch is operated, the item screen does not appear. Trouble (1) • When the contrast/brightness setting screen selector switch is operated, the screen does not change. Relative —...
Page 733: The Crusher Cannot Be Operated With The Crusher Manual Forward/Reverse Switch On The Monitor
SEN02095-00 40 Troubleshooting E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor • The crusher cannot be rotated forward or in reverse with the crusher manual FORWARD/ Trouble REVERSE switch on the monitor. • The crusher can be operated with the crusher manual FORWARD/REVERSE switch under the fol- Relative lowing condition: information...
Page 734: The Conveyor Cannot Be Operated With The Conveyor Manual Forward/Reverse Switch On The Monitor
40 Troubleshooting SEN02095-00 E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor • The conveyor cannot be rotated forward or in reverse with the conveyor manual FORWARD/ Trouble REVERSE switch on the monitor. • The conveyor can be operated with the conveyor manual FORWARD/REVERSE switch under the Relative following condition: information...
Page 735: Komtrax System Does Not Operate Normally
SEN02095-00 40 Troubleshooting E-24 KOMTRAX system does not operate normally Trouble • KOMTRAX system does not operate normally. • If KOMTRAX system administrator makes request for checking system on machine side for trouble, Related carry out following troubleshooting. information • Even if KOMTRAX system has trouble, it does not particularly appear on machine. Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch OFF, then carry out troubleshooting.
Page 736 40 Troubleshooting SEN02095-00 Cause Standard value in normal state/Remarks on troubleshooting a Turn starting switch ON and carry out troubleshooting. Number of mails not LED (12) Normal state transmitted yet 7-segment 0 – 9 Possible causes and a Turn starting switch ON and carry out troubleshooting (See *) standard value LED (13) Normal state...
Page 738 SEN02306-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H-mode) 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 ...............
Page 739 SEN02306-01 40 Troubleshooting 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 .....................
Page 740: System Chart For Hydraulic And Mechanical Systems
SEN02306-01 40 Troubleshooting System chart for hydraulic and mechanical systems BR380JG-1E0...
Page 741 40 Troubleshooting SEN02306-01 a This is a system chart that has been drawn up by simplifying the whole hydraulic and mechanical circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems. BR380JG-1E0...
Page 742: Information Contained In Troubleshooting Table
SEN02306-01 40 Troubleshooting Information contained in troubleshooting table a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their contents fully before proceeding to actual troubleshooting work. Trouble Phenomena occurring on machine Related Information on occurred failures and troubleshooting information Cause Standard value in normal state/Remarks on troubleshooting...
Page 743: The Speed Or Power Of The Whole Work Equipment And Travel Is Low
SEN02306-01 40 Troubleshooting H-1 The speed or power of the whole work equipment and travel is low1 Trouble • The speed or power of the whole work equipment and travel is low. Related • Carry out troubleshooting in the WORK or TRAVEL mode. information Cause Standard value in normal state/Remarks on troubleshooting...
Page 744 40 Troubleshooting SEN02306-01 Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Ratio of oil pressure Oil pressure to be Turn all work equipment Turn all work equipment measured switches ON switches OFF...
Page 745: The Engine Speed Lowers Extremely Or The Engine Stalls
SEN02306-01 40 Troubleshooting H-2 The engine speed lowers extremely or the engine stalls Trouble • The engine speed lowers extremely or the engine stalls. Relative • Carry out troubleshooting in the WORK or TRAVEL mode. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 746: The Work Equipment And Travel Systems Do Not Work
40 Troubleshooting SEN02306-01 H-3 The work equipment and travel systems do not work Trouble • The work equipment and travel systems do not work. Relative — information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 747: Fine Control Performance Or Response Is Low
SEN02306-01 40 Troubleshooting H-5 Fine control performance or response is low Trouble • Fine control performance or response is low. Relative • Carry out troubleshooting in the WORK mode. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 748: The Conveyor Does Not Operate
40 Troubleshooting SEN02306-01 H-6 The conveyor does not operate Trouble • The conveyor does not operate. Relative • Carry out the following troubleshooting when the travel system and other work equipment are nor- information mal. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 749: The Speed Or Power Of The Conveyor Is Low
SEN02306-01 40 Troubleshooting H-7 The speed or power of the conveyor is low Trouble • The speed or power of the conveyor is low. Relative • Carry out the following troubleshooting when the travel speed is normal. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 750: The Crusher Does Not Operate
40 Troubleshooting SEN02306-01 H-8 The crusher does not operate Trouble • The crusher does not operate. Relative • Carry out the following troubleshooting when the travel system and other work equipment are nor- information mal. Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 751: The Speed Or Power Of Crusher Is Low
SEN02306-01 40 Troubleshooting H-9 The speed or power of crusher is low Trouble • The speed or power of crusher is low. Relative • Carry out the following troubleshooting when the travel speed is normal. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 752: The Feeder Does Not Feed Smoothly (Vibration Frequency Is Low)
40 Troubleshooting SEN02306-01 H-11 The feeder does not feed smoothly (Vibration frequency is low) Trouble • The feeder does not feed smoothly (Vibration frequency is low). Relative • Carry out the following troubleshooting when the travel speed is normal. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out...
Page 753: The Speed Of Magnetic Separator Belt Is Low
SEN02306-01 40 Troubleshooting H-13 The speed of magnetic separator belt is low Trouble • The speed of magnetic separator belt is low. Relative • Carry out the travel speed is normal. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 754: The Speed Or Power Of The Side Conveyor Is Low
40 Troubleshooting SEN02306-01 H-15 The speed or power of the side conveyor is low Trouble • The speed or power of the side conveyor is low. Relative • Carry out the travel speed is normal. information Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting.
Page 755: The Primary Conveyor And The Side Conveyor Do Not Move Up And Down
SEN02306-01 40 Troubleshooting H-16 The primary conveyor and the side conveyor do not move up and down Trouble • The primary conveyor and the side conveyor do not move up and down. Relative • Carry out the following troubleshooting when the travel system and other work equipment are nor- information mal.
Page 756: The Machine Deviates During Travel
40 Troubleshooting SEN02306-01 H-17 The machine deviates during travel Trouble • The machine deviates during travel. • Before carrying out the troubleshooting, set the mode selector switch in the TRAVEL mode. Relative • Set the conveyor to up position (travel position) and carry out troubleshooting. information •...
Page 757 SEN02306-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting Possible causes and The final drive may have a defect in it. Check it directly. standard value a You may check the final drive by abnormal sound, abnormal heating, 9 Defective final drive in normal state metal powder in drain oil, etc.
Page 758: The Travel Speed Is Low
40 Troubleshooting SEN02306-01 H-18 The travel speed is low Trouble • The travel speed is low. • Travel operation may be interlocked by (1) Mode selector switch or (2) conveyor height, rendering the machine unable to travel. Radio Travel Conveyor height Operating Mode controller...
Page 759 SEN02306-01 40 Troubleshooting Cause Standard value in normal state/Remarks on troubleshooting a Prepare with engine stopped, then run engine at high idle and carry out troubleshooting. Possible 8 Defective travel motor causes and Travel lever Leakage from travel motor standard value Max.
Page 760: The Machine Is Not Steered Well Or Steering Power Is Low
40 Troubleshooting SEN02306-01 H-19 The machine is not steered well or steering power is low Trouble • The machine is not steered well or steering power is low. • The steering may be heavy on rough grounds. Relative • The steering may be heavy on rough grounds when the travel speed is low. information •...
Page 761: The Travel Motor Does Not Work (Only One Side)
SEN02306-01 40 Troubleshooting H-20 The travel motor does not work (only one side) Trouble • The travel motor does not work (only one side). Relative • Before carrying out the troubleshooting, set the mode selector switch in the TRAVEL mode. information Cause Standard value in normal state/Remarks on troubleshooting...
Page 762: The Crusher Clearance Cannot Be Adjusted
40 Troubleshooting SEN02306-01 H-22 The crusher clearance cannot be adjusted Trouble • The crusher clearance cannot be adjusted. • Carry out the following troubleshooting when no foreign matter is caught between the fixed jaw and swing jaw of the crusher. Relative •...
Page 764 SEN02307-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting Troubleshooting of engine (S-mode) 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......................
Page 765 SEN02307-00 40 Troubleshooting S-16 Vibration is excessive ........................... 23 BR380JG-1E0...
Page 766: Method Of Using Troubleshooting Chart
40 Troubleshooting SEN02307-00 Method of using troubleshooting chart The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks. The questions and check items are used to pinpoint high probability causes by simple inspection or from phenomena without using troubleshooting tools. Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the most probable one to make final confirmation accord-...
Page 767 SEN02307-00 40 Troubleshooting <Example of troubleshooting> Exhaust gas is black Let us assume that a trouble of “Exhaust gas is black” occurred and we checked the [Questions] and [Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is lighting red].
Page 768 40 Troubleshooting SEN02307-00 There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 5 items in the [Causes] section. The method of pinpointing the “cause” from the causal relationship and approaching the “troubleshooting” is explained according to Step 1 –...
Page 769: Starting Performance Is Poor
SEN02307-00 40 Troubleshooting S-1 Starting performance is poor General causes why starting performance is poor Causes Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically.
Page 770: Engine Does Not Start
40 Troubleshooting SEN02307-00 S-2 Engine does not start a) Engine does not turn Causes General causes why engine does not turn Internal parts of engine seized o See “S-4 Engine stops during operations” Defective electrical system Confirm recent repair history Degree of use of machine Operated for long period Horn does not sound...
Page 771 SEN02307-00 40 Troubleshooting b) Engine turns but no exhaust smoke comes out Causes General causes why engine turns but no exhaust smoke comes Fuel is not being supplied Supply of fuel is extremely small Improper selection of fuel (particularly in winter) Confirm recent repair history Degree of use of machine Operated for long period...
Page 772 40 Troubleshooting SEN02307-00 c) Exhaust smoke comes but engine does not start (fuel is Causes being injected) General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel Confirm recent repair history...
Page 773: Engine Does Not Pick Up Smoothly
SEN02307-00 40 Troubleshooting S-3 Engine does not pick up smoothly General causes why engine does not pick up smoothly Causes Insufficient intake of air Insufficient supply of fuel Defective condition of fuel spray Improper selection of fuel Controller is controlling in derate mode (limiting injection rate (output) because of an error in electrical system) Confirm recent repair history Degree of use of machine Operated for long period...
Page 774: Engine Stops During Operations
40 Troubleshooting SEN02307-00 S-4 Engine stops during operations General causes why engine stops during operations Causes Seized parts inside engine Insufficient supply of fuel There is overheating Problem in drive devices on applicable machine side o Carry out troubleshooting for devices on applicable machine Confirm recent repair history Degree of use of machine Operated for long period...
Page 775: Engine Does Not Rotate Smoothly
SEN02307-00 40 Troubleshooting S-5 Engine does not rotate smoothly General causes why engine does not rotate smoothly Causes Air in fuel system Defective speed sensor (Error at degree that it is not indicated) Confirm recent repair history Degree of use of machine Operated for long period Occurs at a certain speed range Q Q Q Q Q Occurs at low idle...
Page 776: Engine Lack Output (Or Lacks Power)
40 Troubleshooting SEN02307-00 S-6 Engine lack output (or lacks power) General causes why engine lacks output Causes Insufficient intake of air Insufficient supply of fuel Defective spray condition of fuel Improper selection of fuel There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)”.
Page 777: Exhaust Smoke Is Black (Incomplete Combustion)
SEN02307-00 40 Troubleshooting S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black Causes Insufficient intake of air Defective condition of fuel injection Improper selection of fuel There is overheating o See “S-14 Coolant temperature becomes too high (Overheating)”.
Page 778: Oil Consumption Is Excessive (Or Exhaust Smoke Is Blue)
40 Troubleshooting SEN02307-00 S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive Causes Abnormal consumption of oil Long-time operation of engine at low idle or high idle (Do not run engine at idle for more than 20 minutes continuously) External leakage of oil Wear of pats in lubrication system...
Page 779: Oil Becomes Contaminated Quickly
SEN02307-00 40 Troubleshooting S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly Causes Entry of exhaust gas into oil due to internal wear Clogging of lubrication passage Use of improper fuel Use of improper oil Operation under excessive load Confirm recent repair history E E E Degree of use of machine Operated for long period...
Page 780: Fuel Consumption Is Excessive
40 Troubleshooting SEN02307-00 S-10 Fuel consumption is excessive General causes why fuel consumption is excessive Causes Leakage of fuel Defective condition of fuel injection (fuel pressure, injection timing) Excessive injection of fuel Confirm recent repair history Degree of use of machine Operated for long period Q Q Q More than for other machines of same model Condition of fuel...
Page 781: Oil Is In Coolant (Or Coolant Spurts Back Or Coolant Level Goes Down)
SEN02307-00 40 Troubleshooting S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) General causes why oil is in coolant Causes Internal leakage in lubrication system Internal leakage in cooling system Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased Oil level Gradually increased...
Page 782: Oil Pressure Drops
40 Troubleshooting SEN02307-00 S-12 Oil pressure drops General causes why oil pressure drops Causes Leakage, clogging, wear of lubrication system Defective oil pressure control Improper selection of fuel (improper viscosity) Deterioration of oil due to overheating Confirm recent repair history Degree of use of machine Operated for long period Oil pressure monitor indicates low oil pressure Non-specified oil is being used...
Page 783: Oil Level Rises (Entry Of Coolant/Fuel)
SEN02307-00 40 Troubleshooting S-13 Oil level rises (Entry of coolant/fuel) General causes why oil level rises Causes Coolant in oil (milky) Fuel in oil (smells diluted diesel fuel) a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant” Confirm recent repair history Degree of use of machine Operated for long period Fuel must be added more frequently...
Page 784: Coolant Temperature Becomes Too High (Overheating)
40 Troubleshooting SEN02307-00 S-14 Coolant temperature becomes too high (overheating) General causes why coolant temperature becomes too Causes high Lack of cooling air (deformation, damage of fan) Drop in heat dissipation efficiency Problem in coolant circulation system Rise in hydraulic oil temperature o Carry out troubleshooting for machine Confirm recent repair history Degree of use of...
Page 785: Abnormal Noise Is Made
SEN02307-00 40 Troubleshooting S-15 Abnormal noise is made General causes why abnormal noise is made Causes Abnormality due to defective parts Abnormal combustion Air sucked in from intake system a Judge if the noise is an internal noise or an external noise before starting troubleshooting.
Page 786: Vibration Is Excessive
40 Troubleshooting SEN02307-00 S-16 Vibration is excessive General causes why vibration is excessive Causes Defective parts (abnormal wear, breakage) Misalignment between engine and chassis Abnormal combustion a If abnormal noise is made and vibration is excessive, carry out trouble- shooting for “S-15 Abnormal noise is made”, too. Confirm recent repair history Degree of use of machine Operated for long period Suddenly increased...
Page 788: Br380Jg-1E0
SEN02737-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual ..........................2 Coating materials list............................4 BR380JG-1E0...
Page 789: Disassembly And Assembly
* *** **** 79 T- Sketches of special tools means that they can not be supplied from Komatsu in Japan (i.e. locally Various special tools are illustrated for the con- made parts). venience of local manufacture. a General tools that are necessary for removal or installation are described as [1],[2]•••etc.
Page 790 79 T- * *** **** means that they can not be supplied from Komatsu in Japan (i.e. locally made parts). a General tools that are necessary for d i s a s s e m b l y a n d a s s e m b l y a r e described as [1],[2]•••etc.
Page 791: Coating Materials List
The recommended coating materials such as adhesives, gasket sealants, and greases used for disas- sembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Cate- Komatsu Part number Q'ty Container...
Page 792 50 Disassembly and assembly SEN02737-00 Cate- Komatsu code Part number Q'ty Container Main features and applications gory • Used to lubricate sliding portions. LM-G 09940-00051 60 g (to prevent squeaking) • Used to prevent scuffing and seizure of press- fitted portions, shrink-fitted portions, and...
Page 793 SEN02737-00 50 Disassembly and assembly Cate- Komatsu code Part number Q'ty Container Main features and applications gory • “S” is used for high-temperature season SUNSTAR and “W” for low-temperature season as PENGUINE Polyethyl- SEAL 580 417-926-3910 320 ml ene con- adhesive for glass.
Page 794 50 Disassembly and assembly SEN02737-00 BR380JG-1E0...
Page 796 SEN02738-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 50 Disassembly and assembly1 Work equipment Disassembly and assembly of crusher ......................2 Replacing cheek plates........................... 3 Turning over and replacing fixed jaw plate...................... 4 Turning over and replacing swing jaw plate ....................5 Replacing toggle plate ............................
Page 797: Disassembly And Assembly Of Crusher
SEN02738-00 50 Disassembly and assembly Disassembly and assembly of crusher 1. Cheek plate 10. Toggle seat 2. Protector 11. Swing jaw 3. V-belt 12. Swing jaw plate 4. Lock cylinder 13. Crusher chamber 5. Crusher motor 14. Fixed jaw plate 6.
Page 798: Replacing Cheek Plates
50 Disassembly and assembly SEN02738-00 Replacing cheek plates 3. After removing the upper and lower cheek plates, remove all dirt and sand from the cheek Prepare the special tools for the cheek plate. plate mounting faces (front, rear, right, and left). Part No.
Page 799: Turning Over And Replacing Fixed Jaw Plate
SEN02738-00 50 Disassembly and assembly Turning over and replacing fixed 4. Measure the clearance on each side of fixed jaw plate (3) and determine the point where the jaw plate fixed jaw plate is aligned with the crusher Remove the cheek plates. frame.
Page 800: Turning Over And Replacing Swing Jaw Plate
50 Disassembly and assembly SEN02738-00 Turning over and replacing swing 3. Check that swing jaw plate wedge (3) is loos- ened fully. Install wire (A) to the center, remove jaw plate the remaining bolt, and sling the swing jaw plate wedge. Removal a Push out the swing jaw plate about 30 mm Loosen the bolt of the crusher inspection...
Page 801 SEN02738-00 50 Disassembly and assembly Installation When turning over swing jaw plate (4), lower it to the stand. Install the wires on the opposite side and insert the swing jaw plate in the crusher frame. When replacing swing jaw plate (4), lower it to the stand.
Page 802: Replacing Toggle Plate
50 Disassembly and assembly SEN02738-00 Replacing toggle plate 4. Start the engine. Loosen the bolt of the crusher inspection 5. Set mode selector switch (3) in the inspection hatch, open the crusher inspection hatch, and position. fix it to the hook. Put a warning tag to the starting switch t o n o t i f y t h e p er so n s a r o u n d t h e 2.
Page 803 SEN02738-00 50 Disassembly and assembly 8. Fully loosen tension springs (2) (M42 on both 12. Stop the engine. sides). It is very dangerous to go to the follow- 13. Take out toggle plate (1). ing step without fully loosening ten- Toggle plate: 101 kg sion springs (2).
Page 804 50 Disassembly and assembly SEN02738-00 25. Check clearance of discharge setting (A) and 17. Press crusher clearance decrease switch (4) on the control box to push out fixing link (7) and adjust it to the desired value. adjust the hanging height of the wire simultane- For the method of adjust the clearance of dis- ously.
Page 805: Replacing Toggle Seats
SEN02738-00 50 Disassembly and assembly Replacing toggle seats 4. Sling the toggle seat. Toggle seat on swing jaw side: 44.3 kg Before replacing the toggle seats, be sure to per- form the following items. Since the toggle seats are not interchange- able, take care not to mistake them when installing.
Page 806: Disassembly And Assembly Of Lock Cylinder
50 Disassembly and assembly SEN02738-00 Disassembly and assembly of Using a pipe of a proper size, remove cle- vis (1) and washer (3). lock cylinder a Protect the pipe contact parts with Do not disassemble the parts other than cloths. those described in this section.
Page 807 SEN02738-00 50 Disassembly and assembly Remove seals (4), (5), (6), and (7). Disassembly of clevis a Take care that rings (8) and (9) will Remove ring (10) with snap ring pliers. not be damaged. a Check the positions of the seal and ring and the direction of the lip.
Page 808 50 Disassembly and assembly SEN02738-00 Installation of clevis and flange Install seals (4), (5), (6), and (7). a Take care not to mistake the positions of the seal and ring or the direction of the lip. a If there is rust or a flaw on the fitting part, remove it.
Page 809 SEN02738-00 50 Disassembly and assembly Using a pipe, install clevis (1) and washer (3). a Protect the pipe contact parts with cloths. Fitting part: Same oil as currently applied one, grease, etc. (Apply thinly) Threaded part: Anti-seizure compound (Molybdenum spray, etc.) a Tighten the flange slowly so that it will not be seized or will not catch some- thing.
Page 810: Removal And Installation Of Primary Conveyor Assembly
50 Disassembly and assembly SEN02738-00 Removal and installation of Remove either lock bracket (2). (Prevention of interference when the conveyor primary conveyor assembly is inserted) a Bolt size: M16 × 4 pieces Disassembly Remove conveyor hose (1). a Put male and female plugs to the removed hose and elbow.
Page 811 SEN02738-00 50 Disassembly and assembly Remove pin (5) and rear sling bracket (6). Lower the cylinder. a Bolt size: M12 × 4 pieces a Place wooden blocks under the conveyor in advance. Loosen sling bracket mounting bolt (7) and remove conveyor lock pin (8). 10.
Page 812 50 Disassembly and assembly SEN02738-00 Installation 12. Place stable stands under the conveyor and lift off the conveyor assembly. Carry out installation in the reverse order to removal. BR380JG-1E0...
Page 813: Replacement Of Belt
SEN02738-00 50 Disassembly and assembly Replacement of belt When performing the following work, call a belt sticking work subcontractor (Operation and Mainte- nance Manual 7-15) as a supervisor. Ask the sub- c o n t r a c t o r t o c a r r y o u t t h e s t i c k i n g w o r k (vulcanization at normal temperature) in the field.
Page 814 50 Disassembly and assembly SEN02738-00 Pull out the cut belt (C). a At this time, do not remove the right and left joints of the head pulley assembly. Stick the belt. a Ask the belt sticking work subcontractor (See Operation and Maintenance Manual 7-15) to stick the belt.
Page 815: Replacement Procedure For Primary Belt Conveyor Motor
SEN02738-00 50 Disassembly and assembly Replacement procedure for Disconnect conveyor motor hoses (2) from the body. primary belt conveyor motor a After removing the hoses, put dummy Loosen tension adjustment bolt (1) to reduce plugs to their ends and motor ports. the belt tension.
Page 816 50 Disassembly and assembly SEN02738-00 Replace the motor and install the flange to the new motor. a Bolt size: M12 × 10 pieces (A) Insert wooden block to fix pulley. (B) Fix head pulley assembly with V-block to prevent misalignment. (C) Adjust height with jack.
Page 817: Replacement Procedure For Primary Belt Conveyor Head Pulley Frame
SEN02738-00 50 Disassembly and assembly Replacement procedure for primary belt conveyor head pulley frame a If the belt conveyor head pulley frame has been deformed or its parts have been removed, perform the following check and then adjust or replace the parts. Rotate the belt conveyor.
Page 818 50 Disassembly and assembly SEN02738-00 Remove belt cleaner (3). Fix the head pulley with a V-block and wooden Set blocks [1] between head pulley (4) block as shown below so that it will not be mis- and guard (5) on both sides of the head aligned with the frame.
Page 819 SEN02738-00 50 Disassembly and assembly Remove spring pin (3). 10. Remove lower bracket (6). a M16 × 3 (2 places on right and left sides) When replacing frame on motor side 11. Remove bolts (7) and cover (8). Sling frame (4) with a crane in advance. a Bolt size: M12 ×...
Page 820 50 Disassembly and assembly SEN02738-00 13. Remove frame assembly (10) as a unit. 16. Position the head pulley and motor flange and connect them with bolts (15). 14. Install motor (12) and flange (13) to new frame (11). 17. Install cover (16) to the head pulley frame and secure it with bolts (17).
Page 821 SEN02738-00 50 Disassembly and assembly When replacing frame on bearing side 22. Remove bolts (21) and cover (22). 19. Sling frame (18) with the crane in advance. 23. Remove bearing cover (23). 20. Remove upper bracket (19). a M16 × 3 (2 places on right and left sides) 24.
Page 822 50 Disassembly and assembly SEN02738-00 25. Remove bolts (25) to remove the bearing from 28. Install cover (27) to the head pulley frame and the frame. secure it with bolts (28). 26. Remove the frame and replace it with a new Sub-assembly of head pulley frame one.
Page 823 SEN02738-00 50 Disassembly and assembly BR380JG-1E0...
Page 824 50 Disassembly and assembly SEN02738-00 31. Install upper bracket (25). 34. Remove bearing cover (28). a M16 × 3 (2 places on right and left sides) a Before tightening the screws, see steps 29 and 30 and check the dimensions again. 32.
Page 825 SEN02738-00 50 Disassembly and assembly 38. Rotate tension adjustment bolt (1) to increase the belt tension. a Increase the belt tension to the mark made when he belt was loosened. 39. Referring to steps 29 and 30, check again that the distance between the head pulley and frame is in the standard range.
Page 826: Procedure For Folding Engine
50 Disassembly and assembly SEN02738-00 Procedure for folding engine front Remove engine front cover bottom mounting bolts (3). cover Right and left side: 1 place each When the engine fuel supply pump or engine con- M12: 2 pieces (Width across flats: 19 mm) troller needs to be replaced, the engine front cover a Do not remove M16 bolts (4) (1 place can be folded toward the magnetic separator to...
Page 827 SEN02738-00 50 Disassembly and assembly Slowly fold the engine front cover toward the magnetic separator and rest it against the magnetic separator frame. a Weight of engine front cover assembly: Approx. 130 kg a Put pads between the cover and magnetic separator frame to protect the paint of the cover.
Page 828 50 Disassembly and assembly SEN02738-00 BR380JG-1E0...
Page 830: Diagrams And Drawings
SEN01361-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 90 Diagrams and drawings Hydraulic diagrams and drawings Hydraulic circuit diagram (1/2) ........................3 Hydraulic circuit diagram (2/2) ........................5 BR380JG-1E0...
Page 831: Hydraulic Circuit Diagram
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2) BR380JG-1E0 SEN001361-00 BR380JG-1E0...
Page 832 90 Diagrams and drawings SEN01361-00 Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2) BR380JG-1E0 BR380JG-1E0...
Page 834 SEN01362-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 90 Diagrams and drawings Electrical diagrams and drawings 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)......................
Page 835: Electrical Circuit Diagram
Electrical circuit diagram (1/4) Electrical circuit diagram (1/4) BR380JG-1E0 SEN01362-01 BR380JG-1E0...
Page 836: Electrical Circuit Diagram
Electrical circuit diagram (2/4) Electrical circuit diagram (2/4) BR380JG-1E0 SEN01362-01 BR380JG-1E0...
Page 837: Electrical Circuit Diagram
Electrical circuit diagram (3/4) Electrical circuit diagram (3/4) BR380JG-1E0 SEN01362-01 BR380JG-1E0...
Page 838: Electrical Circuit Diagram
Electrical circuit diagram (4/4) Electrical circuit diagram (4/4) BR380JG-1E0 SEN01362-01 BR380JG-1E0...
Page 839 Connector arrangement diagram (1/2) Connector arrangement diagram (1/2) BR380JG-1E0 Connector Number Address of Connector Number Address of Connector Number Address of Model Component name Model Component name Model Component name of pins stereogram of pins stereogram of pins stereogram DT (Gray) Intermediate connector B74B Emergency stop switch...
Page 840 Connector arrangement diagram (2/2) Connector arrangement diagram (2/2) BR380JG-1E0 SEN01362-01 BR380JG-1E0...

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