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SEN01341-03

MOBILE CRUSHER

BR380JG-1E0

SERIAL NUMBERS 2001 and up

SEN01343-03

MOBILE CRUSHER 1SHOP MANUAL

BR380JG-1E0

Machine model Serial number
BR380JG-1E0 2001 and up

00 Index and foreword 1
Index

Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

BR380JG-1E0 1

SEN01343-03 00 Index and foreword

Composition of shop manual 1
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. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN01341-03

00 Index and foreword SEN01342-03
Index SEN01343-03 q
Foreword and general information SEN01344-00

01 Specification SEN01345-00
Specification and technical data SEN01346-00

10 Structure, function and maintenance standard SEN01347-00
Engine and cooling system SEN01348-00
Power train SEN01349-00
Undercarriage and frame SEN01350-00
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic system, Part 2 SEN01352-00
Hydraulic system, Part 3 SEN01353-00
Work equipment SEN01354-00
Electrical system SEN01355-00

20 Standard value table SEN01356-00
Standard service value table SEN02288-00

30 Testing and adjusting SEN01357-01
Testing and adjusting, Part 1 SEN02303-00
Testing and adjusting, Part 2 SEN02304-00
Testing and adjusting, Part 3 SEN02305-01 q

40 Troubleshooting SEN01358-02
Failure code table and fuse locations SEN02088-00
General information on troubleshooting SEN02089-01
Troubleshooting by failure code, Part 1 SEN02090-00
Troubleshooting by failure code, Part 2 SEN02091-00
Troubleshooting by failure code, Part 3 SEN02092-00
Troubleshooting by failure code, Part 4 SEN02093-00
Troubleshooting by failure code, Part 5 SEN02094-00
Troubleshooting of electrical system (E-mode) SEN02095-00

2 BR380JG-1E0

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 Q
Work equipment SEN02738-00 Q

90 Diagrams and drawings SEN01360-01
Hydraulic diagrams and drawings SEN01361-00
Electrical diagrams and drawings SEN01362-01

BR380JG-1E0 3

SEN01343-03 00 Index and foreword

Table of contents 1
00 Index and foreword
Index SEN01343-03
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4

Foreword and general information SEN01344-00
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 .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36

01 Specification
Specification and technical data SEN01346-00
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 5
Table of fuel, coolant and lubricants ............................................................................................ 6

10 Structure, function and maintenance standard
Engine and cooling system SEN01348-00
Engine mount, damper ................................................................................................................ 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train SEN01349-00
Power train .................................................................................................................................. 2
Drive system for components...................................................................................................... 3
Final drive.................................................................................................................................... 4
Sprocket ...................................................................................................................................... 6
Undercarriage and frame SEN01350-00
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................. 4
Carrier roller ................................................................................................................................ 6
Track roller................................................................................................................................... 7
Track shoe................................................................................................................................... 8
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic piping drawing ............................................................................................................. 2
Hydraulic tank and hydraulic oil filter........................................................................................... 3
Hydraulic pump ........................................................................................................................... 4
Hydraulic system, Part 2 SEN01352-00
Control valve ............................................................................................................................... 2
Self pressure reducing valve ....................................................................................................... 10
CLSS ........................................................................................................................................... 15
Functions and operation by valve................................................................................................ 19

4 BR380JG-1E0

00 Index and foreword SEN01343-03

Hydraulic system, Part 3 SEN01353-00
Crusher motor ............................................................................................................................. 2
Grizzly feeder motor.................................................................................................................... 6
Conveyor motor........................................................................................................................... 7
Travel motor ................................................................................................................................ 8
Valve control................................................................................................................................ 16
Solenoid valve............................................................................................................................. 26
EPC valve ................................................................................................................................... 28
Electromagnetic selector valve ................................................................................................... 32
Hydraulic cylinder........................................................................................................................ 34
Work equipment SEN01354-00
Grizzly feeder semiautomatic system ......................................................................................... 2
Abnormal load stop system......................................................................................................... 3
Primary belt conveyor ................................................................................................................. 4
Grizzly feeder .............................................................................................................................. 8
Crusher ....................................................................................................................................... 9
Crusher tooth tip adjustment system........................................................................................... 14
Vibrator........................................................................................................................................ 17
Electrical system SEN01355-00
Engine control ............................................................................................................................. 2
Work equipment and pump controller ......................................................................................... 12
Electronic control system ............................................................................................................ 15
Machine monitor system ............................................................................................................. 28
Sensor......................................................................................................................................... 54

20 Standard value table
Standard service value table SEN02288-00
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3

30 Testing and adjusting
Testing and adjusting, Part 1 SEN02303-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed............................................................................................................. 6
Measuring intake air pressure (boost pressure).......................................................................... 7
Checking exhaust gas color ........................................................................................................ 8
Adjusting valve clearance ........................................................................................................... 9
Measuring compression pressure ............................................................................................... 11
Measuring blow-by pressure ....................................................................................................... 13
Measuring engine oil pressure .................................................................................................... 14
Handling fuel system parts .......................................................................................................... 15
Releasing residual pressure from fuel system ............................................................................ 15
Measuring fuel pressure.............................................................................................................. 16
Measuring fuel return rate and leakage ...................................................................................... 18
Bleeding air from fuel circuit........................................................................................................ 20
Checking fuel circuit for leakage ................................................................................................. 22
Checking and adjusting track shoe tension................................................................................. 23
Measuring and adjusting oil pressure in work equipment and travel circuits .............................. 25
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........................................................................................ 40
Measuring oil leakage ................................................................................................................. 41
Bleeding air from each part ......................................................................................................... 42
Testing travel deviation................................................................................................................ 45
Adjusting mirrors ......................................................................................................................... 46

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SEN01343-03 00 Index and foreword

Testing and adjusting, Part 2 SEN02304-00
Special functions of machine monitor.......................................................................................... 2
Testing and adjusting, Part 3 SEN02305-01
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 ................................................................................ 38
Inspection and maintenance of magnetic separator.................................................................... 44
Check and adjustment of muck discharge conveyor................................................................... 46
List of companies which handles radio controllers ...................................................................... 48
Handling voltage circuit of engine controller................................................................................ 49
Procedure for turning on KOMTRAX terminal ............................................................................. 50
KOMTRAX terminal lamp indications .......................................................................................... 53
Preparation work for troubleshooting for electrical system.......................................................... 56
Procedure for testing diodes ....................................................................................................... 60

40 Troubleshooting
Failure code table and fuse locations SEN02088-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02089-01
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................................................................................................ 10
Wiring table for connector pin numbers....................................................................................... 12
T-adapter box and T-adapter table .............................................................................................. 45
Troubleshooting by failure code, Part 1 SEN02090-00
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 ........................................................... 8
Failure code [7RD2KB] Short circuit in conveyor reverse relay .................................................. 10
Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay ....................... 12
Failure code [7RE1KB] Short circuit in crusher ON switch.......................................................... 14
Failure code [7RE2KA] Disconnection in crusher OFF switch .................................................... 16
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch............................. 18
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch ....................... 20
Failure code [7RE8KB] Short circuit in magnetic separator ON switch....................................... 22
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch ................................. 24
Failure code [7REAKB] Short circuit in accessory input circuit ................................................... 26
Failure code [7REDMA] Abnormality in primary conveyor pressure sensor ............................... 28
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor ................................... 30
Failure code [7RENKZ] Abnormality in clearance potentiometer ................................................ 32
Failure code [7REPKA] Disconnection in feeder OFF switch...................................................... 34
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 ............................................ 42
Failure code [7RF3KA] Disconnection in crusher reverse EPC valve......................................... 43
Failure code [7RF3KB] Short circuit in crusher reverse EPC valve ............................................ 44
Failure code [7RF3KY] Short circuit in crusher reverse EPC valve ............................................ 45
Failure code [7RF4KA] Disconnection in feeder forward EPC valve........................................... 46
Failure code [7RF4KB] Short circuit in feeder forward EPC valve .............................................. 47
Failure code [7RF4KY] Short circuit in feeder forward EPC valve .............................................. 48

6 BR380JG-1E0

00 Index and foreword SEN01343-03

Troubleshooting by failure code, Part 2 SEN02091-00
Failure code [7RFAKY] Short circuit in engine stop relay ........................................................... 4
Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay ................................ 6
Failure code [7RFBKB] Short circuit in muck conveyor solenoid ................................................ 8
Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid ..................... 9
Failure code [7RFCKA] Disconnection in magnetic separator solenoid...................................... 10
Failure code [7RFCKB] Short circuit in magnetic separator solenoid ......................................... 11
Failure code [7RFCKY] Short circuit in magnetic separator solenoid ......................................... 12
Failure code [7RFHKB] Short circuit in conveyor forward relay .................................................. 14
Failure code [7RFHKY] Short circuit in conveyor forward relay .................................................. 16
Failure code [7RFKKB] Short circuit in lock cylinder pull relay ................................................... 18
Failure code [7RFKKY] Short circuit in lock cylinder pull relay ................................................... 20
Failure code [7RFLKA] Disconnection in accessory EPC solenoid ............................................ 22
Failure code [7RFLKB] Short circuit in accessory EPC solenoid ................................................ 23
Failure code [7RFLKY] Short circuit in accessory EPC solenoid ................................................ 24
Failure code [7RFMKY] Short circuit in abnormal pressure relay ............................................... 26
Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay .................... 28
Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve............................ 30
Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve ............................... 31
Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve ............................... 32
Failure code [7RFPKB] Short circuit in lock cylinder push relay ................................................. 34
Failure code [7RFPKY] Short circuit in lock cylinder push relay ................................................. 36
Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor ..................................... 38
Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve ................................... 40
Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve....................................... 42
Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve....................................... 44
Failure code [7RJMMW] Lock cylinder slipping .......................................................................... 45
Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor .................................. 46
Failure code [7RJPKB] Short circuit in radio control work-mode switch ..................................... 48
Failure code [7RJQKB] Short circuit in radio control travel-mode switch .................................... 49
Failure code [7RJRKB] Short circuit on travel signal .................................................................. 50
Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor ............................. 52
Failure code [AA10NX] Air cleaner Clogging .............................................................................. 54
Failure code [AB00KE] Charge voltage too low .......................................................................... 56
Troubleshooting by failure code, Part 3 SEN02092-00
Failure code [B@BAZG] Engine oil pressure too low ................................................................. 4
Failure code [B@BAZK] Engine oil level reduction ..................................................................... 6
Failure code [B@BCNS] Radiator coolant overheat ................................................................... 7
Failure code [B@BCZK] Radiator coolant level reduction .......................................................... 8
Failure code [B@HANS] Hydraulic oil overheat.......................................................................... 10
Failure code [CA111] Abnormality in engine controller................................................................ 10
Failure code [CA115] Abnormality in engine NE and Bkup speed sensors................................. 11
Failure code [CA122] Charge pressure sensor too high ............................................................. 12
Failure code [CA123] Charge pressure sensor too low .............................................................. 14
Failure code [CA131] Throttle sensor too high............................................................................ 16
Failure code [CA132] Throttle sensor too low ............................................................................. 18
Failure code [CA144] Coolant temperature sensor too high ....................................................... 20
Failure code [CA145] Coolant temperature sensor too low ........................................................ 22
Failure code [CA153] Charge temperature sensor too high........................................................ 24
Failure code [CA154] Charge temperature sensor too low ......................................................... 26
Failure code [CA155] Charge temperature too high and engine speed derated......................... 28
Failure code [CA187] Sensor power source 2 too low ................................................................ 30
Failure code [CA221] Ambient pressure sensor too high............................................................ 32
Failure code [CA222] Ambient pressure sensor too low ............................................................. 34
Failure code [CA227] Sensor power source 2 too high............................................................... 36
Failure code [CA234] Engine overspeed .................................................................................... 37
Failure code [CA238] Abnormal power source for Ne speed sensor .......................................... 38
Failure code [CA271] Short circuit in fuel pump actuator............................................................ 39

BR380JG-1E0 7

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 .......................................... 48
Failure code [CA331] Disconnection or short circuit in injector No.2 .......................................... 50
Failure code [CA332] Disconnection or short circuit in injector No.4 .......................................... 52
Troubleshooting by failure code, Part 4 SEN02093-00
Failure code [CA342] Abnormality in engine controller data consistency ................................... 3
Failure code [CA351] Abnormality in injector drive circuit ........................................................... 4
Failure code [CA352] Sensor power source 1 too low ................................................................ 6
Failure code [CA386] Sensor power source 1 too high............................................................... 8
Failure code [CA428] Water detection sensor too high ............................................................... 10
Failure code [CA429] Water detection sensor too low ................................................................ 12
Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 14
Failure code [CA441] Power source voltage too low................................................................... 16
Failure code [CA442] Power source voltage too high ................................................................. 18
Failure code [CA449] Common rail pressure sensor too high (2) ............................................... 20
Failure code [CA451] Common rail pressure sensor too high..................................................... 22
Failure code [CA452] Common rail pressure sensor too low ...................................................... 24
Failure code [CA488] Charge temperature too high and torque derated .................................... 26
Failure code [CA553] Common rail pressure sensor too high (1) ............................................... 26
Failure code [CA559] Supply pump no pressure......................................................................... 27
Failure code [CA689] Abnormality in engine Ne speed sensor................................................... 28
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 ......................................... 38
Failure code [CA2186] Throttle pedal sensor power source too low........................................... 39
Failure code [CA2249] Supply pump no pressure (2) ................................................................. 40
Failure code [CA2311] Abnormal resistance in pump regulator valve......................................... 42
Failure code [CA2555] Disconnection in air intake heater relay.................................................. 44
Failure code [CA2556] Short circuit in air intake heater relay ..................................................... 46
Troubleshooting by failure code, Part 5 SEN02094-00
Failure code [D162KY] Short circuit in horn relay ....................................................................... 4
Failure code [D162KZ] Disconnection or short circuit in horn relay ............................................ 6
Failure code [DA22KK] Solenoid power source too low.............................................................. 8
Failure code [DA25KP] Abnormality in pressure sensor power source....................................... 10
Failure code [DA2RMC] CAN communication error (work equipment and pump controller) ...... 14
Failure code [DA2SKQ] Abnormality in model code input........................................................... 16
Failure code [DAFRMC] CAN communication error (monitor controller)..................................... 18
Failure code [DDA6KA] Disconnection in engine stop switch ..................................................... 20
Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor................................... 22
Failure code [DHPAMA] Abnormality in F pump pressure sensor............................................... 24
Failure code [DHPBMA] Abnormality in R pump pressure sensor .............................................. 26
Failure code [DUB0KY] Short circuit in beacon solid state relay................................................. 28
Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay...................... 30
Failure code [DXA0KA] Disconnection in PC-EPC Solenoid ...................................................... 32
Failure code [DXA0KB] Short circuit in PC-EPC Solenoid .......................................................... 33
Failure code [DXA0KY] Short circuit in PC-EPC Solenoid .......................................................... 34
Failure code [DXE0KA] Disconnection in LS-EPC solenoid........................................................ 35
Failure code [DXE0KB] Short circuit in LS-EPC solenoid ........................................................... 36
Failure code [DXE0KY] Short circuit in LS-EPC solenoid ........................................................... 37
Troubleshooting of electrical system (E-mode) SEN02095-00
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

8 BR380JG-1E0

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 .................................................................. 20
E-8 Some items are not displayed on the machine monitor........................................................ 22
E-9 Contents of display by machine monitor are different from applicable machine................... 22
E-10 Fuel level monitor was lighted in red while engine running ................................................ 23
E-11 Engine coolant temperature gauge does not indicate normally .......................................... 24
E-12 The fuel level gauge does not display normally. ................................................................. 26
E-13 The hydraulic oil temperature gauge does not display normally ........................................ 27
E-14 The travel, work, and inspection modes do not change. .................................................... 28
E-15 The crusher clearance adjustment mode does not change................................................ 30
E-16 The crusher rotation direction does not change ................................................................. 32
E-17 Machine does not travel ..................................................................................................... 34
E-18 Travel cannot be controlled by radio control....................................................................... 36
E-19 The feeder cannot be turned ON and OFF by radio control ............................................... 40
E-20 One-touch start, stop switch cannot be operated by radio control ..................................... 44
E-21 The monitor switches do not work ...................................................................................... 47
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE
switch on the monitor ......................................................................................................... 48
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE
switch on the monitor ......................................................................................................... 49
E-24 KOMTRAX system does not operate normally................................................................... 50
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02306-01
System chart for hydraulic and mechanical systems .................................................................. 4
Information contained in troubleshooting table............................................................................ 6
H-1 The speed or power of the whole work equipment and travel is low.................................... 8
H-2 The engine speed lowers extremely or the engine stalls ..................................................... 10
H-3 The work equipment and travel systems do not work .......................................................... 11
H-4 Abnormal sound comes out from around the hydraulic pump.............................................. 11
H-5 Fine control performance or response is low ....................................................................... 12
H-6 The conveyor does not operate............................................................................................ 13
H-7 The speed or power of the conveyor is low.......................................................................... 14
H-8 The crusher does not operate .............................................................................................. 15
H-9 The speed or power of crusher is low .................................................................................. 16
H-10 The feeder does not operate .............................................................................................. 16
H-11 The feeder does not feed smoothly (Vibration frequency is low)........................................ 17
H-12 The magnetic separator does not operate ......................................................................... 17
H-13 The speed of magnetic separator belt is low...................................................................... 18
H-14 The side conveyor does not operate .................................................................................. 18
H-15 The speed or power of the side conveyor is low ................................................................ 19
H-16 The primary conveyor and the side conveyor do not move up and down .......................... 20
H-17 The machine deviates during travel ................................................................................... 21
H-18 The travel speed is low....................................................................................................... 23
H-19 The machine is not steered well or steering power is low .................................................. 25
H-20 The travel motor does not work (only one side) ................................................................. 26
H-21 When the travel switch of the radio controller is depressed, the machine does not travel. 26
H-22 The crusher clearance cannot be adjusted ........................................................................ 27
Troubleshooting of engine (S-mode) SEN02307-00
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor ................................................................................................ 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lack output (or lacks power) ..................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 14

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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 .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant/fuel) ................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23

50 Disassembly and assembly
General information on disassembly and assembly SEN02737-00
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Work equipment SEN02738-00
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................................................................................................................. 7
Replacing toggle seats ................................................................................................................ 10
Disassembly and assembly of lock cylinder ................................................................................ 11
Removal and installation of primary conveyor assembly ............................................................ 15
Replacement of belt .................................................................................................................... 18
Replacement procedure for primary belt conveyor motor ........................................................... 20
Replacement procedure for primary belt conveyor head pulley frame........................................ 22
Procedure for folding engine front cover ..................................................................................... 31

90 Diagrams and drawings
Hydraulic diagrams and drawings SEN01361-00
Hydraulic circuit diagram (1/2)..................................................................................................... 3
Hydraulic circuit diagram (2/2)..................................................................................................... 5
Electrical diagrams and drawings SEN01362-01
Electrical circuit diagram (1/4) ..................................................................................................... 3
Electrical circuit diagram (2/4) ..................................................................................................... 5
Electrical circuit diagram (3/4) ..................................................................................................... 7
Electrical circuit diagram (4/4) ..................................................................................................... 9
Connector arrangement diagram (1/2) ........................................................................................ 11
Connector arrangement diagram (2/2) ........................................................................................ 13

10 BR380JG-1E0

00 Index and foreword SEN01343-03

BR380JG-1E0 11

SEN01343-03

BR380JG-1E0 Mobile crusher

Form No. SEN01343-03

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)

12

SEN01344-00

MOBILE CRUSHER 1SHOP MANUAL

BR380JG-1E0

Machine model Serial number
BR380JG-1E0 2001 and up

00 Index and foreword 1
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...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

BR380JG-1E0 1

SEN01344-00 00 Index and foreword

Safety notice 1 (Rev. 2006/09)
Important 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always
k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.

2 BR380JG-1E0

etc. Precautions during work wires. torques. machine. If it is impossible to use the 10) Be sure to assemble all parts again in their handrails. 6) When removing a cover which is under internal pressure or under pressure from a spring. be careful not to break or damage the electrical wir- ing. from the negative (–) terminal first. release the pressure completely from the 11) When installing high pressure hoses. 15) Take care when removing or installing the 5) When raising a heavy component (heavier tracks of track-type machines. 7) When removing components. circuit. or from spilling out. damage.). not to get scalded. Operate the hoist or crane slowly may suffer from gas poisoning. BR380JG-1E0 3 . raised by the hoist or crane. parts and parts which must not be reused with new parts. aged by contact with other parts when the nents of the oil.00 Index and foreword SEN01344-00 3) When disassembling or assembling. in particular. aged tubes are dangerous. 14) When measuring hydraulic pressure. lad. remove the leads check that the measuring tools are cor- from the battery. always leave 2 bolts in diagonal positions. 9) As a general rule. N e v e r j u m p o n o r o ff t h e cal parts. use a hoist or crane. so be loosen it slowly to prevent the oil from extremely careful when installing tubes for spurting out. so never let anyone stand at ropes. 4) Before starting work. first machine is operated. Dam- drain plug. Loosen those bolts gradually and alternately to release the pressure. When installing hoses and 3. Damaged wiring may cause electrical fires. take fingers or hand. 8) When removing piping. Always use slings which have 16) If the engine is operated for a long time in ample capacity and install them to proper a place which is not ventilated well. stop the fuel or oil port the machine with blocks. When than 25 kg). Be careful not to get your extreme care not to get rolled or caught in fingers caught in a hole. a make sure that they are not twisted. wipe it up immediately. in particular. Fuel 4) 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 and can even start fires. do not use gasoline to ders or steps when getting on or off the wash parts. so be careful installed. ladders or steps. the engine (measuring oil pressure. the track separates starting work. use a stand to original places. you places. and then remove the cover. stop the engine. or air circuits. check 2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y when the engine is stopped. open the windows and doors to ven- other part. coolant to cool before carrying out any always tighten them to the specified work on the oil or water circuits. Do not use it to clean electri- m a c h i n e . be sure that they will not be dam- 1) Before disconnecting or removing compo. Accord- to prevent the component from hitting any ingly. machine. high pressure circuits. sup. chains. 13) When aligning 2 holes. be particu- part. water. Do not work with any part still tilate well. and hooks) are free from either end of the track. such as guards. Always use the handrails. jacks. Always remove the lead rectly assembled. Before removing the track. or parts which vibrate vio- When working on or around a rotating lently or rotate at high speed. temperature. never insert your revolving speed. Wait for the oil and 12) When assembling or installing parts. or an oil pressure pickup plug. When removing the oil filler cap. In addition. rotating parts or moving parts. When installing protective parts 3) Before starting work. onto the floor. When larly careful to check that they are checking the machine without stopping installed correctly. stop the engine. check that the slings (wire suddenly. If any fuel or oil drips stands before starting work. Replace any damaged provide safe footing.

6) Do not sling a load with 1 wire rope alone.SEN01344-00 00 Index and foreword 4. stop the crane and check the condi- tion of the slung load. load.000 kg} load at a lifting angle of grasp them but press them from 150°. to them with shackles. may be caught.) If the load is slippery. if available. 8) When installing wire ropes to an angular 3) Keep putting on gloves during sling work. 9) Use the specified eyebolts and fix wire 5) Use proper sling according to the weight ropes. 2) Check the slings before starting sling work. untwisting of the rope. 4 BR380JG-1E0 .2 kN {4. Install 2 or more wire during hoisting. it may rotate and may slip cause the rope to slip off the hook out of the rope. (Put on leather gloves. apply pads to protect the wire ropes. When hoisting a load with 2 or more ropes. and check its center of gravity. the load may slip and fall.000 12) When lifting up a load. q Do not step on the load.6 kN {2. observe the follow- kg} of total weight can be suspended. wire ropes. If too etc.8 kN {1. 7) Limit the hanging angle to 60°. This weight is reduced to 9. q Do not stand under the load. the force subjected to each rope will increase with the hanging angle. When settling angle of 120°.6 the wire ropes with the hand. of the load and method of slinging. each of them is subjected to a force above. q After the wire ropes are stretched. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. k Slinging with 1 rope may cause maximum strength at the middle por- tion. thick wire ropes are used to sling a light 10) Apply wire ropes to the middle portion of load. etc. q Slinging near the tip of the hook may If it is slung so. ing. sling a load vertically.000 kg} vertically. turning of the load during hoisting. Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. apply proper mate- 4) Measure the weight of the load by the eye rial to prevent the wire rope from slipping. at various hanging angles. which can result in a dangerous accident. the hook. The table below shows the variation of allow- able load in kN {kg} when hoisting is made with 2 ropes. do not kN {2. The sign maker must always stand in front of the load and guide the operator safely. as a rule. When the 2 ropes 11) Do not use twisted or kinked wire ropes. each of which is allowed to sling up to 9. The hook has the ropes symmetrically. 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. or slipping of the rope from its original wind- ing position on the load. chains.000 kg}. up to 19. If the 2 ropes sling a 19. and pads.8 kN {1. If you grasp them.000 q Wind in the crane slowly until wire kg} when the 2 ropes make a hanging ropes are stretched. your fingers as large as 39.

etc. In Disas. then lower it slowly. inspect the wire 14 17. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 7. south. 11) After operating the hoist. Wire ropes (Standard “Z” twist ropes without galvanizing) 6. controller. observe the fol.8 0. stop the hoist at then remove the sling. stop the operation. clutch. porarily at 30 cm above the floor.1 3) Operate the hoist at a safe place. turn the power switch OFF.9 after the mark of 4. turning on a switch which was turned OFF q Do not lift up the load slantingly. 9) Consider the travel route in advance and lift up a load to a safe height.6 2. Type 6X37-A) k When raising a heavy part (heavier Nominal Allowable load than 25 kg). diameter of rope sembly and assembly. and 15) After finishing the work.7 1.6 west. No. stop it tem.6 14. referring to a Read the Operation and Maintenance the table below. 7) Do not drag a sling. 50 221. 25 55. use a hoist.4 of the control buttons without fail.7 ropes.6 2.3 32.9 tion earth leakage breaker. related to that switch are not in operation q When lifting down a load. Selecting wire ropes 1) Select adequate ropes depending on the 5. and put them in the specified place. Precautions for using overhead hoist crane (JIS G3525. over 16 22.3 1) Before starting work. crane collision 20 35.3 3. 12 12. 5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the the crane while the slung load is swinging.3 5. by the electric shock prevention earth 13) When lifting down a load. check that the devices lowing. lower the load ure. Precautions for using mobile crane weight of parts to be hoisted. BR380JG-1E0 5 . stop it just after it leaves the ground and check safety. 6. work.3 wind stop device. 30 79. rails. crane is moving longitudinally or laterally. do not swing the control switch. When and lift it up again.6 8. 40 141. Do not ropes and chains used for the sling leave the sling installed to the hook. state. leakage breaker. the specified position and raise the hook q Remove kinks and dirt from the wire to at least 2 m above the floor.00 Index and foreword SEN01344-00 q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted. electric shock preven- 18 28. 12) Remember the position of the main switch so that you can turn off the power immedi- ately in an emergency. q Check that the load is stable. and check safety.3 1. and power application warning lamp.6 22. the weight of a mm kN ton part heavier than 25 kg is indicated 10 8.6 2) Observe the signs for sling work.4 4) Check the direction indicator plates (east. and then lift it up. and north) and the directions 60 318. brake. breaking strength of the rope used 6) Do not raise or lower a load while the (Safety coefficient: 6).6 prevention device. Manual of the crane carefully in advance and operate the crane safely. 8) When lifting up a load. and 14) If you find an obstacle around the hoist.

ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. Precautions for disconnecting and con- necting hoses and tubes in air conditioner circuit 1) Disconnection k Collect the air conditioner refrigerant gas (R134a). Accordingly. you must be qualified for handling the refrigerant and put on protective goggles. will not enter them.SEN01344-00 00 Index and foreword 8. dust. k If the refrigerant gas (R134a) gets in your eyes. 6 BR380JG-1E0 . 2] When connecting the air conditioner hoses and tubes. check that O-rings (1) are fitted to their joints. when collecting or adding it. see the precautions for installation in each section of "Disassembly and assembly". 4] When connecting the refrigerant pip- ing. you may lose your sight. a Example of O-ring (Fitted to every joint of hoses and tubes) a For tightening torque. 2) Connection 1] When installing the air conditioner cir- cuit hoses and tubes. apply compressor oil for refriger- ant (R134a) (DENSO: ND-OIL8. take care that dirt. etc. water. 3] Check that each O-ring is not dam- aged or deteriorated.

safety. BR380JG-1E0 7 . and basic information. In addition. the manual is divided into the following sections. and coolant necessary for the work are also explained. oil. 50. function. q Shop manuals are divided into the “Chassis volume” and “Engine volume”. adjusting. and replacing parts. Troubleshooting This section explains how to find out failed parts and how to repair them. tightening torque and quantity and weight of coating material. installing. but also serves as reference material for troubleshooting. function and maintenance standard This section explains the structure. 00. 30. q Engine volume This section explains the method of reproducing. as well as precautions for them. Specification This section explains the specifications of the machine. Index and foreword This section explains the shop manuals list. and assembling each component. 01. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. If one of them is required. consult KOMATSU distributors. table of contents. disassembling. see the engine volume of the engine model mounted on the machine. 10. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting. revisions. It serves not only to give an understanding of the structure. see the Chassis volume. 2. and maintenance standard values of each component. In this case. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. Standard value table This section explains the standard values for new machine and judgement criteria for testing. 90. repairing. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. Disassembly and assembly This section explains the special tools and procedures for removing. q Materials and specifications are subject to change without notice. The troubleshooting is divided by failure modes. and method of adjusting each part. and troubleshooting. For the engine unit. Structure. grease. Get the most up-to-date information before you start any work. 20. For ease of understanding. or other change of notices will be sent to KOMATSU distributors. 1. 40. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis- assembly and service. Revision and distribution Any additions.00 Index and foreword SEN01344-00 How to read the shop manual 1 q Some attachments and optional parts in this shop manual may not be delivered to certain areas. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. The structure and function sub-section explains the structure and function of each component.

For reference. Symbol Item Remarks k Safety Special safety precautions are necessary when performing work. etc. and quantity to be drained. and capacity. the ones and tens digits of the form number of each brochure is increased by 1. 2 Coat Places to be coated with adhesives. 5 Oil. con- ventionally used Gravitational System of units is indicated in parentheses { }. during assembly. etc. etc. 01. 6 Drain Places where oil. 5. (Example: 00. 4 Weight of parts of component or parts. Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. must be added. Special technical precautions or other precautions for preserving stan- a Caution dards are necessary when performing work. coolant Places where oil. the units are indicated with International System of units (SI). 02 …) q Revisions Revised brochures are shown in the shop manual composition table. q Revised edition mark When a manual is revised. 8 BR380JG-1E0 . Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Caution necessary when Weight selecting hoisting wire. or when working posture is important. Units In this shop manual. 4. 3 Tightening Places that require special attention for tightening torque during torque assembly.SEN01344-00 00 Index and foreword 3. etc. must be drained.

022/–0.126 a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. q The above size set temporarily is called the “standard size” and the range of differ- ence from the standard size is called the “tolerance”.022 120 –0. 1. q To specify a finishing size of a part.00 Index and foreword SEN01344-00 Explanation of terms for maintenance standard 1 The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. the finishing size of parts is a little different from one to another. Example) 120 (–0. the size of a hole and the size of the shaft to be fitted to that hole are indi- cated by the same standard size and dif- ferent tolerances of the hole and shaft.076 +0 BR380JG-1E0 9 .030 +0. The tightness of fit is decided by the toler- ance. a tem- porary standard size is set and an allow- able difference from that size is indicated. q Indication of size of rotating shaft and hole and relationship drawing of them Example: Tolerance Standard size Shaft Hole –0. Standard size and tolerance q To be accurate. Example: Standard size Tolerance –0.126) q Usually. q The tolerance with the symbols of + or – is indicated on the right side of the standard size.046 60 –0.

be used is called the “clearance limit”. The limit of changed size is called the “repair limit”. Since the permissible value is estimated from vari- ous tests or experiences in most cases. Interference limit new products or equivalent is called the q The allowable maximum interference “standard value“. q If a product is worn to the allowable value. another part to be assembled is called the q When some parts are repaired. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. shown in the given standard size and tol- erance table is smaller than that of the mating shaft. between them is increased to a certain ance“. it must be judged after consider- ing the operating condition and customer's requirement.SEN01344-00 00 Index and foreword 2. of performance/function is set to the stan. the value “interference limit”. limit of the part of smaller tolerance. which is indicated by the range limit. q The interference limit shows the repair dard value. A value below which the product can be used without causing a problem is called the “allowable value”. q If the clearance between the parts q When some parts are repaired. they must q When the diameter of a hole of a part be replaced or repaired. Clearance limit q The clearance made when new parts are q Parts can be used until the clearance assembled is called the “standard clear. they must be ance is generally adjusted to the standard replaced or repaired. 10 BR380JG-1E0 . exceeds the clearance limit. the clear. Standard clearance and standard value 5. q If the interference between the parts 3. Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used. Standard interference exceeds the interference limit. clearance. which is indicated by a between the hole of a part and the shaft of range or a target value. it must be checked or repaired. q If a part is worn to the repair limit must be replaced or repaired. however. measure the size of their hole and shaft and check that the interference is in the standard range. The limit at which those parts cannot from the minimum clearance to the maxi. the difference between those diameters is called the “interference”. q After repairing or replacing some parts. q The performance and function of a prod- uct lowers while it is used. mum clearance. q A value of performance and function of 6. 4.

it is necessary to be extremely careful when handling wiring harnesses. 2) Defective crimping or soldering of connec- tors The pins of the male and female connec- tors are in contact at the crimped terminal or soldered portion. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connect- ing and disconnecting the connector about 10 times. or because there is cor- rosion or oxidization of the contact sur- faces. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. and protectors or tubes used for protecting the wiring. Furthermore. but if there is exces- sive force brought to bear on the wiring. 2. it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). and “repairs” must be carried out. For this purpose. con- nectors used for connecting and disconnecting one wire from another wire. or because one or both of the con- nectors is deformed or the position is not correctly aligned. they are frequently removed and installed again. and to prevent failures or other troubles before they occur. water. Main failures occurring in wiring harness 1) Defective contact of connectors (defec- tive contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female con- nector. wiring harnesses are more likely to be affected by the direct effects of rain. so they are likely to suffer deformation or damage. or vibration. the plating at the joint will peel and cause improper connection or breakage. “maintenance and inspection“. Points to remember when handling electric equipment 1. during inspection and repair operations. correct “operation“. “troubleshooting“.00 Index and foreword SEN01344-00 Handling electric equipment and hydraulic component 1 To maintain the performance of the machine over a long period. Compared with other electrical components fit- ted in boxes or cases. BR380JG-1E0 11 . For this reason. heat. Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component.

or a heavy object hits the wiring. so remove the oil and water from the compressed air com- pletely before cleaning with com- pressed air.SEN01344-00 00 Index and foreword 3) Disconnections in wiring If the wiring is held and the connectors are pulled apart. wipe it off with a dry cloth or blow it dry with com- pressed air and spray it with a contact restorer. The connector is designed to prevent water from entering. the oil will not let the electricity pass. take care not to splash water over the connector. or components are lifted with a crane with the wiring still connected. the pins will be short-cir- cuited by the water. a If there is oil or water in the com- pressed air. the contacts will become even dirtier. or the sol- dering may be damaged. 4) High-pressure water entering connector The connector is designed to make it diffi- cult for water to enter (drip-proof struc- ture). but at the same time. a When wiping the mating portion of the connector. water may enter the connector. it is difficult for it to be drained. 12 BR380JG-1E0 . Accordingly. or the wiring may be broken. be careful not to use excessive force or deform the pins. if water does enter. but if high-pressure water is sprayed directly on the connector. so there will be defective contact. if water should get into the connector. Therefore. immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating sur- face between the male and female pins. so if any water gets in. depending on the direction of the water jet. the crimping of the connector may separate. If there is oil or grease stuck to the connector.

a Never pull with one hand. 3] Action to take after removing connec- tors After removing any connector. oil. and drying connec- tors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when discon- necting. a If the machine is left disassem- bled for a long time. which are engaged with each other when the connector is installed. When disconnecting the connectors. hold the connectors. or water from getting in the connector portion. then hold the male and female connectors in each hand and pull apart. 2] When removing from clips q Both of the connector and clip have stoppers. cover it with a vinyl bag to prevent any dust. q When removing a connector from a clip. the housing may break.00 Index and foreword SEN01344-00 3. so always cover the con- nector. dirt. For connectors which have a lock stopper. BR380JG-1E0 13 . pull the connector in a parallel direction to the clip for removing stop- pers. Removing. installing. it is particu- larly easy for improper contact to occur. a If the connector is twisted up and down or to the left or right. For connectors held by a screw. press down the stopper with your thumb and pull the connec- tors apart. loosen the screw fully.

a If the connector cannot be cor- rected easily. For connectors with the lock stopper. or water stuck to the connector pins (mating portion). if the wiring harness is mis- aligned. Check that there is no damage or breakage to the outside of the con- nector. warm the inside of the wiring with a dryer. a If there is any oil. 14 BR380JG-1E0 . For connectors fitted with boots. Check that there is no deformation. a If there is any damage or break- age. remove the clamp and adjust the position.SEN01344-00 00 Index and foreword 2) Connecting connectors 1] Check the connector visually. Check that there is no oil. Check also that there are no loose clamps. adjust it to its correct position. dirt. wipe it off with a dry cloth. q If the connector clamp has been removed. 3] Correct any protrusion of the boot and any misalignment of the wiring har- ness. or dirt stuck to the connector. If any water has got inside the connector. push in the connector until the stop- per clicks into position. but be careful not to make it too hot as this will cause short circuits. 2] Fix the connector securely. and then insert it securely. cor- rect any protrusion of the boot. water. In addition. or dam- age to the connector pins. corrosion. be sure to return it to its original position. Align the position of the connector correctly. or the clamp is out of posi- tion. defective contact. replace the connector.

3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. Arrow: 1). Connection (Right of figure) 1] Push in female connector (2) horizon- tally until the lock clicks. 12. q Disconnection q Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b).00 Index and foreword SEN01344-00 3) Heavy duty wire connector (DT 8-pole. Arrow: 1) 2] Since locks (a) and (b) may not be set completely. pull out female connector (2). push in female connector (2) while moving it up and down until the locks are set normally. 2). (b): Locks BR380JG-1E0 15 . (1): Male connector (2): Female connector (a).

SEN01344-00 00 Index and foreword 4) Drying wiring harness If there is any oil or dirt on the wiring har- ness. If water gets inside the connector. a If the connector is blown dry with compressed air. a Hot air from the dryer can be used. b l o w i t w i t h c o n ta c t restorer and reassemble. 3] Carry out a continuity test on the con- nector. so remove all oil and water from the com- pressed air before blowing with air. there is the risk that oil in the air may cause defective contact. leave the wiring harness disconnected and carry out a continu- ity test to check for any short circuits between pins caused by water. do not use high-pressure water or steam directly on the wiring harness. use a dryer to dry the connector. 1] Disconnect the connector and wipe off the water with a dry cloth. wipe it off with a dry cloth. as this will cause deformation or damage to the connector. 16 BR380JG-1E0 . If water gets directly on the connector. After drying. a After completely drying the con- n e c t o r. If the connector must be washed in water. Avoid washing it in water or using steam. 2] Dry the inside of the connector with a dryer. do as fol- lows. but regulate the time that the hot air is used in order not to make the connector or related parts too hot.

resistance. check that all the related connectors are properly inserted. unnec- essary abnormality displays will be generated. (Place it on a suitable dry stand). 3) Cover the control connectors with tape or a vinyl bag. 4) During rainy weather. 2) Before carrying out troubleshooting. a Disconnect and connect the related connectors several times to check. so be extremely careful when handling the controller. 5) Do not place the controller on oil. 3) Always connect any disconnected con- nectors before going on to the next step. 4) When carrying out troubleshooting of cir- cuits (measuring the voltage. a If there is any change. continuity. 5. do not leave the controller in a place where it is exposed to rain. a If the power is turned ON with the connectors still disconnected. or in any hot place. disconnect all wiring harness con- nectors connected to the controller. even for a short time. These con- trol all of the electronic circuits on the machine. Never touch the connector contacts with your hand. there is proba- bly defective contact in that circuit. water. move the related wiring and connectors several times and check that there is no change in the read- ing of the tester. BR380JG-1E0 17 .00 Index and foreword SEN01344-00 4. 6) Precautions when carrying out arc welding When carrying out arc welding on the body. Handling controller 1) The controller contains a microcomputer and electronic control circuits. or current). Fit an arc welding ground close to the welding point. 2) Do not place objects on top of the control- ler. or soil. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before discon- necting or connecting connectors.

3. or repairing the machine in rain or high winds. and also use clean pumps and oil containers. but collect it and ask the customer to dispose of it. there is danger of dust entering the equipment. so it is desirable to use unit exchange. 1. 2. or take it back with you for disposal. or vinyl bags to prevent any dirt or dust from entering. Do not simply drain oil out onto the ground. or when disassembling or assembling hydraulic equipment. tapes. 18 BR380JG-1E0 . it is necessary to be particularly careful. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field.SEN01344-00 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment. When adding hydraulic oil. the openings should be sealed with caps. Sealing openings After any piping or equipment is removed. Do not let any dirt or dust get in during refilling operations Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop. replacing filters. If the opening is left open or is blocked with a rag. Be careful of the operating environment. If an oil clean- ing device is used. it is possible to filter out the dirt that has collected during storage. there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. It is also difficult to check the performance after repairs. Avoid adding hydraulic oil. and the perfor- mance should be checked with special test equipment. Always keep the oil filler and the area around it clean. 4. the most common cause of failure is dirt (foreign material) in the hydraulic circuit. so this is an even more effective method. or places where there is a lot of dust.

the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. Cleaning operations After repairing the hydraulic equipment (pump. or changing the oil. In addition. BR380JG-1E0 19 .00 Index and foreword SEN01344-00 5. Flushing operations After disassembling and assembling the equip- ment. as much as possible of the old hydraulic oil must be drained out. Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm. also drain the oil from the filter and from the drain plug in the circuit. it flows easily. etc. Normally. use flushing oil to remove the contaminants. the sludge can also be drained out easily from the circuit together with the oil. and old oil from the hydraulic circuit. sludge. and secondary flushing is carried out with the specified hydraulic oil. carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil cir- cuit. control valve. 7. (Drain the oil from the hydraulic tank. so it is best to change the oil when it is still warm.) or when running the machine. flushing is carried out twice: primary flushing is carried out with flushing oil. When changing the oil. The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment can- not remove. so it is an extremely effective device.) If any old oil is left. 6.

pull out connec- tor (1) toward you. 12V140 engines) Ambient pressure sensor: PAMB (125. float part A with a small screw- driver while press lock (L2). and then pull out connector (1) toward you.SEN01344-00 00 Index and foreword Connectors newly used for Tier 3 engines 1. if part A does not float. Pull lock type (PACKARD-2) (FRAMATOME-3. connec- tor (1) cannot be pulled out toward you. 12V140 engines) Oil temperature sensor: TOIL Oil pressure sensor: POIL Coolant temperature sensor: TWTR. 1) Slide lock (L1) to the right. 114 engines) (B) (on the wiring harness side) of connec- Ne speed sensor of flywheel housing: tor (2) outward. NE (107 – 170. FRAMATOME-2) q 107 – 170. Slide lock type 2. (125. 12V140 engines q Various temperature sensors q Various pressure sensors and NE Example) speed sensor Intake air temperature sensor in Examples) intake manifold: TIM Intake air pressure in intake manifold: Fuel temperature sensor: TFUEL PIM (125. 20 BR380JG-1E0 . 170. 170. a Even if lock (L2) is pressed. 170. 12V140 engines) etc. 2) While pressing lock (L2). In this case. 12V140 engine q 107 – 170. Oil pressure switch Disconnect the connector by pulling lock (107. 12V140 engines) Disconnect connector (1) according to the fol- lowing procedure.

pull out connector (3) in the direction of the arrow. use flat-head screwdriver [1] since you cannot insert your fingers.00 Index and foreword SEN01344-00 3. 114 engine Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04) 3) While pressing lock (D). BR380JG-1E0 21 . pull out connector (4) in the direction of the arrow. 2) While pressing up lock (C) of the connec- tor with flat-head screwdriver [1]. 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. q 107 engine a If the lock is on the underside. pull out connector (3) in the direction of the arrow. Push lock type q 107. 1) While pressing lock (C). q 114 engine q 107.

Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc. 2] Turn housing (H1) in the direction of the arrow until it “clicks”. housing (H1) becomes heavy to turn. 12V140 engine 4. 1] Insert the connector to the end. 2] Pull out housing (H1) in the direction of the arrow. while setting its groove. q 140 engine pullout connector (5) in the direction of the Example) arrow. a Housing (H1) is left on the wiring har- ness side. Example) Fuel pressure in common rail: PFUEL etc.SEN01344-00 00 Index and foreword q 125 – 170. 1] Turn housing (H1) in the direction of the arrow. Turn-housing type (Round green connector) 4) While pressing lock (E) of the connector. Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2) 2) Connect the connector according to the following procedure. Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. a When connector is unlocked. 22 BR380JG-1E0 . 1) Disconnect connector (6) according to the (AMP-3) following procedure.

Indicates size of wire by nominal No. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover. 3 and below) Insulator Soft polyvinyl chloride automobile Heat-resis. Annealed copper for elec- General wiring wire for AV tor tric appliance (Nominal No. Size (Nominal No.. heat-resistant. Annealed copper for elec- General wiring in extremely tant low-volt. Color codes are shown in Table 3. Indicates type of wire by symbol.) 1. Annealed copper for elec. symbol. and color of each electric wire are indicated by sym- bols. Example: AEX 0. of 0. –30 to +60 low-voltage tor tric appliance General wiring AVS wire for (Nominal No. the material. and material of wire are shown in Table 1. (Table 1) Using Sym- Type Material temperature Example of use bol range (°C) Low-voltage Conduc. 5 and above) automobile Insulator Soft polyvinyl chloride Thin-cover Conduc. The electric wire code is helpful in understanding the electric circuit diagram. tor tric appliance AEX –50 to +110 cold district. Relational information of troubleshooting.Indicates blue. low-voltage wire for automobile. Type.) is shown in Table 2. they are not indi- cated.). Type.00 Index and foreword SEN01344-00 How to read electric wire code 1 a The information about the wires unique to each machine model is described in Troubleshooting section.85 L . In the electric circuit diagram.. having nomi- nal No. Conduc. thickness. (Since AV and AVS are classified by size (nominal No.85 Indicates color of wire by color code. wiring at high-tem- age wire for Heat-resistant crosslinked Insulator perature place automobile polyethylene BR380JG-1E0 23 . and material AV and AVS are different in only thickness and outside diameter of the cover. symbol.

6 16.96 109.76 0.0 2.0 8.32 58/0.6 er D AEX Standard 5.26 41/0.18 7/0.2 1. 50/0.32 50/0.32 37/0.6 – Cov- AV Standard – – – – – – – 4.0 17.80 169/0.2 2.30 5.80 85/0.8 11.75f (0.9 3.20/0.0 8.1 area (mm2) d (approx.51 0.2 2.6 Nominal No.6 9.9 2.0 1.0 8.45 84/0.0 13.80 eter of strand Conductor Sectional 7. denotes flexible”.19 42.5 3.5) 0.0 AVS Standard 2.0 2.6 er D AEX Standard 2.SEN01344-00 00 Index and foreword 2.7 4.9 1.25) 2f 2 3f 3 5 Number of strands/Diam.85) 1.2 10.4 3.27 1. 8 15 20 30 40 50 60 85 100 Number of strands/Diam.36 20.29 63.18 16/0.88 1.0 13.80 217/0.9 2.25f (1.8 6.32 30/0.23 area (mm2) d (approx.56 0. Dimensions (Table 2) Nominal No.32 65/0.) 3.18 11/0.4 13.8 10.5 2.73 54.95 13.5 1.29 1.0 13.8 4.) 1.3 7.3 2.61 35.6 “f” of nominal No.8 11.26 26/0.7 3.0 17.84 84.32 eter of strand Conductor Sectional 0.2 10.08 3.96 2.09 3.80 108/0. 24 BR380JG-1E0 .45 41/0.80 127/0.4 12.5 7. 0.4 13.80 70/0.6 AVS Standard – – – – – – – – – Cov- AV Standard 5.5f (0.1 – 3.0 3.0 8.6 16.

Color codes table (Table 3) Color Code Color of wire Color Code Color of wire B Black LgW Light green & White Br Brown LgY Light green & Yellow BrB Brown & Black LR Blue & Red BrR Brown & Red LW Blue & White BrW Brown & White LY Blue & Yellow BrY Brown & Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red & Black GB Green & Black RG Red & Green GL Green & Blue RL Red & Blue Gr Gray RW Red & White GR Green & Red RY Red & Yellow GW Green & White Sb Sky Blue GY Green & Yellow Y Yellow L Blue YB Yellow & Black LB Blue & Black YG Yellow &Green Lg Light green YL Yellow & Blue LgB Light green & Black YR Yellow & Red LgR Light green & Red YW Yellow & White Remarks: In a color code consisting of 2 colors. Types of circuits and color codes (Table 4) Type of wire AVS or AV AEX Charge R WG – – – – R – Ground B – – – – – B – Start R – – – – – R – Light RW RB RY RG RL – D – Instrument Y YR YB YG YL YW Y Gr Signal G GW GR GY GB GL G Br L LW LR LY LB – L – Type of Br BrW BrR BrY BrB – – – circuit Lg LgR LgY LgB LgW – – – O – – – – – – – Others Gr – – – – – – – P – – – – – – – Sb – – – – – – – Dg – – – – – – – Ch – – – – – – – BR380JG-1E0 25 . 4. Example: “GW” means that the background is Green and marking is White. the first color is the color of the background and the second color is the color of the marking.00 Index and foreword SEN01344-00 3.

Do not pull the wires. q When using forcing screws to remove any components. and make match marks in the necessary places before removal to prevent any mistake when assembling. q Confirm the match marks showing the installation position. 1) Face seal type hoses and tubes Nominal Plug (nut end) Sleeve nut (elbow end) number 02 07376-70210 02789-20210 03 07376-70315 02789-20315 04 07376-70422 02789-20422 05 07376-70522 02789-20522 06 07376-70628 02789-20628 10 07376-71034 07221-21034 12 07376-71234 07221-21234 2) Split flange type hoses and tubes Nominal Flange (hose end) Sleeve head (tube end) Split flange number 04 07379-00400 07378-10400 07371-30400 05 07379-00500 07378-10500 07371-30500 3) If the part is not under hydraulic pressure. Precautions when carrying out removal work q If the coolant contains antifreeze. prepare a container of adequate size to catch the oil. q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. dispose of it correctly. q To prevent any excessive force from being applied to the wiring.5 28 24 07049-02430 24 20 30 27 07049-02734 27 22.5 11 10 07049-01012 10 8. q Check the number and thickness of the shims. q When raising components.SEN01344-00 00 Index and foreword Precautions when carrying out operation 1 [When carrying out removal or installation (disassembly or assembly) of units. cover them or fit plugs to prevent dirt or dust from entering. q Before removing any unit. q When draining oil. be sure to follow the general precautions given below when carrying out the operation.5 20 18 07049-01822 18 15 22 20 07049-02025 20 17 25 22 07049-02228 22 18. always hold the connectors when dis- connecting the connectors.5 18 16 07049-01620 16 13. tighten the forcing screws uniformly in turn. a Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations.5 34 26 BR380JG-1E0 . Nominal Dimensions Part Number number D d L 06 07049-00608 6 5 8 08 07049-00811 8 6. be sure to use lifting equipment of ample strength. q After disconnecting hoses or tubes. and keep in a safe place.] 1. clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. the following corks can be used.5 12 12 07049-01215 12 10 15 14 07049-01418 14 11.

q Replace all gaskets. or rust. q When coating with gasket sealant. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. and the joints for fuel leakage. Fuel system Check the piping for damage. and lock plates with new parts. operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. q If the piping or hydraulic equipment have been removed. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage. and the joints for air suction and exhaust gas leakage. retighten or repair it. burrs. retighten it. Cooling system Check the piping for damage. 3. 3) Next. a For details. If any part is loosened or damaged. q When coating with adhesive. a When operating the hydraulic cylinders for the first time after reassembling cylinders. check that the snap ring is fitted securely in the ring groove. cotter pins. If any part is loosened. stopping the cylinder 100 mm from the end of its stroke. oil and grease q If the coolant has been drained. q For the tightening torque. q After fitting snap rings. pumps and other hydraulic equipment removed for repair. “Bleeding air”. q When tightening split flanges.00 Index and foreword SEN01344-00 2. or water. Then check the coolant level again. Then check the oil level again. always bleed the air as follows: 1) Start the engine and run at low idle. q If the hydraulic equipment has been removed and installed again. clean the part and remove all oil and grease. if there are any. q When connecting wiring connectors. then coat uniformly with gasket sealant. run the engine at normal speed. and add coolant to the specified level. check that there is no deformation or deterioration. coat the surface with anti-friction compound (LM-P). retighten or repair it. If any part is loosened or damaged. q Clean all parts. retighten or repair it. Run the engine to circulate the coolant through the system. dirt. 4) After doing this. q When using eyebolts. Precautions when completing the operation 1) Refilling with coolant. the mounting bolts and nuts for looseness. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times. screw them in fully. dents. and align the direction of the hook. and the joints for coolant leakage. see Testing and adjusting. and correct any damage. see “Disassembly and assembly”. follow the same procedure. then coat the threaded por- tion with 2 – 3 drops of adhesive. q Coat rotating parts and sliding parts with engine oil. check that there is no dirt or damage. clean the surface and remove all oil and grease. the mounting bolts and nuts for looseness. a When using the machine for the first time after repair or long storage. q Install the hoses without twisting or interference and fix them with intermediate clamps. the mounting bolts and nuts for looseness. q When press fitting parts. tighten the drain valve. tighten uniformly in turn to prevent excessive tightening on one side. always bleed the air from the system after reassembling the parts. q Bend the cotter pins and lock plates securely. clean the connector to remove all oil. BR380JG-1E0 27 . add engine oil to the speci- fied level. O-rings. Run the engine to circulate the oil through the system. Precautions when carrying out installation work q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. If any part is loosened or damaged. then connect securely.

If any part is damaged. referring to “Troubleshooting” and “Disassembly and assembly”.SEN01344-00 00 Index and foreword 4) Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler. exhaust pipe and their mounting parts for a crack and damage. 5) Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any bolt or nut is loosened. If any abnormal sound is heard. 28 BR380JG-1E0 . retighten it. 2] Check the mounting bolts and nuts of the muffler. repair the muffler. replace it. exhaust pipe and their mounting parts for looseness.

prepare an oil receiving container. 3) a Since some hydraulic oil flows out. some hydraulic oil flows out when the hose is disconnected. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3). Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). pull it back to check its connecting condition. Type 1 1. (Fig. This does not indicate abnormality. 1) a The adapter can be pushed in about 3. the rubber cap portion moves toward the hose about 3. 2) After inserting the hose in the mating adapter perfectly. aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). BR380JG-1E0 29 . (Fig. 5) a When the hose is pulled back. a Do not hold rubber cap portion (4).5 mm. prepare an oil receiving container. k Even if the residual pressure is released from the hydraulic tank. loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. (Fig.00 Index and foreword SEN01344-00 Method of disassembling and connecting push-pull type coupler 1 k Before carrying out the following work. 2) After hose joint (2) is pushed into adapter (3). (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. Accordingly. press rubber cap portion (4) against adapter (3) until it clicks. however.5 mm. 2.

9) 30 BR380JG-1E0 . pull out whole body (7) to discon- nect it. (Fig. 7) 3) While holding the condition of Steps 1) and 2). Connection q 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. 8) 2. 6) 2) While holding the condition of Step 1). turn lever (8) to the right (clockwise). (Fig.SEN01344-00 00 Index and foreword Type 2 1. Disconnection 1) 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. (Fig.

10) 2) While holding the condition of Step 1). 12) 2.00 Index and foreword SEN01344-00 Type 3 1. (Fig. (Fig. Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. Disconnection 1) 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. 13) BR380JG-1E0 31 . pull out whole body (9) to discon- nect it. (Fig. push cover (10) straight until it contacts contact surface (b) of the hexagonal por- tion at the male end. 11) 3) While holding the condition of Steps 1) and 2).

4 10 14 34.0 – 41.520 – 1.0 – 100.0 20 30 455 – 565 46.4 – 2.SEN01344-00 00 Index and foreword Standard tightening torque table 1 1.5 – 29.5 14 22 153 – 190 15.5 – 19.150 – 1.8 – 14.5 – 58.7 12 27 74.5 – 4.450 200 – 250 36 55 2.2 a Fig.630 295 – 370 a The following table corresponds to the bolts in Fig.2 – 1.450 – 3.5 10 17 59 – 74 6. B.910 155 – 195 33 50 1.5 – 78. Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 5.890 – 3.8 – 3. Table of tightening torques for bolts and nuts a Unless there are special instructions.960 – 2.5 1.5 – 90.2 7.0 27 41 1.0 8 13 13.3 – 46.8 0. tighten metric nuts and bolts to the torque below.0 – 12.7 – 23. A a Fig.440 118 – 147 30 46 1.6 – 1.7 1.040 250 – 310 39 60 2. B 32 BR380JG-1E0 . Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11.5 8 13 27 – 34 2.0 – 7. (When using torque wrench) a The following table corresponds to the bolts in Fig.9 – 9.5 16 24 235 – 285 23. A.5 12 19 98 – 123 10.6 – 9.0 22 32 610 – 765 62.0 24 36 785 – 980 80.5 18 27 320 – 400 33.1 3.

0} 24 24 32 58.7 – 19. Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 10 14 59 – 74 6.0 – 49.010 {76.12 33 tor.5} 103 {10.64 {1. 363 – 480 {37.35 {0.0 – 7.0 – 12.0 – 15.6 {1.0 – 37.0 {11.0 – 1.5} 03.4 – 176.0} 4.54 {2. Table of tightening torques for O-ring boss plugs a Unless there are special instructions. tighten split flange bolts to the torque below.9 {15.5 – 3.3} 11.15} 12 12 19 14.5 – 29.5 {2.0 {5.5 – 5.82 {0.6 – 0.5} 210.128 – 186 {13.9 {4.5 – 12.0 – 18. Table of tightening torques for O-ring boss piping joints a Unless there are special instructions.4 {33.0} 422 {43.5} 29.5 {28.0} 14 42 746 – 1.5} 05.3} 16 16 24 24.75} 10 10 17 9.4 – 367.8} 14 14 22 19.8 {11.88 – 8.5 – 13.5 – 2.0} 68.9} 7.5 – 24.5} 52 52 – 274.5 – 34.5} 323.0 – 19.2 {4.0} 151.0} 36 36 36 127.0} 18 18 27 34.5 – 6.4 {13.81 – 12.0} 10. Thread diameter Width across flats Tightening torque Nm {kgm} Nominal No.00 Index and foreword SEN01344-00 2.1 {18.8 – 78.8 – 147.4 {13.5} 49.5 16 22 235 – 285 23.0} 17.0} 157 {16.4 {6.0} 20 20 30 44.1 {3.3 {2.0} 33 33 – 107.5 3.3 – 44.5} 22.0} 30 30 32 93.0} 127.5} 42 42 – 181. mm mm Range Target 02 14 35 – 63 { 3. Nominal Thread diameter Width across flats Tightening torque Nm {kgm} No.6 {7.5 – 4.0} BR380JG-1E0 33 . Table of tightening torques for split flange bolts a Unless there are special instructions.3 – 240. tighten O-ring boss piping joints to the torque below.74 {1.27 {1.6 – 24.5 { 9.0 – 103} 883 {90.5} 39.0 – 8.7 {21. tighten O-ring boss plugs to the torque below.5} 107.0 – 2. mm mm Range Target 08 8 14 5.5 12 17 98 – 123 10.04 20 Varies depending 84 – 132 { 8.5} 44 { 4.1 – 122.06 24 on type of connec.4 {3.1 – 53.

type of erence) thread 34 – 54 { 3.0} 78 { 8. a Apply the following torque when the threads are coated (wet) with engine oil.0} 24 1-14UNS 25.38 ± 0.0 – 25. Thread size Tightening torque mm Nm kgm 6 8±2 0. 107 and 114 engine series to the torque below.20 8 10 ± 2 1.0 – 10.20 12 24 ± 4 2.5 03 24 59 – 98 { 6.0} 216 {22.5} – 9/16-18UN 14. Table of tightening torques for 102.41 10 43 ± 6 4. 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions.45 ± 0.2 (10) 41 177 – 245 {18.85 ± 1. - No.0 – 30.51 34 BR380JG-1E0 .0} 33 – – (12) 46 197 – 294 {20.5} 103 {10.0} 18 – – 04 27 84 – 132 { 8.0} 294 {30.5} 14 – – 22 54 – 93 { 5.61 12 77 ± 12 7. tighten the hoses (taper seal type and face seal type) to the torque below. 107 and 114 engine series to the torque below.5 – 9.0} 157 {16.SEN01344-00 00 Index and foreword 5.5 – 6.4 06 36 177 – 245 {18. Tightening torque Thread size Bolts and nuts mm Nm kgm 6 10 ± 2 1.5} 22 13/16-16UN 20.5} – 11/16-16UN 17.0} 245 {25.0} 42 – – 6.02 ± 0. Table of tightening torques for 102.0} 36 – – (14) 55 246 – 343 {25. 107 and 114 engine series (Eye joints) a Unless there are special instructions.67 ± 0.5 – 13.22 ± 0. of across Thread diame- Thread size Number of Range Target ter (mm) (Ref- hose flats (mm) threads.20 10 12 ± 2 1.3 02 19 44 { 4.45 ± 0. tighten the metric bolts and nuts of the 102.5} 74 { 7.0 – 25. Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions.81 ± 0.41 14 36 ± 5 3.5 – 5.0 – 19. Tightening torque Nm {kgm} Taper seal Face seal Nominal Width Nominal No.0} 216 {22.20 8 24 ± 4 2.6 05 32 128 – 186 {13.0} 30 1-3/16-12UN 30.5} 34 – 63 { 3.22 14 — — 7.02 ± 0. tighten the metric eye joints of the 102.0 – 35.

Thread size Tightening torque inch Nm kgm 1/16 3±1 0.53 ± 0. tighten the taper screws (unit: inch) of the 102.45 ± 0. 107 and 114 engine series (Taper screws) a Unless there are special instructions.20 3/8 15 ± 2 1. 107 and 114 engine series to the torque below.92 BR380JG-1E0 35 .20 1/2 24 ± 4 2.81 ± 0.67 ± 0.51 1 60 ± 9 6.41 3/4 36 ± 5 3.10 1/8 8±2 0.31 ± 0. Table of tightening torques for 102.12 ± 0.22 ± 0.00 Index and foreword SEN01344-00 8.20 1/4 12 ± 2 1.

402 2.669 0.787 0.354 10 0.039 0.220 1. see the example given below.024 1.465 3.65 inches.992 3.614 1.142 30 1.472 0.583 3.835 2.386 3.969 2.732 1.SEN01344-00 00 Index and foreword Conversion table 1 Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. Example: Method of using the conversion table to convert from millimeters to inches 1.441 2.496 1. This gives 550 mm = 21.575 1.417 1.819 3.205 2.591 0.622 3. take this as (B).425 3. and then draw a hori- zontal line from (A).677 2.898 36 BR380JG-1E0 . 2) Carry out the same procedure as above to convert 55 mm to 2. Millimeters to inches (B) 1 mm = 0.693 1.157 0.866 0.890 1.323 (A) 60 2.740 3.339 1.756 2. take this as (A).638 2.165 inches.346 3.276 0.165 2.118 0.228 3.827 0.701 3. 3) The original value (550 mm) was divided by 10.551 0.661 3. so multiply 2.543 3.953 2.874 2.811 1. Therefore. 2.598 2.244 2. 2) Locate the number 5 in the row across the top.110 80 3.858 3.480 2.315 0.087 2.394 0.079 0.102 1.772 1. 3) Take the point where the 2 lines cross as (C).512 0.559 2.197 0.032 3.748 20 0. 1) The number 550 does not appear in the table.126 2.071 3. Convert 550 mm into inches.536 40 1. 55 mm = 2.236 0.181 1.268 3.913 2.520 2.008 2.630 0.378 1.654 1.457 1. then draw a perpendicular line down from (B).929 (C) 50 1. so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm.063 1.709 0.299 1. Convert 55 mm into inches. This point (C) gives the value when converting from millimeters to inches.260 1.047 2.189 3.984 1.504 90 3.150 3.165 inches by 10 (move the decimal point one place to the right) to return to the original value.717 70 2.165 inches. For details of the method of using the conversion table.945 0.307 3.906 0.850 1.362 2. 1) Locate the number 50 in the vertical column at the left side.433 0.795 2.03937 in 0 1 2 3 4 5 6 7 8 9 0 0 0.780 3.283 2.

85 119.25 26.181 1.89 20 44.80 194.26 Liters to U.889 26.321 1.811 1.756 2.520 2.18 90.472 0.536 40 1.220 1.397 7.209 13.630 0.340 6.23 112.303 40 10.171 17.10 143.512 0.944 50 13.42 200.68 41.64 213.780 3.157 0.28 134.307 3.680 12.41 6.23 15.66 30.41 103.551 0.654 1.32 59.774 10.548 5.455 22.82 11.496 1.205 2.559 2.126 2.197 0.60 191.063 1.614 1.48 136.398 21.906 3. Gallons 1 l = 0.434 3.693 1.05 218.480 2.55 72.605 20.00 99.047 2.362 2.677 2.661 3.339 1.283 2.394 0.813 20.299 1.14 165.323 60 2.110 80 3.032 3.98 185.53 61.05 121.039 0.832 25.189 8.80 97.S.S.583 3.907 17.228 3.425 3.322 15.46 125.019 20 5.165 2.78 85.44 211.01 196.040 24.755 5.260 1.795 2.473 13.03937 in 0 1 2 3 4 5 6 7 8 9 0 0 0.528 0.604 6.85 216.341 20.441 2.73 63.598 2.748 20 0.416 12.94 163.03 207.379 16.361 25.638 2.21 101.244 2.14 68.787 0.625 25.624 11.870 80 21.62 105.24 209.102 1.906 0.57 83.984 1.268 3.37 178.772 1.71 51.775 24.402 2.386 3.00 Index and foreword SEN01344-00 Millimeters to inches 1 mm = 0.133 7.057 1.643 16.98 40 88.504 90 3.087 2.05 24.2642 U.491 4.227 4.71 149.57 180.819 3.982 9.07 60 132.359 11.020 19.378 1.150 3.700 17.378 10 2.190 22.20 4.926 22.850 1.793 1.465 3.039 10.827 0.869 7.30 145.59 94.16 79.64 19.247 23.19 187.510 9.93 30 66.077 20.276 0.73 160.454 8.30 48.264 0.992 3.37 81.079 0.718 8.929 50 1.62 202.719 22.142 30 1.568 24.48 39.433 0.953 2.35 167.21 90 198.25 123.591 0.76 171.008 2.795 15.585 1.740 3.024 1.189 3.669 0.27 37.34 70.709 0.732 1.511 90 23.858 3.315 0.55 169.549 19.913 2.87 130.567 10.890 1.831 11.866 0.543 3.575 1.969 2.91 55.457 1.53 158.586 60 15.717 70 2.417 1.228 70 18.96 174.118 0.44 114.51 147.095 11.529 14.001 14.662 21.492 18.03 50 110.071 3.07 35.076 6.874 2.642 2.32 156.39 189.058 15.236 0.78 182.849 2.835 2.12 70 154.246 9.12 57.622 3.153 BR380JG-1E0 37 .86 33.09 46.96 77.89 141.2046 lb 0 1 2 3 4 5 6 7 8 9 0 0 2.983 23.265 14.170 3.39 92.64 116.83 205.964 18.346 3.925 8.50 50.283 5.945 0.17 80 176.661 30 7.435 17.850 16.61 8.66 127.46 28.096 25.69 138.737 14.698 3.134 21.304 24.285 19.113 2.Gal 0 1 2 3 4 5 6 7 8 9 0 0 0.84 10 22.963 4.02 13.888 12.91 152.43 17.756 19.812 6.152 12.82 108.75 74.898 Kilogram to pound 1 kg = 2.115 16.354 10 0.701 3.

298 14.9 36.738 14.5 1077.078 14.6 1236.7 1396.2 14.760 1.9 593.179 20 4.8 839.0 224.8 1150.357 19.6 180.7 180 1301.1 817.958 15.978 60 13.7 896.559 10.2 477.8 1273.4 1200.2 354.9 253.2 1410.599 6.2 788.2 542.9 470.9 564.1 1034.3 296.919 8.3 824.198 13.777 kgm to ft.4 140 1012.3 947.037 18.3 636.117 21.7 120 868.139 8.0 969.9 376.4 484.5 983.6 1330.2 137.0 1280.5 455.998 11.5 549.017 20.6 86.4 80 578.0 190 1374.6 491.8 30 217.2 43.300 3.6 802.6 585.379 30 6.839 5.6 1113.2 882.9 159.457 20.718 16.880 1.819 7.3 419.6 1359.917 19.440 0.418 13.9 1432.4 1417.359 8.21997 U.9 1121.SEN01344-00 00 Index and foreword Liters to U.8 94.1 1345.233 ft.318 12.278 16.939 6.7 150 1084.058 16.237 20.137 19.119 10.2 571.098 12.2 1099.9 1338.2 1070.0 658.7 1179.4 701.6 1142.9 65.4 50 361.6 614.8 1056.5 1388.758 12.239 9.778 50 10.4 38 BR380JG-1E0 .1 1222.3 108.838 16.6 708.5 332.039 7.3 202.1 100 723.679 9.897 21.0 1063.438 11.1 195.498 16.2 1005.3 1258.8 499.2 231.938 17.8 933.337 21.0 629.658 11.3 513.598 17.7 1207.7 123.3 1381.4 390.818 18.4 50.5 643. Gallons 1 l = 0.4 173.7 462.799 9.0 1186.0 1403.378 80 17.1 383.7 1424.6 397.9 998.719 5.1 1439.4 889.4 1323.9 687.8 188.2 665.8 311.579 40 8.279 5.4 672.660 0.0 130.399 4.5 209.K.1 166.950 4.9 1027.257 18.4 20 144.0 101.158 17.5 426.6 274.878 12.220 0.Gal 0 1 2 3 4 5 6 7 8 9 0 0 0.2 260.259 7.159 6.200 2.8 962.5 1048.557 21.697 18.3 325.6 57.019 9.797 20.0 752.8 1244.080 3.420 2.3 79.0 441.7 90 651.6 303.0 318.7 990.9 1215.1 1251.0 347.1 1287.2 1193.3 1041.1 40 289.5 238.520 3.740 3.K.7 245.5 21.7 340.8 622.9 1092.9 904.899 10.860 3.7 368.1 911.8 716.5 766.1 1128.2 759.5 115.lb 0 1 2 3 4 5 6 7 8 9 0 0 7.0 160 1157.8 60 434.4 110 795.1 600.5 1265.477 18.320 1.3 1352.7 773.4 1106.640 2.7 556.3 730.577 90 19.5 954.178 70 15.5 737.540 1.980 10 2.1 70 506.0 846.3 607.4 267.0 535.281 11.2 1316.2 976.3 1135.9 781.677 20.638 13.479 7.699 7.9 1309.1 130 940.619 4.6 925.5 1171.1 412.6 1019.5 860.7 151.618 15.499 5.8 745.1 10 72.8 528.8 405.7 679.459 9.528 12.518 14.8 1367.6 831.1 694.5 1294.4 170 1129.858 14.2 448.7 28.339 10.3 1164.100 1.398 15.lb 1 kgm = 7.3 853.059 5.9 282.9 810.0 875.4 918.5 520.

9 71.778 1.9 50 711.8 384.8 896.143 3.086 3.1 469.664 1.845 2.674 2.00 Index and foreword SEN01344-00 kg/cm2 to lb/in2 1 kg/cm2 = 14.731 2.176 2.759 2.337 1.101 3.190 2.550 110 1.987 3.574 2.460 2.906 1.266 90 1.432 2.589 2.7 825.508 1.542 BR380JG-1E0 39 .034 2.361 2.351 1.237 1.4 42.262 160 2.773 2.1 654.707 1.470 3.072 3.195 1.3 412.053 1.044 3.0 967.119 150 2.309 1.489 2.499 3.493 1.062 2.916 2.7 184.3 99.418 2.513 3.2 597.4 739.479 1.9 583.223 1.347 2.6 369.3 924.7 312.6 753.745 2.385 3.2233 lb/in2 0 1 2 3 4 5 6 7 8 9 0 0 14.764 1.077 2.532 2.394 1.1 213.1 341.4 483.124 80 1.522 1.802 2.621 1.5 554.7 953.172 3.930 2.271 3.095 1.579 1.158 3.109 1.735 1.437 1.365 1.660 2.721 1.422 1.873 2.333 2.148 2.944 2.4 70 995.816 2.300 3.678 1.6 497.958 2.3 796.3 540.024 1.389 2.280 1.536 1.849 1.010 1.792 1.636 1.058 3.2 981.1 910.138 1.294 1.020 2.2 725.015 3.9 327.6 113.546 180 2.6 241.380 1.5 810.4 355.565 1.877 1.920 1.5 938.4 867.5 30 426.702 2.963 1.901 2.375 2.560 2.399 240 3.0 839.442 3.1 85.451 1.749 1.8 768.166 1.0 10 142.887 2.257 230 3.290 2.617 2.428 3.2 60 853.688 190 2.318 2.115 220 3.650 1.3 668.1 782.7 440.593 1.209 1.8 512.252 1.693 120 1.134 2.977 140 1.091 2.081 1.806 1.646 2.475 2.001 3.219 2.5 170.038 1.6 881.233 2.214 3.2 156.5 298.859 2.518 2.162 2.503 2.527 3.607 1.005 2.603 2.631 2.286 3.357 3.2 28.446 2.4 611.048 2.863 1.067 1.717 2.973 210 2.205 2.304 2.323 1.4 227.152 1.129 3.949 1.404 170 2.328 3.314 3.9 199.414 3.343 3.200 3.991 2.6 625.892 1.456 3.7 56.8 128.835 130 1.934 1.465 1.229 3.105 2.247 2.8 640.030 3.0 526.7 696.5 682.821 1.6 1.9 455.830 200 2.0 270.2 20 284.0 398.181 1.371 3.276 2.485 3.8 256.7 40 568.788 2.186 3.243 3.408 100 1.

0 50 122.4 –30 –22.1 97 206.2 28.4 0.1 160 320.8 24.9 –11 12.2 –26.4 22.9 16 60.8 91 195. 1°C = 33.2 –28.0 –17.0 32.8 –18 –0.0 –22.6 57.0 –28.8 –3.0 140 284.0 35.6 8.8 18 64.8 46 114.9 165 329.2 54 129.1 –15 5.4 58 136.4 –31.7 –16 3.1 43 109.0 –18.0 15.0 –6.2 37.1 115 239.0 40 BR380JG-1E0 .7 145 293.1 61 141.0 86 186.0 –10.2 99 210.2 63 145. and read the corresponding Fahrenheit temperature on the right.6 11.2 31.2 –7.2 1.4 14.2 20.3 110 230.3 65 149.8 40.3 38 100.6 5. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.8 –25.8 2.7 35 95.8 16.3 26 78.4 33.1 12 53.3 47 116.4 67 152.6 96 204.7 62 143.6 –34.4 –40 –40.8 35.4 31.8 0 32.4 –23.8 27.6 51 123.0 14 57.6 30.2 45 113.2 34.2 17.4 94 201.2 –20.4 –7.8°F °C °F °C °F °C °F °C °F –40.4 –21.6 42 107.4 17.7 71 159.9 –2 28.7 98 208.2 72 161.4 46.0 –16.0 –1.6 –24.9 57 134.3 –19 –2. When convert from Centigrade to Fahrenheit degrees.4 –5.9 93 199.0 –16.0 51.6 –27.0 –15.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.0 95 203.1 30 86.2 135 275.6 4 39.0 41 105.6 13 55.4 49 120.2 –1.1 70 158.9 25 77.2 –17 1. When convert from Fahrenheit to Centigrade degrees.4 15 59.4 24 75.6 43.6 33.8 64 147.4 76 168.2 15.8 10.1 –6 21. consider the center column to be a table of Centi- grade values.9 7 44.3 83 181.0 –11.9 –20 –4.1 3 37.0 18.6 –14 6.6 36.6 31 87.6 60 140.8 –37.0 79.7 170 338.2 10 50.4 –2.8 32.1 79 174.1 34 93.2 –35 –31.2 9.8 27 80.4 –3 26.0 12.8 68.3 74 165.0 –18.7 2 35.0 –13 8.4 11.6 71.2 3.8 54.2 90 194.4 60.9 84 183.4 6.0 –4 24.8 –22.6 19. consider the center column to be a table of Fahren- heit temperatures and read the corresponding Centigrade temperature in the column at the left.8 82 179.0 10.8 100 212.6 –2.0 77 170.8 9 48.7 80 176.7 11 51.4 25.6 2.8 18.7 –25 –13.3 –10 14.2 28 82.2 6.4 130 266.0 –3.7 29 84.2 26.3 92 197.3 8 46.4 36.1 52 125.4 6 42.6 27.9 66 150.8 55 131.2 –23.6 105 221.4 40 104.0 –19.6 –5 23.0 –9.1 21 69.7 53 127.8 21.8 –6.0 1.6 87 188.9 75 167.0 26.7 44 111.0 –25.6 22 71.0 21.3 –1 30.8 73 163.2 1 33.2 81 177.6 22.7 89 192.3 17 62.4 3.0 7.0 –12.2 19 66.6 25.1 88 190.7 –7 19.6 69 156.2 –4.0 5 41.0 –13.6 0 32 89.0 23 73.2 23.7 125 257.0 23.0 –20.6 150 302.4 –12 10.0 –14.9 120 248.2 –8.2 36 96.0 59 138.6 –21.6 33 91.8 7.8 30.7 20 68.4 –26.2 48.8 –9 15.4 73.4 85 185.6 13.0 –13.6 78 172.4 175 347.0 4.0 68 154.0 29.9 48 118.2 62.4 20.8 5.0 –10.2 76.4 28.3 155 311.4 8.9 39 102.8 13.8 –0.0 –11.0 37.8 37 98.0 65.0 –15.0 –17.6 –5.6 16.2 –8 17.3 56 132.2 12.4 –8.0 –12.8 –27.

SEN01344-00 BR380JG-1E0 Mobile crusher Form No. SEN01344-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 42 .

............................................................. 6 BR380JG-1E0 1 ......................................... coolant and lubricants.............................................................................................................................................................................. 2 Specifications ............................................................................................................................. 3 Weight table ........................... 5 Table of fuel............................................... SEN01346-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 01 Specification 1 Specification and technical data Specification dimension drawings ................................................

275 2 BR380JG-1E0 .SEN01346-00 01 Specification Specification dimension drawings 1 Dimensions 1 Unit: mm A Overall length 12.500 B Overall height 3.870 (2.280 F Length of track on ground 3.810) D Width of track 500 E Tread 2.200 C Overall width (when transporting) 2.

water-cooled. speed at no load rpm 2.500 {73.500 Overall width (During work) 2.870 mm (During transportation) 2.000 × 900 × 475 (Concrete) Performance Maximum feed-in material dimensions mm 425 × 425 × 425 (Stone) Travel speed km/h Lo: 0.04} Overall length mm 12.8 {1. 35 A Battery – 12 V.690} Rated output kW/rpm {HP/rpm} 140 / 2. Hi: 3.01 Specification SEN01346-00 Specifications 1 Machine model BR380JG-1E0 Serial Number 2001 and up Operating weight kg 34. 45 pieces on each side Track Shoe width mm 500 Tension adjuster – Grease cylinder type (With cushion spring) Type of travel brake – Hydraulic lock Model name and type – KCJ4222 single toggle jaw crusher Crusher Nominal dimensions mm 1.810 Dimensions Overall width of track mm 2. 25 Ground pressure kPa {kg/cm2} 101.69 {6.065 × 550 Speed rpm 170 – 330 (If equipped 150 – 290) Drive method – Hydraulic motor V-belt drive BR380JG-1E0 3 .050 Min.200 Minimum ground (During work) 100 / 200 mm clearance (During travel) 300 Length of track on ground mm 3.3. 5. 4 rows Number of Carrier roller (Each side) piece 2 rollers Track roller (Each side) piece 5 Undercarriage Type of track shoe – Assembly-type triple grouser.8.330 Min.6 / 1.000 Maximum feed-in material dimensions mm 1.050 {187 / 2.0 Gradeability deg. fuel consumption g/kWh {g/HP} 227 {167} Starting motor – 24 V.780 Overall height (Including grouser) mm 3.275 Track gauge mm 2.050} Engine Max. torque Nm/rpm {kgm/rpm} 721 / 1. Mi: 2. direct injection type with turbocharger and aftercooler Number of cylinders – Bore × Stroke mm 6 – 107 × 124 Total displacement l {cc} 6.500} Performance Max. vertical. speed at no load rpm 1. 110 Ah × 2 Type of radiator – Aluminum wave type.5 kW Alternator – 24V.280 Name – SAA6D107E-1 Type – 4-stroke.

gear type x 1 motor Conveyor motor – MSE02-2-123-R02-1240-K000.798 740 pins (To rod end) Min.000 x 3.7 Capacity Capacity above trough m3 1. piston type x 2 (With brake valve and shaft brake) Crusher motor – KMF125B-5.p. piston type x 1 Magnetic separator motor – S-280AD2S-K2875 x 1 Side conveyor motor – 2-200AS2S-E3343 (If equipped) Conveyor Crusher outlet Side conveyor Section – elevator adjuster telescopic (Standard) (Standard) (If equipped) Type – Double acting Double acting.000 (Rating) Drive method – Direct coupling with hydraulic motor Type – Fixed hopper Hopper Overall capacity m3 3. Double acting type bear lock type type Hydraulic Cylinder bore mm 35 130 50 cylinder Piston rod diameter mm 20 90 25 Stroke mm 220 480 270 Max. distance between mm 400 1.SEN01346-00 01 Specification Machine model BR380JG-1E0 Serial Number 2001 and up Type – Grizzly feeder with 2-level deck and speed controller Feeder Type of vibrator – Horizontal double shaft type Dimensions of trough mm 1.m Variable.9 Hydraulic pump Type and number of units – HPV 95 + 95. piston type (With safety valve) x 1 Hydraulic Hydraulic equipment (For travel and work) Feeder motor – MSF-53. variable displacement piston type x 2 Delivery l/min 212 x 2 Set pressure MPa {kg/cm2} 37.318 470 pins (To rod end) Hydraulic tank – Enclosed box type Hydraulic oil filter – Return side of tank Hydraulic oil cooler – Air-cooled 4 BR380JG-1E0 .220 Vibration frequency c. 1. distance between mm 620 1. if equipped) Control valve Operating method – Hydraulic Travel motor – HMV110ADT-2.2 {380} Type and number of units – 8-spool valve (10-spool valve.

395 Grizzly feeder assembly 2.321 Magnetic separator assembly 1.520 Primary conveyor assembly 2.01 Specification SEN01346-00 Weight table 1 k 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 751 • Engine 591 • Damper 6 • Hydraulic pump 154 Radiator and oil cooler assembly 123 Hydraulic tank and filter assembly (Excluding hydraulic oil) 135 Fuel tank assembly (Excluding fuel) 136 Main frame 418 Rear cover 118 Control valve 251 Travel motor 93 x 2 Crusher motor 53 Primary conveyor motor assembly 21 Grizzly feeder motor 17 Track frame assembly 5.476 • Track frame 3.938 • Idler 100 x 2 • Idler cushion 124 x 2 • Carrier roller 14 x 4 • Track roller 36 x 10 • Final drive (Including travel motor) 337 x 2 Track shoe assembly • Standard triple shoe (500 mm) 2.310 Hopper 1.459 Crusher assembly 13.130 BR380JG-1E0 5 .

SEN01346-00 01 Specification Table of fuel.) in the table. coolant and lubricants 1 a For details of the notes (Note 1.. 6 BR380JG-1E0 .. see Operation and Maintenance Manual. Note 2.

7 Final drive case (each) 3.6 — BR380JG-1E0 7 .7 4.01 Specification SEN01346-00 Unit: l BR380JG-1E0 Reservoir Specified (l) Refill (l) Engine oil pan 25.5 3.8 — Jaw crusher motor bearing case 4.3 Grizzly feeder vibrator case 15 15 Hydraulic system 209 112 Fuel tank 400 — Cooling system 20.4 24 Damper case 0.

SEN01346-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 8 .SEN01346-00 BR380JG-1E0 Mobile crusher Form No.

... oil cooler and aftercooler ................................. 2 Radiator............ SEN01348-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure............................. damper...................................... 3 BR380JG-1E0 1 .............................................................................................. function and maintenance standard 1 Engine and cooling system Engine mount........................................

function and maintenance standard Engine mount. damper 1 1. Rear engine mount The damper assembly is a wet type. Drive plate 5. Muffler Outline 2. Friction plate 8.SEN01348-00 10 Structure. Front engine mount Oil capacity: 0. 3. Damper assembly 2 BR380JG-1E0 .8 l 4. Stopper pin 7. Torsion spring 6.

Radiator Radiator : Aluminum wave type. Shroud 8. Radiator inlet hose 10. function and maintenance standard SEN01348-00 Radiator. Fuel cooler 6.10 Structure. oil cooler and aftercooler 1 1. Oil cooler Oil cooler : CF40-1 4. Radiator outlet hose Outline 2. Net 11. Radiator cap 9. Fan 7. Reservoir tank BR380JG-1E0 3 . Aftercooler 5. 4 rows 3.

SEN01348-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 4 .SEN01348-00 BR380JG-1E0 Mobile crusher Form No.

...................... 6 BR380JG-1E0 1 .. 3 Final drive ............................................................................................................................................................................................................. 2 Drive system for components ..................................................................................................................................................................................................... SEN01349-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure.... function and maintenance standard 1 Power train Power train................... 4 Sprocket .................................................................................................................................

Option connection port (magnetic separator) 12. Jaw crusher motor (KFM125B-5) (MSE02-2-123-R02-1240-K000) 3. Grizzly feeder 8. Grizzly feeder motor (MSF-53) 7. Travel motor (HMV110ADT-2) 11. Primary belt conveyor lift cylinder 6. Jaw crusher 2 BR380JG-1E0 . Engine 14. Final drive 10.SEN01349-00 10 Structure. Hydraulic pump 13. function and maintenance standard Power train 1 1. Control valve 4. Idler 9. Option connection port (side conveyor) 5. Primary belt conveyor motor 2. Primary belt conveyor 15.

10 Structure. function and maintenance standard SEN01349-00 Drive system for components 1 BR380JG-1E0 3 .

SEN01349-00 10 Structure. function and maintenance standard Final drive 1 4 BR380JG-1E0 .

06 – 0. 1 planetary gear (Number of teeth: 42) 3.17 – 0.56 1.66 1. 1 plane- 19 0.00 Backlash between No. No. Check Item Criteria Remedy Backlash between No. 2 sun gear 20 Wear of tooth profile of sprocket Repair limit: 6 Repair hard Standard size Repair limit chrome plating 21 Tooth width of sprocket or replace 71 68 BR380JG-1E0 5 . Drain plug 4. Sprocket 11. 1 sun gear (Number of teeth: 10) 5. 1 planetary carrier 7. 1 planetary 15 0. function and maintenance standard SEN01349-00 1. Level plug 2. 1 sun 17 0.00 gear and No.14 – 0.16 – 0.57 1. No. 2 sun gear (Number of teeth: 21) 6.25 — tary carrier and motor Replace Backlash between No. Cover 8.46 1.000 Unit: mm No. 2 planetary gear (Number of teeth: 36) Specifications Reduction ratio: – ((10 + 95)/10) × ((21 + 95) / 21) + 1 = – 57.10 Structure. 2 planetary gear 0.10 gear and ring gear Backlash between No. Floating seal 12.00 tary carrier and No. 2 planetary carrier 9.47 1. No. Travel motor 13. 2 plane- 18 0.38 – 0.13 – 0. No. Ring gear (Number of teeth: 95) 10. 2 plane- 16 0. No. No. 1 planetary gear Backlash between No. 2 sun gear Standard clearance Clearance limit 14 and No.10 tary gear and ring gear Backlash between No.

Check Item Criteria Remedy Standard size Repair limit 1 Wear of tooth tip 294.SEN01349-00 10 Structure.5 Build-up welding 2 Thickness of tooth root 17 11 for rebuilding or 3 Width of tooth 71 68 replace Repair limit: 6 4 Wear of tooth shape (measure with the full-size drawing of sprocket tooth shape) 6 BR380JG-1E0 .5 282. function and maintenance standard Sprocket 1 Unit: mm No.

function and maintenance standard SEN01349-00 Full-size drawing of sprocket tooth shape BR380JG-1E0 7 .10 Structure.

SEN01349-00 BR380JG-1E0 Mobile crusher Form No. SEN01349-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 8 .

..... 7 Track shoe ................................................................................................................................................................................................................................................................................................................................................................................................. 2 Idler ............ 6 Track roller ................................................. 8 BR380JG-1E0 1 ................................................................................................................................. function and maintenance standard 1 Undercarriage and frame Track frame and recoil spring.................................. 4 Carrier roller ................................................................... SEN01350-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure....................................................

Center guard 8. Front guard Specifications Number of track rollers: 5 (Each side) 2 BR380JG-1E0 . Track roller 6. Track shoe 7. Idler Standard shoe 2.SEN01350-00 10 Structure. Carrier roller Link pitch: 190 mm 4. Final drive Number of shoes (Each side): 45 5. Track frame Shoe width: 500 mm 3. function and maintenance standard Track frame and recoil spring 1 1.

function and maintenance standard SEN01350-00 Unit: mm No.3 kN 87.920 kg} BR380JG-1E0 3 .4 kN 558 x 238 417 531.4 {11.4 — — Standard size Repair limit Free length Installed Installed Free Installed x Outside 11 Recoil spring length load length load Replace diameter 109. Check item Criteria Remedy Vertical width of idler guide Standard size Tolerance Repair limit 9 Track frame 107 — — Idler support 105 — — Repair by build- up welding or Lateral width of idler guide replace 10 Track frame 250 — — Idler support 247.150 kg} {8.10 Structure.

function and maintenance standard Idler 1 4 BR380JG-1E0 .SEN01350-00 10 Structure.

074 Standard Tolerance Standard Inter. Check item Criteria Remedy Standard size Repair limit 1 Outside diameter of protruding 538 — 2 Outside diameter of tread 500 488 Rebuild or 3 Thickness of tread 26 20 replace 4 Step measurement of tread 19 25 5 Total width 159 — 6 Width of tread 37.5 — Standard Tolerance Standard Clearance Clearance between shaft and size Shaft Hole clearance limit 7 bushing –0.062 Clearance between bushing 9 0.164 65 0.350 –0.Interference Replace bushing Interference between idler and size Shaft Hole ference limit 8 bushing +0.176 – 0.032 72 0.170 — +0.10 Structure.108 –0.250 +0.008 –0.040 – 0. function and maintenance standard SEN01350-00 Unit: mm No.514 — –0.5 – 1.0 — and support BR380JG-1E0 5 .

101 — +0.338 – 0.44 – 0. function and maintenance standard Carrier roller 1 Unit: mm No.76 — 6 BR380JG-1E0 .190 –0.061 –0.301 40 0.168 Standard Tolerance Standard Interference Interference between roller and size Shaft Hole interference limit 7 bushing +0.016 –0.016 – 0. Check item Criteria Remedy Standard size Repair limit 1 Outside diameter of flange 145 — 2 Outside diameter of tread 120 106 3 Width of tread 43 — 4 Thickness of tread 23 16 5 Width of flange 14 — Standard Tolerance Standard Clearance Clearance between shaft and size Shaft Hole clearance limit Replace 6 bushing –0.SEN01350-00 10 Structure.040 47 0.170 +0.040 Standard clearance Clearance limit 8 Axial clearance of roller 0.491 — –0.

10 Structure.315 +0.5 38.5 — Standard Tolerance Standard Clearance limit Clearance between shaft and size Shaft Hole clearance 8 bushing –0.215 – 0.5 — 7 Width of flange 25.5 –0.215 +0. Interference bushing Interference between roller and size Shaft Hole ference limit 9 bushing +0.195 60 0.030 BR380JG-1E0 7 .023 – 0. function and maintenance standard SEN01350-00 Track roller 1 Unit: mm No.5 Rebuild or 4 Overall width 225 — replace 5 Inside width 85 — 6 Width of tread 44.153 +0.510 1.053 +0.030 67 0.153 — +0. Check item Criteria Remedy Standard size Repair limit 1 Outside diameter of flange 188 — 2 Outside diameter of tread 156 144 3 Thickness of tread 44.195 Replace Standard Tolerance Standard inter.

SEN01350-00 10 Structure. function and maintenance standard Track shoe 1 a P portion shows the link of bushing press fitting end. 8 BR380JG-1E0 .

4 6 Shoe bolt pitch 62 7 18 8 Inside width 82. Check item Criteria Remedy Standard size Repair limit 1 Link pitch 190.5 14 of bushing Master 129.7 10 Tread width 36.2 Standard 10.2 replace Impact Load 16 Thickness of spacer — 17 Bushing 88.5 (bushing press-fitting portion) 5 160.5 19.9 Protrusion of Regular 2.4 – 147 kN {8 – 15 ton} *: Dry type track link BR380JG-1E0 9 . function and maintenance standard SEN01350-00 Unit: mm No.25 193.5 replace Protrusion of Regular 3.2 Thickness of Reverse or 15 When turned / bushing metal 5.10 Structure.2 – 245 kN {9 – 25 ton} Press-fitting — 18 Regular pin 127.5 Adjust or 11 pin Master 2.4 – 274.0 Overall length Regular 212 13 of pin Master 212 Overall length Regular 137.25 Reverse or When turned Standard size replace 2 Bushing outside diameter Normal load Impact load 59 — 54 Standard size Repair limit 3 Link height 104 96 Repair or Thickness of link metal replace 4 27.4 kN {13 – 28 ton} force *19 Master pin 78.8 9 Link Overall width 42.75 12 bushing Master 0.

380 regular pin and link +0.400 +0.000 –0.400 +0.SEN01350-00 10 Structure. function and maintenance standard Unit: mm No.300 +1.) a.080 Standard Tolerance Standard Clearance between master pin size Shaft Hole clearance *25 and bushing –0. Height of — Triple-grouser rebuild or grouser 26 16 replace *: Dry type track link 10 BR380JG-1E0 . of shoes (each side) 45 — Standard Tolerance Standard inter- Interference between size Shaft Hole ference 21 bushing and link +0.02 – 0.230 – 0.200 –0.000 –0.160 – 0.200 – 0.280 Standard Tolerance Standard Clearance between regular pin size Shaft Hole clearance 23 and bushing +0.100 –0.700 Standard size Repair limit Lug welding.230 Interference between +0.300 replace Standard Tolerance Standard inter- Interference between master size Shaft Hole ference *24 pin and bushing –0.230 22 38 0.00 – 1.030 37. Regular link 490 ± 49 Triple shoe 120 ± 10 Shoe bolt {50 ± 5} Retighten 20 Tightening torque Additional tightening Lower limit torque b.000 –0.200 38 1.200 Adjust or 38 0.390 +0. Master link (Nm {kgm}) angle (deg.) (Nm {kgm}) — — — No.17 –0.60 –0.100 +0.160 59 0.100 +0.250 –0. Check item Criteria Remedy Tightening torque Additional tightening (Nm {kgm}) angle (deg.8 0.

5 BR380JG-1E0 11 . function and maintenance standard SEN01350-00 Triple grouser shoe Unit: mm No.10 Structure.5 3 26 Length of base 4 19 Rebuild or 5 20 replace 6 Length at tip 14 7 19 Standard size Repair limit 8 Thickness 34.5 24. Check item Criteria Remedy Standard size Repair limit 1 Height 26 16 2 Thickness 8.

SEN01350-00 BR380JG-1E0 Mobile crusher Form No. SEN01350-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 12 .

.................... 4 BR380JG-1E0 1 .................................................................................................................................. function and maintenance standard 1 Hydraulic sysmtem................. 2 Hydraulic tank and hydraulic oil filter ................................................................ 3 Hydraulic pump ............................. Part 1 Hydraulic piping drawing....................................................................................................................... SEN01351-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure......

Lock cylinder 4.SEN01351-00 10 Structure. Right travel motor 8. Crusher motor 3. Left travel motor 2. Hydraulic pump 7. Hydraulic tank 5. function and maintenance standard Hydraulic piping drawing 1 1. Feeder motor 2 BR380JG-1E0 . Control valve 6.

Suction strainer {0.9 kPa 6. Strainer Pressure valve 5.49 kPa {0 – 0. Sight gauge Suction cracking pressure:0 – 0. Bypass valve Relief cracking pressure: 16.7 ± 6. function and maintenance standard SEN01351-00 Hydraulic tank and hydraulic oil filter 1 1. Oil filler cap Tank capacity: 200 l 3. Hydraulic tank Specifications 2.07 kg/cm2} 7.10 Structure.3 kg/cm2} BR380JG-1E0 3 .17 ± 0. Filter element Amount of oil inside tank: 143 l 4.5 ± 0.005 kg/cm2} Bypass valve set pressure:150 ± 30 kPa {1.

function and maintenance standard Hydraulic pump 1 HPV95 + 95 4 BR380JG-1E0 .SEN01351-00 10 Structure.

10 Structure. LS-EPC valve 6. PC valve 5. IM: PC mode selector current ISIG: LS set selector current PAF: Front pump delivery port PAR: Rear pump delivery port PBF: Front pump pressure input port PBR: Rear pump pressure input port PD1F: Case drain port PD1R: Air bleeder PD2F: Drain port PD2R: Drain port PENF: Front pump control pressure detection port PENR: Control pressure detection port PEPC: EPC basic pressure input port PFC: Front pump delivery pressure detection port PLSF: Load pressure input port PLSFC: Load pressure detection port PLSR: Load pressure input port PLSRC: Load pressure detection port PM: PC mode selector pressure detection port PRC: Rear pump delivery pressure detection port PS: Pump suction port PSIG: LS set selector pressure detection port 1. PC-EPC valve BR380JG-1E0 5 . Rear pump 3. LS valve. Front pump 2. LS valve 4. function and maintenance standard SEN01351-00 Outline q This pump consists of 2 variable capacity swash plate piston pumps. and EPC valve. PC valve.

function and maintenance standard 1. Rocker cam 5. Cylinder block 8. Rear shaft 11.SEN01351-00 10 Structure. Piston 7. Front shaft 2. Valve plate 9. Rear case 12. End cap 10. Cradle 3. Servo piston 13. Front case 4. PC valve 6 BR380JG-1E0 . Shoe 6.

which torque transmitted to its shaft to oil pressure is secured to the case. q Cylinder block (7) is supported to shaft (1) by q This surface is designed so that the oil pres- spline (14). sure balance is maintained at a suitable level. BR380JG-1E0 7 . cylinder block (7). of cylinder block (7) is suctioned and dis- q Tip of piston (6) is shaped as a concave ball charged through valve plate (8). q Shaft (1) is supported by front and rear bear. q The oil inside the respective cylinder chambers ings (15). q Piston (6) carries out relative movement in the q It is possible to change the discharge amount axial direction inside each cylinder chamber of by changing the swash plate angle. and shoe (5) is caulked to it to form one unit. and forms a static pres- and delivers pressurized oil corresponding to sure bearing when it slides. function and maintenance standard SEN01351-00 Function q Rocker cam (4) conducts high pressure oil to q The pump converts the engine rotation and the cylinder surface (B) with cradle (2). the load. q Cylinder block (7) seals the pressurized oil to Structure valve plate (8) and carries out relative rotation. q Rocker cam (4) has flat surface (A). q Piston (6) and shoe (5) constitute the spherical bearing.10 Structure. and shoe (5) is always pressed against this surface while sliding in a circular movement.

q In this way. in this process.SEN01351-00 10 Structure. q On the other hand. rocker cam (4) moves plate angle (a) = 0). the volume of chamber (F) grows larger and. q A single piston (6) suctions and discharges the oil by the amount (F) – (E). 8 BR380JG-1E0 . q As cylinder block (7) rotates and the volume of chamber (E) becomes smaller. however. the pressurized oil is discharged. th e axia l d ir ection of cylinde r bloc k ( 7) q Suction and discharge of pressurized oil is not changes. and shoe (5) slides on flat surface (A). flat surface (A) acts as a cam in relation to shoe (5). the difference between along cylindrical surface (B). the swash plate angle is not set to 0) q With center line (X) of rocker cam (4) at a swash plate angle (a) in relation to the axial direction of cylinder block (7). piston (6) slides on the inside of cylinder block (7). Namely pumping q (a) is named the swash plate angle. carried out in this state. so angle (a) volumes (E) and (F) inside cylinder block (7) between center line (X) of rocker cam (4) and becomes 0. action is not performed. function and maintenance standard Operation of pump q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches (1). the oil is suc- tioned. the axial direction of cylinder block (7) (swash q When this happens. so a difference between vol- umes (E) and (F) is created inside cylinder block (7). (Actually.

the difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases. q Space of the pressure receiving area of servo piston (12) are not identical on the left side and right side. q The relationship in the size of pressure (PP) at the small diameter piston end and pressure (PEN) at the large diameter piston end. q Servo piston (12) is used for changing swash plate angle (a). and the ratio between the area receiving the pres- sure of the small diameter piston and the large diameter piston controls the movement of servo piston (12). function and maintenance standard SEN01351-00 Control of delivery q If the swash plate angle (a) becomes larger. Main pump discharge pressure (self pressure) (PP) is always brought to the pres- sure chamber of the small diameter piston side. BR380JG-1E0 9 . q This linear movement is transmitted to rocker cam (4) via slider (13). q Servo piston (12) carries out linear reciprocal movement according to the signal pressure from the PC and LS valves. q Output pressure (PEN) of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. rocker cam (4) slides on the surface while continuing revolving movement. q Being supported by cradle (2) on the cylindrical surface.10 Structure.

10 BR380JG-1E0 . setting force the spring changes. called the LS differential pressure (the differ- ence between pump discharge pressure PP and control valve outlet port pressure PLS). Sleeve PDP : Drain port 2.SEN01351-00 10 Structure. and pressure (PSIG) (called the LS selector pressure) from the pro- portional solenoid valve enter this valve. Piston PLP : LS control pressure output port 3. As the result. Spring PP : Pump port 5. Plug 8. q The relationship between the LS differential pressure between the pump discharge pres- sure (PP) and LS pressure (PLS) ( d PLS) [= (PP) – (PLS)] and pump delivery (Q) changes as shown in the diagram according to LS selector current (ISIG) of the LS-EPC valve. It will change in the range of 0. q Pump discharge pressure (PP). the specified median of the pump delivery volume switching point changes as shown in the dia- gram. too.69 to 2. Sleeve PSIG : LS mode selector pilot port 7. q This valve controls pump delivery (Q) according to differential pressure ( dPLS)[= PP – PLS]. pressure (PLS) (called the LS pressure) coming from the control valve output.2 MPa {in the range of 7 to 22 kg/cm2}. Spool PLS : LS pressure input port 4. function and maintenance standard 1. Locknut Function q The LS (load sensing) valve detects the load and controls the discharge amount. q If (ISIG) changes from 0 to 1A. LS valve PA : Pump port 1. Sheet PPL : Control pressure input port 6.

q The same pump pressure (PP) is conducted to q Magnitude of the force resulting from this LS the smaller diameter end from the port (J). port of the control valve brought to spring q Pump pressure (PP) is conducted to the larger chamber (B). the pressure moves in such determine the position of spool (6). force of spring (4) and the q According to the difference in the areas on pump delivery pressure (self pressure) (PP) servo piston (12). and main pump discharge pres. function and maintenance standard SEN01351-00 Operation 1) When the control valve is situated at neutral q The LS valve is a 3-way selector valve.10 Structure. with q Spool (6) is pushed to the right. LS pressure (PLS) will be set to 0 MPa {0 kg/cm2}. (See the figure) q If the control lever is at the neutral position when the engine is started. servo piston (12) is pushed to the left. and port (C) pressure (PLS) (LS pressure) from the outlet and port (D) will be connected. magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for the LS valve entering port (G) also changes the position of spool (6). sure (PP) brought to port (H) of sleeve (8). (Setting force of the spring is changed) q Before the engine is started. (It is intercon- nected to the drain circuit via the control valve spool) BR380JG-1E0 11 . q However. pressure (PLS). that the swash plate angle may be minimized. diameter end from the port (K).

and (E) of spool (6) are connected. changing the LS dif- and pump pressure PP drops).) q The pressure at the large diameter end of servo piston (12) becomes drain pressure (PT). 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). and pump pressure (PP) enters port (J) at the small diameter end. function and maintenance standard 2) Action for the direction of maximizing the pump delivery q When the difference between pump discharge q If the output pressure of the EPC valve for the pressure (PP) and LS pressure (PLS). so the pressure across circuits (D) and (K) becomes drain pressure (PT). 12 BR380JG-1E0 . so servo piston (12) is pushed to the left side. Therefore. spool (6) is ferential pressure (dPLS) [Difference between pushed to the left by the combined force of LS oil pressures (PLS) and (PP)] when ports (D) pressure (PLS) and the force of spring (4). becomes smaller (for example. q When spool (6) moves. when the area q If piston (7) is pushed to the right. rightward force is w o r d s . port (D) and port (E) are interconnected and connected to the PC valve. setting force of opening of the control valve becomes larger of spring (4) is weakened. the swash plate is moved in the direction to make the dis- charge amount larger. q The PC valve is connected to the drain port. (The operation of the PC valve is explained later. in other LS valve enters port (G).SEN01351-00 10 Structure.

q When spool (6) moves. setting force of spring (4) is reduced. As the result. it is pushed to the right. but because of the difference in area between the large diameter end and the small diameter end on servo piston (12). pump pressure (PP) pushes spool (6) to the right. BR380JG-1E0 13 . q Pump pressure (PP) also enters port (J) of the small diameter end of the piston. the servo piston (12) moves into the direction of reducing the swash plate angle. it enters the large diameter end of the pis- ton. 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).10 Structure. q As LS selector pressure (PSIG) is input to port (G). function and maintenance standard SEN01351-00 3) Action for the direction of minimizing the pump delivery q When LS differential pressure (dPLS) becomes larger (for example. pump pressure (PP) flows from port (C) to port (D) and from port (K).

69 MPa ship is (A0) x (PP) = (A1) x (PEN). function and maintenance standard 4) When servo piston is balanced q Let us take the area receiving the pressure at q Force of spring (4) is adjusted in such that the the large diameter end of the piston as (A1).] q At this point. q If (PSIG) [Output pressure of LS-EPC valve.9 MPa {0 to 30 kg/cm2}] is input to port (G). and the pressure flowing MPa{17. so the pressure applied across the piston when it is balanced becomes (PP) : (PEN) C 5 : 3. position of the balanced stop of this spool (6) the area receiving the pressure at the small may be determined when (PP) – (PLS) = 1. sure. 0 q If the main pump pressure (PP) of the LS valve to 2. the range of (PP) – (PLS) = 2.2 to 0. the relationship between the pres- sure receiving areas across servo piston (12) is (A0) : (A1) = 3 : 5. (PEN). and the relation. [Spool (6) will be stopped at a position where the distance of the opening from port (D) to port (E) and the dis- tance from port (C) to port (D) is almost the same.75 kg/cm2} at the median of the speci- into the large diameter end of the piston as fied value. and the combined force of spring (4) and LS the position of the balanced stop is changed in pressure (PLS) are balanced.7 diameter end as (A0). servo piston {22 to 7 kg/cm2} in proportion to (PSIG) pres- (12) will stop in that position. 14 BR380JG-1E0 .SEN01351-00 10 Structure. q The swash plate of the pump will be held at the intermediate position.

q And if the pump delivery pressure goes low. Pin PM : Mode selector pressure pilot port 4. Cover 8. function and maintenance standard SEN01351-00 2. Spool PPL : Control pressure output port (to LS valve) 5. Wiring Function q When the pump discharge pressure (PP1) q If the engine speed goes below the specified (self-pressure) and (PP2) (other pump pres. BR380JG-1E0 15 . the PC valve controls the pump sends a command current to PC-EPC valve so that the volume of oil beyond the discharge solenoid in order to reduce the slope angle in pressure-based specific flowrate may not be proportion to reduction in the engine speed. the controller reduces the pump delivery to recover the speed. Retainer 6. conducted however you may increase the con- trol valve stroke. Namely it is intended at con- trolling the horse power for the pumps so that it may not exceed the engine hose power. the controller sure) are high. this valve decreases the pump delivery. Plug PA2 : Pump pressure pilot port 2. Servo piston assembly PDP : Drain port 3. relation between the mean dis- charge pressure of the front and rear pumps [(PP1) + (PP2)]/2 and the pump delivery (Q) will becomes as shown in the diagram if the relation is represented as the parameter the current value (X) to be given to PC-EPC valve solenoid. q If the pump discharge pressure increases due to increased load during operation. q In this case.10 Structure. it increases the pump delivery. value because of increased load. Sheet 7. q The controller continues counting the actual engine speed. q If the engine speed is slowed down due to increased load. PC valve PA : Pump port 1.

the selected working mode.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) q Command current (X) is being sent to PC-EPC a Other pump's pressure denotes the pressure valve solenoid (1) from the pump controller. of the pump situated on the opposite side. the force pushing piston (2). q This command current acts on PC-EPC valve For the front pump pressure. 16 BR380JG-1E0 . bined spool-pushing force is balanced by the setting force of springs (4) and (6) as well as the pump pressures (PP1) (self-pressure) and (PP2) (another pump's pressure). the other q Spool (3) stops at a position where the com. q The size of command current (X) is determined by the nature of the operation (lever opera- tion). the other pump's to output the signal pressure in order to modify pressure is that of the rear pump. pump's pressure is that of the front pump. and the set value and actual value of the engine speed. And for the rear pump pressure. q The pressure [port (C) pressure] output from PC valve is changed depending on the above position.

it will be con. BR380JG-1E0 17 . fixed. and servo piston (9) (6). q Accompanied with move of servo piston (9). q When pump pressures (PP1) and (PP2) are q If the servo piston moves further. the pressure entering the large diame- The spring load changes as the servo piston ter end of the piston from port (J) becomes (9) extends and contracts the springs (4) and drain pressure (PT). function and maintenance standard SEN01351-00 Action of spring q Load of springs (4) and (6) on the PC valve is q Self pressure (PP1) enters port (B) and the determined by the swash plate position. small diameter end of servo piston (9). and q As servo piston (9) moves to right. spring (4) alone will operate. q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing solenoid (1) changes. spring force becomes weaker. q Port (C) and (D) are connected.10 Structure. nected. moves to the left side. retracted. q Port (C) of the PC valve is connected to port (E) of the LS valve. spring (6) is other pump pressure (PP2) enters port (A). sure entering the LS valve becomes drain q The spring load is changed by servo piston (9) pressure (PT). trend. and the pres- q After that. q Spring load of springs (4) and (6) is also springs (4) and (6) will be expanded and the affected by the command current (X) to PC. so does the force push. EPC valve solenoid. spool (3) will be positioned in the left tacted again seat (5) and spring (6) will be side. as it extends or compresses springs (4) and q If port (E) and port (G) of the LS valve are con- (6). small. ing piston (2).

the connecting between port (C) and port (D) is shut off and the pump discharge pressure ports (B) and (C) are con- nected. function and maintenance standard q As the spring force is weakened. spool (3) moves to the right. 18 BR380JG-1E0 . the pressure on port (C) rises and the pressure on the large diameter end of the piston also rises. Thus. the pushing force of the solenoid in PC-EPC valve gener- ates and the pushing force of springs (4) and (6) are balanced. q Servo piston (9) stop position (= Pump deliv- ery) is decided by the position where the push- ing force generated from the pressures (PP1) and (PP2) applied to spool (3). the leftward move of servo piston (9) is stopped. q As a result.SEN01351-00 10 Structure.

q As a result. q If pump pressure (PP2) increases further and spool (3) moves further to the right. shown in above figure. level q The position in which servo piston (9) stops at of this pressure becomes approximately half of this time is further to the right than the position pump pressure (PP2). the pressure on port (C) (= J) is q Part of the pressure to be conducted from port decreased and the rightward move servo pis- (C) to LS valve flows from port (B) to port (C) ton (9) is stopped. stopping servo piston (9). the opening and spool (3) will be moved to the position of port (C) and port (D) becomes larger. pump pres- sure (PP1) flows to port (C) and acts to make the pump delivery the minimum. pushing spool (3) to the right becomes larger q When spool (3) moves to the left. the force back spool (3). this pressure from port (J) enters the large diameter end of servo piston (9). and (D) via LS valve. q When the load is large and pump discharge springs (4) and (6) are compressed and push pressures (PP1) and (PP2) are high. function and maintenance standard SEN01351-00 (2) When load on actuator is large and pump discharge pressure is high Outline q When servo piston (9) moves to the right. when pump pressures (PP1) and (PP2) are low. BR380JG-1E0 19 . Operation q When port (E) and port (G) of the LS valve are connected.10 Structure. At the end this flow.

the relationship between average pump pressure (PP1 + PP2)/ 2.SEN01351-00 10 Structure. q The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q) becomes as shown below. and pump delivery (Q) is proportional to the force of the PC-EPC valve solenoid and moves in parallel. so the relationship between the aver- age pump pressure (PP1 + PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased. q Namely. function and maintenance standard q 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. the force of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the pump pressure applied to the spool (3). q If command voltage (X) sent to PC-EPC valve solenoid (1) increases further. 20 BR380JG-1E0 .

function and maintenance standard SEN01351-00 3.10 Structure. Plunger BR380JG-1E0 21 . Connector 2. Body 4. Rod 7. Spring 5. Coil 3. LS (PC)-EPC valve C : To LS (PC) valve P : From self pressure reducing valve T : To tank 1. Spool 6.

1) When signal current is 0 (coil is tion. and q Spool (5) is pushed to the left by spring (4).SEN01351-00 10 Structure. function and maintenance standard Function Operation q The EPC valve consists of the proportional solenoid portion and the hydraulic valve por. de-energized) q When it receives signal current (i) from the q When there is no signal current flowing from the controller. q The pressurized oil from the LS (PC) valve is drained to the tank via port (C) and port (T). outputs it to the LS (PC) valve. sure in proportion to the size of the signal. it generates the EPC output pres. coil (2) is de-energized. controller to coil (2). q Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the LS (PC) valve. 22 BR380JG-1E0 .

and pres. q The maximum volume of pressurized oil is sion force of plunger (7). pressurized oil does q Spool (5) moves up and down so that the pro. q Pressures on port (C) increases and the force q Spool (5) is pushed toward right side by rod to act on spool (5) surface and the spring load (6). 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) q When a very small signal current flows to coil q As the signal current flows to coil (2). coil (2) is energized. q When this happens. maximum. the signal current is at its q Rod (6) pushe spool (5) to the right.10 Structure. (7) is also at its maximum. increasing q Spool (5) is pushed to the left. and port (P) is the circuit pressure across EPC valve and LS shut off from port (C). q The circuit pressure between the EPC valve and the LS (PC) valve is controlled in propor- tion to the size of the signal current. pulsion force of plunger (7) may be balanced with pressure of port (C) + spring load of spring (4). BR380JG-1E0 23 . so the propulsion force of plunger surized oil flows from port (P) to port (C). is generated on the right side of plunger (7). coil (2) is (2). on spring (4) become larger than the propul. and a propulsion force energized. (PC) valve to the maximum level. not flow to the tank. conducted from port (P) to port (C). q Port (C) and port (T) are connected. q Since port (T) is closed.

SEN01351-00 BR380JG-1E0 Mobile crusher Form No. SEN01351-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 24 .

................................................................................................................................................................................................................................................................................................... 19 BR380JG-1E0 1 .............................................. Part 2 Control valve ........................................................... SEN01352-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure........................... 2 Self pressure reducing valve............................................................................. 15 Functions and operation by valve ............................................................................................................... function and maintenance standard 1 Hydraulic system........ 19 Functions and operation by valve ........... 10 CLSS........................

SEN01352-00 10 Structure. function and maintenance standard Control valve 1 8-spool valve 2 BR380JG-1E0 .

To conveyor motor and cylinder solenoid selector valve B2. To crusher motor port MA A5. To front pump control PP1. From 4-spool EPC valve P8. right travel valve. To right travel motor port PB A6. From rear pump PR. Service valve (Magnetic separator motor valve) BR380JG-1E0 3 . From travel PPC valve P4. From 4-spool EPC valve P6. To oil cooler TS. Service valve (Side conveyor motor valve) 5. From self pressure reducing valve PP2. To rear pump control PLS2. From travel PPC valve P11. To hydraulic tank PLS1. function and maintenance standard SEN01352-00 Outline q This control valve consists of a 6-spool valve and 2 service valves and is equipped with a merge-divider valve. To magnetic separator motor BP1. left travel valve. From 5-spool ON/OFF valve P-2 To hydraulic tank P-3 From 5-spool ON/OFF valve P-4. feeder motor valve.10 Structure. crusher motor valve. From self pressure reducing valve PST. To left travel motor port PB B3. From 4-spool EPC valve P9. From 5-spool ON/OFF valve T. To bear lock cylinder A-1. To magnetic separator motor B1. To crusher motor port MB B5. From 5-spool ON/OFF valve P1. From self pressure reducing valve PS. To hydraulic tank P7. To left travel motor port PA A3. From travel PPC valve P5. To right travel motor port PA B6. A1. Cover 2 3. Plug B-1. From 4-spool EPC valve P2. To hydraulic tank P-1. Cover 1 2. To hydraulic tank TSW To crusher motor 1. From travel PPC valve P10. To side conveyor motor B-2. To grizzly feeder motor A4. From 5-spool ON/OFF valve P12. 6-spool valve (Lock cylinder reset valve. q The component valves are assembled into 1 unit with bolts and the paths are connected internally. To conveyor motor and cylinder solenoid selector valve A2. To side conveyor motor A-2. To grizzly feeder motor B4. accessory valve) 4. To hydraulic tank P3.

Main relief valve 7.SEN01352-00 10 Structure. Grizzly feeder spool 3. Crusher spool 4. Left travel spool 2. Accessory spool 10. Lock cylinder reset spool 4 BR380JG-1E0 . Side conveyor spool 9. Unload valve 6. function and maintenance standard 1. Right travel spool 5. Magnetic separator spool 8.

2 kg} {11.78 kg} {1.5 N 54. 94.0 — {1.1 28.5 — {12.5 N 13 Spool return spring 36. Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed 9 Spool return spring Outside diameter length load length load 120.8 53.5 x 34.4 N 10 Spool return spring 54.0 — {3.2 x 34.0 kg} {2.6 kg} {7.4 N 23.5 — damaged or {14.1 N 75.42 kg} 29.6 N 96.7 kg} 17.10 Structure.1 x 10.3 N replace it. Plug Unit: mm No. Lock cylinder reset spool 5. Right travel spool 6.6 x 34. function and maintenance standard SEN01352-00 1.5 N 13.9 N 12 Spool return spring 48.8 28.4 kg} deformed. Pressure compensation valve 4.3 N 111.4 kg} BR380JG-1E0 5 . Safety-suction valve 8.8 kg} If spring is 139.8 53. 11 Spool return spring 54. Crusher spool 7.9 x 11.3 kg} {9. Suction valve 2. Pressure compensation valve 3.5 — {9.8 53.

Feeder spool 8. Accessory spool 10. function and maintenance standard 1. Return spring 7. Safety-suction valve 11.SEN01352-00 10 Structure. Unload valve 2. Safety-suction valve 12. Safety-suction valve 14. Merge-divider valve (Travel junction valve) 6. Main relief valve 3. Pressure compensation valve 5. Pressure compensation valve 4. Left travel spool 9. LS shuttle valve 6 BR380JG-1E0 . Suction valve 13.

1 x 10.1 28. function and maintenance standard SEN01352-00 Unit: mm No.4 kg} or deformed.8 53.0 kg} {2.6 x 34.4 kg} BR380JG-1E0 7 .3 N 111.5 N 13. 120.6 N 96. Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed 15 Spool return spring Outside diameter length load length load 94.1 N 75.4 N 23.8 53.3 N 54.9 N 18 Spool return spring 48.4 N damaged 16 Spool return spring 54.10 Structure.0 — {3.2 x 34. {12.0 — {1.5 N 19 Spool return spring 36.5 x 34.5 — replace it.5 — {14.5 — {9.6 kg} {7.3 kg} {9.5 N 17 Spool return spring 54.42 kg} 29.2 kg} {11.8 kg} 17.9 x 11.7 kg} If spring is 139.8 53.78 kg} {1.8 28.

function and maintenance standard 1. Safety-suction valve 6.78 kg} {1. LS bypass valve Unit: mm No.8 kg} replace it.1 x 10. Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed 9 Spool return spring Outside diameter length load length load If spring is damaged or 120.8 28.42 kg} 8 BR380JG-1E0 .9 N 10 Spool return spring 48.6 N 96.5 N 13. 54.8 53.SEN01352-00 10 Structure. Merge-divider valve (Main) 4. 17. Side conveyor and magnetic separator spool 5. Main relief valve 2. Merge-divider valve (For LS) 3.2 x 34. Unload valve 8.5 N deformed.5 — {12.0 — {1. Pressure compensation valve 7.3 kg} {9.

function and maintenance standard Self pressure reducing valve 1 a. Port (PC) (to front pump LS valve) 10 BR380JG-1E0 . PPC valve. Port (T) (to hydraulic tank) d. EPC valve) c. Port (P1) (from front pump) b. Port (PR) (supply to electromagnetic valve.SEN01352-00 10 Structure.

Poppet 3.1 kg} {1.1 — spring if any {2 kg} {1.1 x 7.4 kg} {19 kg} 61.5 x 7. Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed Spring (pressure 5 Outside diameter length load length load reducing valve.6 N 17.6 N deforma- 6 16.3 kg} {6 kg} BR380JG-1E0 11 .2 x 7.7 — reducing valve.4 — {6.7 N 58. main) {2. function and maintenance standard SEN01352-00 1.2 16. 7 Spring 71 x 18 59 — {20.8 N 186. main) 19.7 N Replace 19.10 Structure. Pressure reducing valve 4.8 13. Ball Unit: mm No.9 kg} tions are 199. Sequence valve 2.6 N 18.8 kg} damages or Spring (pressure 20.2 12.2 N found.8 N 8 Spring (safety valve) 16.

q Poppet (5) is pushed against the seat by spring (6). (See Fig. When engine is stopped. q Valve (2) is pushed to the left by spring (3). Operation 1. and the passage from port (PR) o (T) is closed.SEN01352-00 10 Structure. 1) 12 BR380JG-1E0 . so the passage between port (P1) o (P2) is closed. and the passage from port (P1) o (PR) is open. q Valve (8) is pushed to the left by spring (7). function and maintenance standard Function q This valve reduces the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valve and PPC valve.

q However. the amount of opening from port (P1). so spool from port (P1) o (PR). and the hydraulic oil spool (8) o opening of poppet (5) o tank port flows in the following circuit: port (PR) o hole (T). poppet (5) opens and the hydraulic oil flows in q When pressure (PR) goes above the set pres. the pressure is 0 MPa {0 kg/cm2}). so spool q As a result. the following circuit: port (PR) o hole (a) inside sure. 3. and is sup- reduced to a certain pressure (set pressure) by plied as pressure (PR). a pressure difference is created on tank port (T). and is sup- plied as pressure (PR). so the loss of engine sure (PR)). when hydraulic oil flows in from port q As a result. discharge amount also increases because of q Valve (2) receives force in the direction to operations.10 Structure. 2) BR380JG-1E0 13 . (a) inside spool (8) o opening of poppet (5) o q As a result. and the opening from port (P1) o horsepower is reduced. function and maintenance standard SEN01352-00 2. Pressure (P1) is the amount of opening at this point. (P2) is adjusted so that pressure (P1) is kept at q If pressure (PR) goes above the set pressure. a pressure difference is created on (8) moves in the direction to close the opening both sides of hole (a) inside spool (8). both sides of hole (a) inside spool (8). poppet (5) opens. pressure (P1) also increases close the passage from port (P1) o (P2) from (pressure (P1) > force of spring (7) + (area spring (3) and pressure (PR) (when the engine (Ød) x pressure (PR)). the pressure is balanced so that pressure (P1) o (P2) increases and the resistance in (P1) = force of spring (7) + (area (Ød) x pres. 3) the amount of opening at this point. At hold and when load pressure (P2) is low. (See Fig. the passage is reduced. NOTE: When load pressure (P2) is lower than output q If load pressure (P2) increases and the pump pressure (PR) of the self pressure reducing valve. (See Fig. a certain value above pressure (PR). Pressure (P1) is (8) moves in the direction to close the opening reduced to a certain pressure (set pressure) by from port (P1) o (PR). so valve (2) moves to is stopped. the right to the end of the stroke. When load pressure (P2) is high.

and allows hydraulic oil to flow from output port (PR) o (T). ball (10) pushes against the force of spring (9).SEN01352-00 10 Structure. so pres- sure (PR) goes down. 4) 14 BR380JG-1E0 . q When pressure (PR) of the self pressure reducing valve becomes abnormally high. etc.) from abnormally high pressure. function and maintenance standard 4. electromagnetic valve. separates from the seat. This action protects the equipment at the destination for the hydraulic pressure supply (PPC valve. (See Fig. When there is abnormally high pressure.

q CLSS is configured with variable capacity pis- tem. PC valve and LS valve. and respective actuators. which has the following characteristics: ton pumps. control valves. fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q Energy saving using variable pump control BR380JG-1E0 15 .10 Structure. q Fine control not influenced by load q The hydraulic pump is configured with pump q Controllability enabling operation even with body. function and maintenance standard SEN01352-00 CLSS 1 Outline of CLSS 1 Features Configuration CLSS stands for Closed center Load Sensing Sys.

q If it becomes higher than the set pressure charge pressure (PP) – LS pressure (PLS)] (when the actuator load pressure is low). q [LS differential pressure (dPLS) = Pump dis. LS differential pressure (dPLS) and pump swash plate angle a For details of functions. high). function and maintenance standard Basic principle 1 1. see the “Hydraulic pump” paragraph. the pump swash plate angle shifts toward the mini- mum position. Pump swash plate angle control q The pump swash plate angle (pump delivery) q 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 valve (when the actuator load pressure is PLS) (load pressure of actuator) is constant.SEN01352-00 10 Structure. 16 BR380JG-1E0 .

BR380JG-1E0 17 . function and maintenance standard SEN01352-00 2.10 Structure. q When actuators are operated together. q The flow of oil from the pump is divided (com- pensated) in proportion to the area of opening (S1) and (S2) of each valve. Pressure compensation control q A pressure compensation valve is installed to the outlet port side of the control valve to bal- ance the load. the pressure difference (dP) between the upstream (inlet port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the load (pres- sure).

Valve 3A. this is always in the divide mode). Unload valve 7B. Unload valve 7A. LS circuit 12. Main relief valve 6B. function and maintenance standard 3. Control valve 9A. Control valve 9B. Tank passage 1B. Actuator 10B. Pump passage 11B. LS circuit 18 BR380JG-1E0 . Spring 3B. System diagram a This shows actuator (6A) at stroke end relief in the merge mode (on the BR380JG-1E0. Merge-divider valve 8A. LS bypass valve 8B. Valve 2B. Spring 4. Main pump 5A. Main pump 5B. Actuator 10A. 1A.SEN01352-00 10 Structure. Tank passage 2A. Main relief valve 6A. Pump passage 11A.

5 MPa {320 ± 5 kg/cm2}) 16. Safety-suction valve (31. Relief valve (Set pressure: 37. when pilot pressure is applied: 10. Accessory spool 6.2 ± 0.5 MPa {210 ± 5 kg/cm2}. Safety-suction valve (17. function and maintenance standard SEN01352-00 Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves 1 1. Lock cylinder reset spool 11. Left travel spool 7.4 ± 0. Right travel spool 10.5 MPa {175 ± 5 kg/cm2}) 15. Grizzly feeder spool 8. Safety-suction valve (When normal: 20.6 ± 0. Suction valve 14.5 MPa {110 ± 5 kg/cm2}) 13. Magnetic separator spool 4.2 ± 0. Pressure compensation valve 18. Crusher spool 9. Unload valve (Cracking pressure: 2.5 MPa {380 ± 5 kg/cm2}) 2.5 MPa {140 ± 5 kg/cm2}) 12. Side conveyor spool 5. Merge-divider valve 17.9 ± 0.5 MPa {30 ± 5 kg/cm2}) 3.8 ± 0. Safety-suction valve (13.10 Structure.7 ± 0. Pressure compensation valve BR380JG-1E0 19 .

force of spring (5). Valve 5. When the unload valve is actuating 1. LS circuit 4. 20 BR380JG-1E0 .SEN01352-00 10 Structure. q Since the control valve is in neutral position. Pump circuit Function Operation q Drains an oil discharge for the portion of the q Pressure of pump circuit (3) is received by the minimum pump swash plate angle while all end of valve (2). q The pump pressure will correspond to a set pressure of LS circuit (1) is 0 MPa{0 kg/cm2}. valve (2) moves to the left. bypass valve. q Pressurized oil of pump circuit (3) stops at sure will be P1). the signal is output to minimize the pump swash plate angle. q When actuated. LS pressure C tank pressure. q The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to the tank circuit (4). control valves are in the holding. load of spring (5) inside the valve (this pres. and the pressure rises as no relief is q Since LS pressure is drained from the LS available. LS pressure C tank pressure C 0 q When this pressure becomes larger than the MPa{0 kg/cm2}. function and maintenance standard Unload valve 1. q Since the pump discharge pressure – LS cir- cuit pressure during unloading is larger than the pump LS control pressure. valve (2). Spring 3. Tank circuit 2. q Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (4).

q As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve. q The pump delivery (Q) is relieved to the tank. (See the system diagram) q When pump discharge pressure (PP) comes close to the relief pressure. BR380JG-1E0 21 . and LS differential pressure (dPLS) becomes 0 MPa{0 kg/cm2}. q The pump is held at a minimum swash plate angle by the cut-off function of PC valve. Operation q When the cylinder reaches the stroke end. the engine throttle and pump controller sends a signal to the sole- noid of the PC valve. operation of PC valve have the prevalence to that of LS valve. pump by the PC valve. 2. q The pump discharge pressure (PP) and LS pressure (PLS) become approximately the same as each has not flow at the upstream and downstream of the spool.10 Structure. q The relief valve acts to relieve the oil flow when the pump is at the minimum swash plate angle in order to maintain the balance. q When cut-off control is being carried out on the q LS control differential pressure (dPLS) of dis. LS valve is actuated to maximize the pump swash plate angle. the pump swash plate charge for the portion of minimum swash plate angle is at the minimum. q Carries out the cut-off function to make pump delivery (Q) the minimum. q Mechanically. function and maintenance standard SEN01352-00 q During operation (a work within a scope of dis. the main relief valve opens. angle will be equal to P1 pressure. Operation of relief valve 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.

q Connected to actuator port (B) through valve (4). 22 BR380JG-1E0 . check valve (5) opens.SEN01352-00 10 Structure. q When the pump pressure rises to reach the load pressure of port (B). Main spool 3. LS circuit 7. LS shuttle valve Function q 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. q Inlet pore (a) inside main spool (2) has a small diameter concurrently serving as a throttle. Valve 5. Operation q When main spool (2) is operated. Hydraulic pump 2. and makes LS pressure C actuator load pressure. Pressure compensation valve 4. Check valve 6. the pump pressure enters port (c) through inlet pore (a) and is led to the LS circuit. function and maintenance standard Introduction of LS pressure 1 1.

Main spool 3. q Bypass flow from LS bypass valve (5) causes a pressure loss to be generated due to the cir- cuit resistance between throttle (c) of main spool (2) and LS shuttle valve (4). LS circuit Function q Releases the residual pressure in LS pressure circuit (6) from orifices (a) and (b). function and maintenance standard SEN01352-00 LS bypass valve 1 1. q Effective LS differential pressure drops to improve a dynamic stability of the actuator. LS shuttle valve 5.10 Structure. Pressure compensation valve 4. BR380JG-1E0 23 . LS bypass valve 6. Hydraulic pump 2. q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres- sure.

Integrated pressure compensation valve q High stress may occur when valve (2) collides with valve chamber seat portion (C) if a high peak pressure is generated in the actuator cir- cuit or repetitive peak pressure occurs continu- ously (example: when using the breaker). shuttle valve (3) in valve (7) does not collide with the valve cham- pressure compensation valve piston (4) inter.SEN01352-00 10 Structure. During independent operation and under maximum load pressure (If the load pressure is higher than other work equipment during a combined operation) 1. q To prevent this. q If the pump pressure (LS pressure) is lower q If high peak pressure is generated at port (C). LS shuttle valve Function q As principle. sure compensation valve. Valve 5. ber. q With the present machine. function and maintenance standard Pressure compensation valve 1 1. Spring 3. a pressure compensation valve with integrated valve (2) and piston (4) is used. than the load at port (c). q The force of spring (5) operates piston (4) and valve (2) to the closing direction. Hydraulic pump 4. 24 BR380JG-1E0 . port (C) and spring chamber (E) q Pressure compensation valve works as the are not interconnected in an integrated pres- load check valve. connects spring chamber (E) and port (C). Shuttle valve 6. this device is adopted for travel valve. Piston 2.

q Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with LS pressure. q Pump flow is divided according to the ratio of the meter-in opening area. q Piston (4) and valve (2) operate in the closing direction (to the right) under the LS circuit pres- sure from other work equipment of port (F). When compensated (If the load pressure is lower than other work equipment during a combined operation) Function q The pressure compensation valve closes under LS pressure of port (D). BR380JG-1E0 25 . the spool meter- in differential pressure [upstream pressure port (A) pressure] – downstream pressure [port (B) pressure] becomes equivalent to all the spools in operation. and the spool meter-in downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment. Operation q Spring chamber (E) is interconnected to port (D).10 Structure. function and maintenance standard SEN01352-00 2. q Since the spool meter-in upstream pressure of port (A) is the pump pressure.

and the pressure will be divided according to the opening area ratio. q If area ratio = 1 or over : The spool meter-in downstream pressure will be greater than the maximum load pressure. function and maintenance standard 3. and the pressure will be divided greater than the opening area ratio. and the pressure will be divided smaller than the opening area ratio. 26 BR380JG-1E0 . q If area ratio = 1 or under : The spool meter-in downstream pressure will be smaller than the maximum load pressure. Pressure compensation valve area ratio Function q The state of division changes according to the area ratio of pressure compensation portion (A1) and (A2).SEN01352-00 10 Structure. Area ratio = (A2)/(A1) q If area ratio = 1 : The spool meter-in downstream pressure will be equal to the maximum load pressure.

10 Structure. Pressure compensation valve inner shuttle valve 4. BR380JG-1E0 27 . function and maintenance standard SEN01352-00 Pressure compensation valve inner shuttle valve 1 1. If holding pressure at port (A) is larger than LS pressure in the springing chamber (B) 1. Piston Function q Shuttle valve (3) is pushed to the right by port (A) pressure and cuts off interconnection between ports (A) and (C). Hydraulic pump 2. q Holding pressure at port (A) is led to the spring chamber (B) to push piston (4) to the left so that piston (4) and valve (2) will not be sepa- rated. Valve 3.

function and maintenance standard 2. 28 BR380JG-1E0 .SEN01352-00 10 Structure. In the case of travel Outline q Since no holding pressure is generated at port (A) of the travel circuit. a pressure compensa- tion valve without shuttle valve (3) is adopted.

q Forwards LS pressure led from respective con- trol valve spools to LS circuits (5). 1. LS circuit (conveyor PAISE/LOWER side) 4. LS circuit (conveyor PAISE/LOWER side) 3. nected. LS circuit (if equipped 4 side) 2.10 Structure. it is pressed to the left by spring (4). q Pilot pressure (PS) is OFF. (6). q Merges and divides LS circuit pressure. When flows from the pumps merge [if pilot pressure (PS) is OFF] a On the BR380JG-1E0. Spring 8. Main spool 5. so main spool (1) is pressed to the left by spring (2) and ports (E) and (F) are interconnected. q Merges pressurized oil (P1) and (P2) dis- charged from the two pumps at ports (E) and (F) and sends to necessary control valve. LS spool 7. BR380JG-1E0 29 . and charged from the two pumps or divides (to ports (A) – (D) and ports (B) – (C) are intercon- respective control valve group). Spring 6. pilot pressure (PS) is always ON and the flow is always divided. (7) and Operation (8) to all the pressure compensation valves. LS circuit (if equipped 4 side) Function q Since pilot pressure (PS) is OFF for LS spool q Merges pressurized oil (P1) and (P2) dis. (3). function and maintenance standard SEN01352-00 Merge-divider valve 1 1.

primary con- veyor. P1 pressure: To crusher P2 pressure: To grizzly feeder. and ports (E) and (F) are divided. interconnects ports (B) and (D) and divides other ports. 30 BR380JG-1E0 . (6). function and maintenance standard 2.SEN01352-00 10 Structure. q Pressurized oil discharged from the two pumps are sent to respective control valves. and mag- netic separator. When flows from the pumps divide [if pilot pressure (PS) is ON] Operation q Pilot pressure (PS) turns ON. (7) and (8) to respective control valves. q Forwards LS pressure led from each control valve spool to LS circuits (5). and shifts main spool (1) to the right. debris discharge conveyor. LS spool (3) shifts to the right. q When pilot pressure (PS) is turned ON.

BR380JG-1E0 31 . travel q Pilot pressure from the travel junction solenoid circuits through travel junction valve so that the valve contracts spring (1). travel circuit) is q When the machine is steered.H.H. and travel junction hydraulic oil will be supplied evenly to both spool (2) moves to the left to the stroke end. travel travel performance.H.10 Structure. When pilot pressure is turned ON Function Operation q This valve connects the L. travel motors to improve machine's straight q Junction circuit between port (PTL) (L.H. function and maintenance standard SEN01352-00 Travel junction valve 1 1. and R. outside pilot closed. circuit) and port (PTR) (R. pressure (PST) closes the travel junction valve to improve steering performance.

the is 0. force of spring (1) against the right side and travel junction spool (2).H.H. and port (PTR) so that the pass between ports (PTL) and (PTR) is the oil flow rates to both motors will be equal- open. 32 BR380JG-1E0 . ized again. travel q If pilot pressure (PST) from the solenoid valve motors become different from each other. function and maintenance standard 2. When pilot pressure is turned OFF Operation q If the oil flow rates to the L. travel junction spool (2) is pressed by the oil flows through the route between port (PTL).SEN01352-00 10 Structure. and R.

SEN01352-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 34 .SEN01352-00 BR380JG-1E0 Mobile crusher Form No.

..................................................................................................... 34 BR380JG-1E0 1 ........................................................................................................................................................ 7 Travel motor .... 32 Hydraulic cylinder..... 28 Electromagnetic selector valve ...................................................... function and maintenance standard 1 Hydraulic system........................................................................................... 2 Grizzly feeder motor....... 26 EPC valve ..................................................................................................................................................... SEN01353-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure....................................................................... 8 Valve control ..................................................... 6 Conveyor motor ................................................... Part 3 Crusher motor ................................................................................................................................................................................................................................................................................................. 16 Solenoid valve...............................................................................................................................................................................................................................................

780 rpm 2 BR380JG-1E0 . function and maintenance standard Crusher motor 1 Type: KMF125B-5 MA: From control valve Specifications MB: From control valve Model: KMF125B-5 S: From back pressure compensation valve Theoretical delivery: 125.7 MPa {375 kg/cm2} Rated speed: 1.0 cm3/rev T: To tank Set pressure of safety valve:36.SEN01353-00 10 Structure.

Housing 9. function and maintenance standard SEN01353-00 1. Safety valve BR380JG-1E0 3 . Drive shaft 6. Valve plate 12. Check valve 2. Cylinder block 11. Case 8. Check valve spring 3. Shuttle valve spring 5. Spacer 7.10 Structure. Center spring 14. Shuttle valve 4. Piston 10. Center shaft 13.

7 N 10.29 kg} spring 13.9 11.4 kg} {1.8 N replace 62. Check item Criteria Remedy Standard size Repair limit Free length × Installed Installed Free Installed 1 Check valve spring Outside diameter length load length load If damaged or deformed.4 × 8.5 × 20.1 kg} 4 BR380JG-1E0 . 3.5 N 2.36 kg} {0.0 — {0. function and maintenance standard Unit: mm No.0 35.5 — {1.SEN01353-00 10 Structure.8 N 2 Shuttle valve spring 16.

so the pressure at the output side of the same pressure as port (MB). shuttle valves (4) and (5). 1. but the motor continues to rotate under tle valve (A) (4) and chamber (C) becomes the inertia. The oil pressure motor becomes abnormally high. so the pressure at port (MB) rises. the Outline supply of pressure oil from the pump to port q The relief valve portion consists of check (MA) is stopped. When starting crusher q When the crusher ON switch is pressed. the starting torque is generated in the motor. it pushes shut- closed. a high braking To prevent this. As a result. and this may rises further until it reaches the set pressure of damage the motor. through check valve (B) (3) and is supplied to port (MA). function and maintenance standard SEN01353-00 Relief valve portion 2. and the motor starts to rotate. This prevents cavitation at port Operation (MA). the the motor (high-pressure side) to prevent any relief oil and the oil from port (S) passes damage. oil is relieved to port (S) from the outlet port of q When relief valve (1) is being actuated. rotation resistance Function is generated in the motor. BR380JG-1E0 5 . q When the crusher is stopped. so the braking effect starts. When stopping crusher q When the crusher OFF switch is pressed. The oil from the out- let port of the motor passes from port (MB) thought the control valve and returns to the tank. closed by the control valve. the abnormally high pressure torque acts on the motor and stops the motor. the return circuit to the tank is and relief valve (1). As a result. As a result. the outlet port q If the pressure at port (MB) becomes higher circuit of the motor from the control valve is than the pressure at port (MA). the pressure at port (MA) rises. the pressure oil from the pump passes through the control valve and is supplied to port (MA). port of the motor. relief valve (1).10 Structure. With the oil from the outlet valves (2) and (3).

function and maintenance standard Grizzly feeder motor 1 P1: From control valve Specifications P2: From control valve Model: MSF-53 T: To hydraulic tank Theoretical delivery: 53. speed: 3.SEN01353-00 10 Structure.6 MPa {210 kg/cm2} Max.4 cc/rev Rated pressure: 20.000 rpm 6 BR380JG-1E0 .

3 MPa {350 kg/cm2} Max. pressure: 34.10 Structure. speed: 165 rpm BR380JG-1E0 7 . function and maintenance standard SEN01353-00 Conveyor motor 1 R: From control valve Specifications L: From control valve Model: MSE02-2-123-R02-1240-K000 1: To hydraulic tank Theoretical delivery: 398 cc/rev Max.

2 cm3/rev delivery Set pressure 37. From travel speed solenoid valve BR380JG-1E0 Item PA.842 rpm capacity Brake releasing pressure 1. MB pressure pickup port Model P. 106. function and maintenance standard Travel motor 1 HMV110ADT-2 MA. To tank Theoretical Max. From control valve Type HMV110ADT-2 PB. Rated speed 1. From control valve T.SEN01353-00 10 Structure.3 MPa {380 kg/cm2} Max. MA pressure pickup port Specifications MB.2 MPa {12 kg/cm2} 8 BR380JG-1E0 .

Retainer guide 20. Motor case 13. Ring 4. function and maintenance standard SEN01353-00 1. Pin 21. Piston 22. Suction-safety valve spring 14. Spool return spring 5. Plate 7. Check valve spring 17. Ball BR380JG-1E0 9 . Output shaft 18. Cylinder 24. Disc 8. Spring 10. Spring 12. Retainer 23. Rocker cam 19. Suction-safety valve 15.10 Structure. Counterbalance valve 3. Valve plate 2. Brake piston 6. Regulator piston 9. Regulator valve 11. Check valve 16.

1 17.6 — {41.43 x 30 42.5 — {0.6 kg} {4.5 x 11.57 N replace 2 Check valve spring 13.2 kg} or deformed. function and maintenance standard Unit: mm No.26 kg} {0.2 kg} {0.16 kg} spring 411 N 329 N 3 Return spring 58.96 N 1.5 24.5 kg} 55 N 44 N 4 Regulator valve spring 21. Check item Criteria Remedy Standard size Repair limit Free length x Installed Installed Free Installed 1 Check valve spring Outside diameter length load length load 2.1 — {5.6 x 6.9 kg} {33. 1.5 kg} 10 BR380JG-1E0 .96 N 31.0 x 6.55 N 1.2 — If damaged {0.5 9.SEN01353-00 10 Structure.

BR380JG-1E0 11 . q As brake piston (12) returns. q The time delay will be set to activate the brake only after the machine has stopped.10 Structure. (11). When stopping travel 1. disc (14) and the brake is released. q The pressurized oil in chamber (A) of brake q The pressurized oil is conducted to chamber piston (12) passes through orifice of brake pis- (A) of brake piston (12) and compresses spring ton (12) and is drained to the motor case. opening the parking brake circuit. and the brake is applied. flow of pressur- ized oil is reduced with slow return valve (22). q Brake piston (12) is pushed to the right by q Since the pushing force to plate (13) and disc spring (11). spool (19). function and maintenance standard SEN01353-00 Operation of parking brake 2. counter- q As the travel lever is operated. When starting to travel q As the travel lever is placed in neutral. plate (13) is separated from q Plate (13) and disc (14) are pushed together. (14) disappears. pressurized oil balance valve spool (19) returns to the neutral from the pump activates counterbalance valve position and closing the parking brake circuit. pushing piston (12) toward left.

function and maintenance standard Brake valve Operation when pressurized oil is supplied q The brake valve consists of suction safety q Operating the travel lever conducts the pres- valve (18A) and counterbalance valve (18). surized oil from the control valve to port (PA). 12 BR380JG-1E0 . q The pressurized oil push-opens suction safety nents shall conform to the following. valve (18A) and then flows to motor outlet port (MB) via motor inlet port (MA). q Functions and operations of respective compo. 1) Counterbalance valve and check valve q The motor outlet side is closed by suction safety valve (18B) and spool (19). so the pres- Function sure at the supply side rises. q When traveling downhill.SEN01353-00 10 Structure. q These valves are used to prevent above by controlling the machine to travel according to the engine speed (pump delivery). resulting in a very dangerous situation. the motor may rotate without load. q If the machine travels with the engine at low speed. causing the machine to run away. the machine travel speed tends to get faster than the motor (engine) speed because of the downward force generated from its own weight.

10 Structure. fices (E1) and (E2). spool (19) is returned to the left by spring (20) and outlet port (MB) is throttled. BR380JG-1E0 13 . open. function and maintenance standard SEN01353-00 q The pressurized oil on the supply side flows to Operation of brake during travelling downhill chamber (S1) via orifice (E1) and orifice (E2) of q If indication of the machine runaway is sensed the spool (19). q Oil flow from the outlet circuit is reduced to ensure the travel speed corresponded to the pump delivery. pushed toward right. while travelling downhill. gen- erating rotation resistance on the motor to pre- vent the machine from running away. q The spool moves to a position where the pres- sure on outlet port (MB) can be balanced against the machine's own weight and the inlet port pressure. q The pressure at the outlet port side rises. q Pressure in chamber (S1) is released via ori- q Port (MB) and port (PB) are connected. the motor will be q As the pressure in chamber (S1) goes above caused to rotate without load to decrease the the spool selector pressure. spool (19) is inlet side oil pressure. ing the motor outlet port side and starting the q As the pressure in chamber (S1) goes below motor rotating. the spool selector pressure.

potentially resulting in dam- ages on the motor and piping. 3) When starting travel q When it drops beyond the spool switching (or when traveling at a constant speed) pressure. spool (19) is returned to the left by q As the travel lever is operated. 14 BR380JG-1E0 . function and maintenance standard 2) Safety valve q When the pressure rises above the set pressure of the suction safety valve. poppet (1) opens. producing large differential (MB) is increased. pressure. Operation (1) When travel is stopped (or when travelling downhill) (Clockwise rotation) q Reduction of the pressure at motor inlet (PA) decreases the pressure in chamber (S1). Function q The pressurized oil passes through notch (A1) of spool (19) into chamber (MA) of the circuit at q As long as the machine travel is stopped (or it the opposite side. q The passage to the suction safety valve func- q The motor tries to continue rotation resorting to tions as a circuit which passes through notch inertial force. the counterbalance q At the time of counterclockwise rotation. q The pump pressure rises.SEN01353-00 10 Structure. motor. the pressurized spring (20). passage (B1). thus pressure on the outlet port (B2) of spool (19). q Since the motor is rotated by inertial force. q The safety valve releases this abnormal pres- sure to the inlet port side of the motor in order to prevent damages to the equipment. it valve closes the inlet and outlet circuits of the makes reverse operation of clockwise rotation. reducing the pressure at outlet oil from the pump moves spool (19) toward right. pressure in the motor outlet port side is abnor- mally increased. is travelling downhill). providing a large tractional force to the valve.

Right travel lever 9. EPC valve B. function and maintenance standard Valve control 1 1. Neutral 3. Travel PPC valve Positions of lever 2. Solenoid selector valve C. Left travel lever 8. Travel "Reverse" 5.SEN01353-00 10 Structure. Travel lock EPC valve A. Solenoid valve 10. Hydraulic block 16 BR380JG-1E0 . Control valve 7. Hydraulic pump 6. Travel "Forward" 4.

forward P5: Travel signal P6: Steering signal T: To tank BR380JG-1E0 17 .H. function and maintenance standard SEN01353-00 Travel PPC valve 1 P: From self pressure reducing valve P1: L. forward P3: R.H. reverse P4: R.10 Structure.H.H. reverse P2: L.

SEN01353-00 10 Structure. function and maintenance standard 18 BR380JG-1E0 .

Body 3.5 x 8.5 {0.4 kg} 8.9 kg} — {0.6 x 15.3 N If damaged or 47.8 kg} deformed.9 {1.5 32. Steering signal spool spring Unit: mm No. Check item Criteria Remedy Standard size Repair limit Free length x Installation Installation Installation Free length 11 Centering spring Outside diameter length load load 108 N 86. Steering signal spool 10. Piston 4. Damper 9.0 kg} {8.1 N 13 Steering signal spring 12.7 N spring. function and maintenance standard SEN01353-00 1. Plate 2. Metering spring 7. replace 16. Valve 8.8 N 7.7 N 13.3 8.8 x 7.15 24.10 Structure.7 kg} — {1. Collar 5. Centering spring 6. 12 Metering spring 26.72 kg} BR380JG-1E0 19 .5 — {11.

retainer (9) is pushed.SEN01353-00 10 Structure. q As a result. it is connected to drain chamber (D) to release the pressure at port (P1). function and maintenance standard 1. q Pilot pressurized oil of the control pump is led to port (A) from port (P1) via fine control hole (f). q When the pressure at port (P1) becomes higher. it is almost simultaneously inter- connected to pump pressure chamber (PP). 20 BR380JG-1E0 . the control valve spool moves to a position where the pressure of chamber (A) (same as pressure at port (P1)) and the force of the return spring of the control valve spool are balanced. spool (1) is also pushed by metering spring (2). spool (1) is pushed back and fine con- trol hole (f) is shut off from pump pressure chamber (PP). to drain chamber (D) via fine control hole (f) in q Pressure at port (P1) also rises in proportion to spool (1). Pressure reducing valve function q The relationship of the position of spool (1) and body (10) [fine control hole (f) is in the middle Operation between drain chamber (D) and pump pres- sure chamber (PP)] does not change until 1) When in neutral retainer (9) contacts spool (1). spool (1) moves up and down until the force of metering spool (2) is balanced with the pressure at port (P1). the stroke of the control lever. 2) During fine control (Neutral o fine control) q When piston (4) is pushed by lever (5). q In this way. At almost the same time. q When fine control hole (f) is shut off from drain chamber (D). and moves down. q Ports (A) and (B) of the control valve and ports q Metering spring (2) contracts in proportion to (P1) and (P2) of the PPC valve are connected the stroke of the control lever.

t h e hi g h e r o ne o f t h e P P C o u tp u t pressures of both sides is output as the steer- ing signal. reverse) or in neutral. q If the pressure of port (P1) is lowered exces- sively. q Pump pressure is supplied until the pressure at port (P1) recovers to the level equivalent to the lever position. whether the machine is being chamber (D). 4) At full stroke q Any signal is not output from port (P6) while q Lever (5) pushes down piston (4). Steering signal q If the operation quantities of both levers are dif- ferent from each other as in the steering opera- ti o n . The oil passes through port (P2) and enters chamber (B) to replenish the cham- ber with pressurized oil.H. Travel signal/Steering function Travel signal q If either of the L. from port (P2) through fine control hole (f') and nected to drain chamber (D). pressure chamber (PP). whether the machine is travelling is judged by the signal of port (P5). (3) and pressure at port (P1).10 Structure. q Fine control hole (f) is shut off from drain cham- ber (D). ized oil at port (P1) is released. flows to drain chamber (D). travel levers is oper- ated. or R. q Accordingly. the pilot pressure oil from the self (When control lever is returned) pressure reducing valve passes through fine q When lever (5) starts to be returned. q Fine control hole (f) is shut off from drain q Accordingly. and retainer the machine is travelling straight (forward or (9) pushes down spool (1). function and maintenance standard SEN01353-00 3) During fine control q Therefore. 2. the higher PPC output pressure of both sides is output as the travel signal. fine control hole (f) is con. and is interconnected to pump steered is judged by the signal of port (P6). BR380JG-1E0 21 . q When the spool of the control valve returns. the oil in drain chamber (D) flows in from fine control hole (f') in the valve on the side that is not working. and it is almost simultaneously inter- connected to pump pressure chamber (PP). q The oil returning from chamber (B) passes q Because of this. spool (1) is pushed down by metering spring (2).H. 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. and the pressur.

22 BR380JG-1E0 . travel signal [port (P5)] and steering signal [port (P6)]. function and maintenance standard Operation 1) When in neutral q No output is made from respective output ports [from port (P1) to (P4)].SEN01353-00 10 Structure.

q When operating L. motor forward [port (P2) output] and R. pressure of both L. BR380JG-1E0 23 .H. motor forward [port (P4) out- put]. spring chamber (l) rises high.H. spring chamber (k) and R. function and maintenance standard SEN01353-00 2) During straight travel a The Illustration shows the circuit for travelling straight forward.10 Structure.H. q Steering signal spool (j) remains at neutral position and does not output a steering signal to port (P6).H.

H. q When the pressure state reaches [(P4 – P2) x (Spool section) > Spring set load]. whichever having a higher output pres- tion (if the difference of the pilot pressure sure. level). 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. q The pressure in right spring chamber (l) is (P4). the spool is switched to the direction of the arrow. the pilot pressure is output as the steer- ing signal.H. or R. q If the operation quantities of both levers are dif. 24 BR380JG-1E0 . is output to port (P6) as the steering sig- between both sides is higher than a certain nal. q The pressure in left spring chamber (k) of steering signal spool (j) is (P2). PPC ferent from each other as in the steering opera.SEN01353-00 10 Structure. valves. q Port (P4) pressure of the L.

motor reverse [port (P1) output] and R. pressure of the R.H.H.H. spring chamber (l) only rises high. BR380JG-1E0 25 . motor forward [port (P4) out- put]. q When operating L. q Steering signal spool (j) strokes to the left to output the steering signal to port (P6).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.

To EPC valve 26 BR380JG-1E0 . and travel lock 1. Control valve PST (Straight travel) (2-stage relief) 3. To travel PPC port P P1. side conveyor. Travel lock A4.SEN01353-00 10 Structure. bear lock reset. function and maintenance standard Solenoid valve 1 For straight travel and 2-stage relief. Side conveyor A2. Control valve (Port P-3) (Magnetic separator) 4. Straight travel and 2-stage relief T. magnetic separator. To tank 2. Control valve (Port P-1) (Side conveyor) 5. Magnetic separator A1. 2-spool ON/OFF valve PPC. Control valve (Port P11) (Bear lock reset) A5. Bear lock reset A3. From self pressure reducing valve ACC.

As a result. the circuit between ports (P) and As a result. Spring 4. Cage Operation When solenoid is de-energized When solenoid is energized q When the signal current does not flow from the q When the signal current flows from the control- controller. in the direction of the arrow. then drained to the tank. solenoid (3) is de-energized. For this reason.10 Structure. BR380JG-1E0 27 . solenoid (3) is energized. At the same time. the pressurized oil from the ator. Connector 5. ler to solenoid (3). port (T) is closed. and actuator flows from port (A) to port (T). the pressurized oil from the control (A) closes and the pressurized oil from the pump flows from port (P) through the inside of control pump does not flow to the actuator. spool (5) to port (A). Coil 7. spool (5) is pushed to the right left by spring (6). Movable core 6. function and maintenance standard SEN01353-00 1. and is this stops the oil from flowing to the tank. and then flows to the actu- At the same time. Block 3. spool (5) is pushed fully to the For this reason. Spool 2.

Spring C1. To control valve (Port P8) 6. From 5-spool ON/OFF valve 28 BR380JG-1E0 .SEN01353-00 10 Structure. Plunger C4. Body 12. To control valve (Port P7) 5. Accessory EPC valve 7. Block 11. Coil C3. To control valve (Port P1) 3. Crusher reverse EPC valve 10. To hydraulic tank 2. Spool T. Rod C2. function and maintenance standard EPC valve 1 1. Feeder forward EPC valve 8. To control valve (Port P5) 4. Connector P. Crusher forward EPC valve 9.

Spool 5.14 N damage or 9.0 8.10 Structure. Body 4.32 kg} deformation BR380JG-1E0 29 . Plunger P. Rod 6. To hydraulic tank Unit: mm No. To control valve 2.4 — — {0. Connector T. Coil C. Check item Criteria Remedy Standard size Repair limit Replace Free length x Installed Installed Free Installed EPC valve Outside diameter length load length load assembly if 7 Return spring there is 3. function and maintenance standard SEN01353-00 q Travel lock EPC valve 1. From 5-spool ON/OFF valve 3.

coil (14) is de-ener- pump controller. q Spool (11) is pushed to the right by spring (12). it generates the EPC output gized. (coil is de-energized) tion. and outputs it to the control valve. q Port (P) closes and the pressurized oil from the self pressure reducing valve does not flow to the control valve. pressure in proportion to the size of the signal. function and maintenance standard Function Operation q The EPC valve consists of the proportional 1) When signal current is 0 solenoid portion and the hydraulic valve por. q When there is no signal current flowing from q When it receives signal current (i) from the the controller to coil (14). 30 BR380JG-1E0 . q The pressurized oil from the control valve is drained to the tank through port (C) and port (T).SEN01353-00 10 Structure.

10 Structure. q Spool (2) moves up and down so that the pro- pulsion force of plunger (6) may be balance with pressure of port (C) + spring load of spring (3). so the propulsion force of plunger surized oil flows from port (P) to port (C). coil (5) is energized. and pres. and a propulsion force energized. BR380JG-1E0 31 . q When this happens. pressurized oil does Ports (C) and (T) are connected. coil (5) is (5). (6) is also at its maximum. to act on surface (a) of spool (2) and the spring q The maximum volume of pressurized oil is load on spring (3) become larger than the pro. increasing pulsion force of plunger (6). port (P) is shut control valve to the maximum level. not flow to the hydraulic tank. maximum. the circuit pressure across EPC valve and the q Spool (2) is pushed to the right. is generated on the left side of plunger (6). function and maintenance standard SEN01353-00 2) When signal current is very small 3) When signal current is maximum (coil is energized) (coil is energized) q When a very small signal current flows to coil q As the signal current flows to coil (5). the signal current is at its q Rod (4) pushes spool (2) to the left. q Since port (T) is closed. q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current. q Pressures on port (C) increases and the force q Spool (2) is pushed to the left by rod (4). conducted from port (P) to port (C). off from port (C).

function and maintenance standard Electromagnetic selector valve 1 For lock cylinder 1. A. To lock cylinder bottom To conveyor RAISE/LOWER cylinder head P.SEN01353-00 10 Structure. Spring Model: DSG-01-3C4-D24 3. To hydraulic tank 32 BR380JG-1E0 . Control valve (from accessory port A1) T.9 MPa {315 kg/cm2} 5. 6. To lock cylinder head To conveyor RAISE/LOWER cylinder bottom B. Cap nut Voltage: DC 24 V 7. Spool Rated oil flow: 40 l/min. Body Specifications 2. Push pin 30. Coil assembly Rated pressure: 4.

Coil assembly Rated pressure: 4. function and maintenance standard SEN01353-00 For Conveyor motor cylinder 1. 6. Control valve (from accessory port B6) T. Spring Model: DSG-01-3C2-D24 3. To hydraulic tank BR380JG-1E0 33 . To conveyor motor L P. Cap nut Voltage: DC 24 V A. To conveyor motor R B.10 Structure. Body Specifications 2. Push pin 30.9 MPa {315 kg/cm2} 5. Spool Rated oil flow: 20 l/min.

function and maintenance standard Hydraulic cylinder 1 Conveyor elevation cylinder Side conveyor cylinder Lock cylinder 34 BR380JG-1E0 .SEN01353-00 10 Structure.

14 1.161 – 2 rod support shaft and bush.252 ing –0.153 Side –0.122 0.013 +0.013 +0.02 3 bottom support shaft and bushing Side –0.0 conveyor –0.015 Conveyor –0.081 0.01 20 0.187 Lock 90 — — — — Conveyor –0.10 Structure.009 +0.0 –0.122 0. function and maintenance standard SEN01353-00 Unit: mm No.14 1.487 conveyor –0.011 – 1 20 0.122 0.036 +0.071 0.072 –0.009 +0.106 BR380JG-1E0 35 .11 – 0.017 – 25 0.0 –0.013 –0.003 0. Check item Criteria Remedy Tolerance Name of Standard Standard Clearance cylinder size Clearance limit Shaft Hole Clearance between piston Conveyor –0.487 rod and bushing elevation –0. 25 1.115 0.015 Lock 75 — — 1.072 –0.252 Clearance between cylinder –0.020 +0.0 Replace elevation –0.122 0.071 0.161 – 25 1.071 +0.013 –0.02 Clearance between piston Side –0.01 Clearance between cylinder elevation 20 0.009 +0.009 +0.0 conveyor –0.009 0.036 – 4 Lock 95 1.07 – 0.0 support shaft and bushing –0.020 +0.

SEN01353-00 BR380JG-1E0 Mobile crusher Form No. SEN01353-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 36 .

9 Crusher tooth tip adjustment system .................................................................................................................................................................................................................. 14 Vibrator ...... 4 Grizzly feeder.................. 2 Abnormal load stop system.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3 Primary belt conveyor ........................... 8 Crusher ...................... SEN01354-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure..................................... 17 BR380JG-1E0 1 ............................................................. function and maintenance standard 1 Work equipment Grizzly feeder semiautomatic system ........................................................................................

the rotary lamp (red) (4) installed to the machine keeps lighting up. this sys- tem decreases the EPC current through the CR710 controller in control box (2) to reduce the speed of grizzly feeder (3) to the minimum. If the front pump outlet pressure is kept above the set crusher load for 0. the griz- zly feeder is automatically reset to the speed in accordance with the feeder speed level of the machine monitor in control box (2). q While this function is operating.5 seconds.3 seconds. it stops supplying material from grizzly feeder (3) to the crusher. Set pressure of pres- Set crusher load sure switch 10.SEN01354-00 10 Structure.1 MPa Crusher load {110 – 195 kg/cm2} a See “Function of setting crusher load. If this system detects an overload on the crusher.8 – 19. If the front pump outlet pressure is kept below the set crusher load for 0. function and maintenance standard Grizzly feeder semiautomatic system 1 Function q 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).” 2 BR380JG-1E0 .

Condition for turning work equipment lamp ON. stops immediately.3 {125} secondary conveyor Abnormal pressure on 19.6 {200} primary conveyor Abnormal pressure on 12. a For the lamp. see “Display of working mode”. function and maintenance standard SEN01354-00 Abnormal load stop system 1 Function q 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. see “Crusher tooth tip adjustment system”. q If a steel block etc.3 {125} magnetic separator Abnormal pressure on 12. the horn sounds for 5 seconds. Judgment of slip of lock cylinder. q If this function operates.3 {125} side conveyor Abnormal pressure on 12. If the inlet pressure of each actua- tor increases above the set pressure. Set abnormal load pressure Contents of error MPa {kg/cm2} Abnormal pressure on 19. is put in the crusher and the lock cylinder slips in the crusher clearance opening direction. a For slip of the lock cylinder. excluding the engine and travel unit.6 {200} vibratory screen BR380JG-1E0 3 . the lamp to show the abnormal sec- tion lights up on the machine monitor.10 Structure. the crusher stops immedi- ately. q After the work equipment is stopped by this function. the whole work equipment.

function and maintenance standard Primary belt conveyor 1 4 BR380JG-1E0 .SEN01354-00 10 Structure.

10 Structure. function and maintenance standard SEN01354-00 BR380JG-1E0 5 .

Head pulley 17.3 (Minimum diameter pat of roller) 6 BR380JG-1E0 . Bearing 15. Rubber 4. Guide roller 7. function and maintenance standard 1. Conveyor belt 2.5 Replace 21 Wear of return roller 89. Scraper rubber 10. Rubber 12.7 22 Wear of guide roller 76. Return roller (Outside) 8.SEN01354-00 10 Structure. Rubber 9. Bearing unit 3.1 (Minimum diameter pat of roller) 71. Carrier roller 6. Belt cleaner 5. Bearing stop screw Unit: mm No. Tail pulley 19.5 89. Rubber 11.1 (Minimum diameter pat of roller) 84. Rubber 14. Slide plate 13. Check item Criteria Remedy Standard size Repair limit 20 Wear of carrier roller 84. Primary conveyor motor 18. Frame 16.

Grizzly feeder A. M-type chute selector lever 3. Upper grizzly bar 4. M-type chute 7.SEN01354-00 10 Structure. Hopper (Fixed type) 2. Trough surface 8 BR380JG-1E0 . function and maintenance standard Grizzly feeder 1 1. Feeder fixing pin (For transportation) 6. Lower grizzly bar 5. Vibrator 8.

Scattering prevention guard 7.10 Structure. Supply opening guard 6. V-sheave 3. Water sprinkler pipe 8. function and maintenance standard SEN01354-00 Crusher 1 1. Oil filler plug 2. Crusher motor 10. V-belt 9. Crusher assembly BR380JG-1E0 9 . Drain plug 4. Turnbuckle 5.

SEN01354-00 10 Structure. function and maintenance standard 10 BR380JG-1E0 .

Swing tooth 13.10 Structure. Crusher motor 6. Main shaft (Crankshaft) 20. Toggle seat 11. Bearing (Frame) 18. Tension spring BR380JG-1E0 11 . Lock cylinder 5. Fixed tooth 15. Toggle seat 9. Protector 3. Balance weight 21. Fixing link 8. Crusher chamber 14. Swing tooth wedge bolt 7. V-belt 4. function and maintenance standard SEN01354-00 1. Swing jaw 12. Toggle plate 10. Cheek plate 2. Tension rod 22. Front frame 16. V-sheave 17. Bearing (Swing jaw) 19.

is subjected to a powerful compression force. and is crushed. but generally speaking. contact (a) caused by the eccentricity of crankshaft (2) and the rocking motion of toggle plate (3) moves in a circle. it is possible to reverse the top and bottom. 12 BR380JG-1E0 . q If lumps of metal or other hard substances that cannot be crushed are loaded inside crushing chamber (6). toggle plate (3) functions to auto- matically change shape and protect the bear- ing of crankshaft (2) from any big impact load.SEN01354-00 10 Structure. The speed of wear also increases if the clearance at the discharge port is made small. q Movable jaw plate (5) installed to swing jaw (1) repeat the movement in Step 1 against fixed jaw plate (4). function and maintenance standard Principle of crushing q With the movement of swing jaw (1). these parts wear more rapidly if the crushed material includes large amounts of sand or moisture. q When fixed jaw plate (4) and movable jaw plate (5) become worn. the more it moves in a narrow oval movement. so it is possible to change the particle size of the crushed material. The closer it comes to con- tact (c). q The wear of fixed jaw plate (4) and movable jaw plate (5) differs according to the conditions and the material being crushed. q The clearance of the discharged port of fixed jaw plate (4) and movable jaw plate (5) can be adjusted by changing the combination of shim plates. As a result. This operation can be car- ried out once only. the rock or rubble loaded into crushing chamber (6) moves to the bottom of the crushing chamber.

Rod 2. Revolution angle sensor 7.SEN01354-00 10 Structure. Fixing link 3. Lock cylinder 8. Fixed tooth 5. Swing jaw 14 BR380JG-1E0 . Swing tooth 6. Toggle plate 4. function and maintenance standard Crusher tooth tip adjustment system 1 1.

adjust it in the "semi- automatic mode". a For the operation of the machine monitor. BR380JG-1E0 15 . function and maintenance standard SEN01354-00 Function Revolution angle sensor (3) senses tooth moving distance (b) through swing jaw (8). The controller operate lock cylinder (4) so that tooth clearance (a) set by the machine monitor will be obtained. Semiautomatic adjustment When adjusting the tooth clearance by setting a target moving distance. toggle plate (7). Inspec- tion mode: Semiautomatic (S). 2. see "Machine monitor system". Automatic adjustment When adjusting the tooth clearance by setting a target tooth clearance. adjust it in the "manual mode". Manual adjustment When measuring and adjusting the tooth clear- ance simultaneously. 3. it is judged that the lock cylinder has slipped. fixing link (6). Inspec- tion mode: Manual (M). Judgment of slip of lock cylinder The crusher angle is measured at the moment when the inspection mode is changed last to another mode or when the starting switch is turned from the OFF position to the ON position. Crusher clearance adjustment mode 1. a For the operation of the machine monitor. adjust it in the "auto- matic mode".10 Structure. and rod (5). a For the operation of the machine monitor. see "Machine monitor system". If the sensor angle increases more than 2° in the tooth clearance opening direction from this crusher angle. Inspec- tion mode: Automatic (A). see "Machine monitor system".

SEN01354-00 10 Structure. function and maintenance standard Revolution angle sensor 1.5 W (25°C) 16 BR380JG-1E0 . Wiring harness 3. 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. Revolution angle sensor 2.

Oil level gauge 9. function and maintenance standard SEN01354-00 Vibrator 1 1. Breather 11. Bearing 4. Grizzly feeder motor 2. Filler plug 10. Gear 5. Shaft 3. Unbalance weight 7. Drain plug 8. Housing 6. BR380JG-1E0 17 . V-checker installation position (at maintenance) Gear matches and unites two marks (B).10 Structure.

SEN01354-00 10 Structure. Standard value Repair limit firmed by V checker 550 (cpm) 468 – 632 11 Replace Frequency (max. Check item Criteria Remedy Frequency (min.100 firmed by V checker 12 Vibrator case oil level Center of level window ± 5 mm Add oil 18 BR380JG-1E0 .000 – 1.) con. function and maintenance standard No.) con- 1.050 (cpm) 1.

SEN01354-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 20 .SEN01354-00 BR380JG-1E0 Mobile crusher Form No.

................................................ 2 Work equipment and pump controller .................. function and maintenance standard 1 Electrical system Engine control .......... 28 Sensor..................................................................................................................................................................................................................................................................................................................... 54 BR380JG-1E0 1 ............................................................................................................................................................................................... 12 Electronic control system ........................................................ SEN01355-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 10 Structure...................... 15 Machine monitor system ........

Supply pump q The engine can be started and stopped with 3. 4.SEN01355-00 10 Structure. Starting motor Outline 2. Battery relay the output to the injector to control the engine 7. Engine controller starting switch (5) only. which controls 6. Fuel control dial q The control signal of fuel control dial (4) is 5. 2 BR380JG-1E0 . Starting switch input to engine controller (3). Battery speed. function and maintenance standard Engine control 1 1.

The engine controller sends a driving signal to the supply pump depending on the signal volt- age to control the fuel injection pump. the engine controller checks the signal voltage from the fuel control dial and sets the engine speed to the speed set by the fuel control dial. Engine speed control q The fuel control dial sends a signal voltage cor- responding to the rotation angle to the engine controller. the starting signal flows to the the signal of the supply pump drive solenoid to starting motor. start the engine. BR380JG-1E0 3 . the starting motor turns to stop the engine. function and maintenance standard SEN01355-00 Operation of system 1 Stopping engine Starting engine q When detecting that the starting switch is set to q When the starting switch is turned to the the “STOP” position. the engine controller cuts START position. Then. and eventually controls the engine speed.10 Structure. When it happens.

Ball 5. Spring 4. Connector 4 BR380JG-1E0 .SEN01355-00 10 Structure. Potentiometer 6. Knob 2. function and maintenance standard Component 1 Fuel control dial 1. Dial 3.

When the throttle voltage is within this area. q The rotation of the shaft changes the resis- tance of the variable resistor in potentiometer (5).10 Structure. sending any throttle signal to the engine controller. the engine is run- ning at low idle. function and maintenance standard SEN01355-00 Function q Turning knob (1) rotates the shaft of potentiom- eter (5). q The hatched area in the right graph is the abnormality detection area. BR380JG-1E0 5 .

function and maintenance standard Engine controller Input and output signals CN-CE01 q Meanings of signal classes in the terminal Input/ Pin No. output A: Power 11 NC(*) — B: Input 12 NC(*) — C: Ground. Signal name table shown below are as follows. return 13 NC(*) B D: Output 14 WATER-IN-FUEL Input B E: Communication 15 Coolant temperature input B CN-CE01 16 Sensor power (+5 V) A Input/ 17 Oil pressure switch B Pin No. shield. *: Never connect to NC or malfunctions or failures will occur. Signal name 18 NC(*) — output 1 NC(*) — 19 NC(*) — 2 IMA PWM Output D 20 NC(*) — 3 Air pressure sensor B 21 NC(*) — 4 NC(*) — 22 NC(*) D 5 NC(*) — 23 Intake manifold temperature B 6 CAN(–) E 24 NC(*) — 7 NC(*) — 25 Accumulator pressure signal B 8 CAN(+) E 26 Engine position sensor signal B 9 NC(*) — 27 Engine speed sensor signal B 10 NC(*) — 28 NC(*) — *: Never connect to NC or malfunctions or failures will occur. 6 BR380JG-1E0 .SEN01355-00 10 Structure.

46 CAN (+) E 47 CAN (–) E 48 NC(*) D 49 PWM OUTPUT D CN-CE02 50 NC(*) D Input/ Pin No.10 Structure. Signal name *: Never connect to NC or malfunctions or failures will occur. function and maintenance standard SEN01355-00 CN-CE01 CN-CE02 Input/ Input/ Pin No. 11 NC(*) B 12 NC(*) B 13 NC(*) B *: Never connect to NC or malfunctions or failures will occur. Signal name Pin No. BR380JG-1E0 7 . Signal name 5 NC(*) B output 6 NC(*) B 1 GND C 7 NC(*) B 2 NC(*) C 8 NC(*) B 3 Power (+24 V) A 9 Fuel dial (+) B 4 NC(*) A 10 NC(*) E *: Never connect to NC or malfunctions or failures will occur. output 1 NC(*) B 2 NC(*) B 3 NC(*) B CN-CE03 4 NC(*) B Input/ Pin No. Signal name output output 29 NC(*) — 14 NC(*) B 30 NC(*) — 15 NC(*) B 31 NC(*) D 16 NC(*) B 32 IMA PWM RETURN C 17 NC(*) B 33 Air pressure sensor supply A 18 NC(*) B 34 NC(*) — 19 NC(*) B 35 NC(*) A 20 NC(*) E 36 NC(*) — 21 NC(*) A 37 Engine position sensor supply A 22 Fuel dial (+5 V) A 38 Air pressure sensor return C 23 Fuel dial (–) C 39 NC(*) — 24 NC(*) B 40 NC(*) — 25 NC(*) B 41 NC(*) — 26 NC(*) B 42 NC(*) C 27 NC(*) B 43 NC(*) — 28 NC(*) B 44 Boost pressure sensor B 29 NC(*) C 45 Injector #1 (+) D 30 NC(*) B 46 Injector #5 (+) D 31 NC(*) B 47 Engine position sensor return C 32 NC(*) C 48 Engine speed sensor return C 33 GND C 49 NC(*) — 34 NC(*) C 50 NC(*) — 35 NC(*) B 51 Injector #2 (–) C 36 NC(*) B 52 Injector #3 (–) C 37 NC(*) C 53 Injector #1 (–) C 38 NC(*) D 54 Injector #2 (+) D 39 Key switch (ACC) B 55 Injector #3 (+) D 40 Heater relay drive D 56 Injector #4 (+) D 41 NC(*) D 57 Injector #6 (+) D 42 Heater relay return C 58 Injector #4 (–) C 43 NC(*) D 59 Injector #6 (–) C 44 NC(*) D 60 Injector #5 (–) C 45 NC(*) — *: Never connect to NC or malfunctions or failures will occur.

Connector 2. O-ring Oil pressure switch 1. function and maintenance standard Coolant temperature sensor 1. Sensor 3.SEN01355-00 10 Structure. Connector 2. Sensor 3. O-ring 8 BR380JG-1E0 .

function and maintenance standard SEN01355-00 Rotation sensor 1. Sensor 3.10 Structure. Connector 2. Connector 2. O-ring BR380JG-1E0 9 . O-ring Boost pressure and temperature sensor 1. Sensor 3.

SEN01355-00 10 Structure. Connector 2. Float 4. Sensor 4. Bracket 3. Connector 2. function and maintenance standard WIF (water-in-fuel detection) sensor 1. Switch 10 BR380JG-1E0 . Tube 3. O-ring Engine oil level sensor 1.

function and maintenance standard Work equipment and pump controller 1 12 BR380JG-1E0 .SEN01355-00 10 Structure.

10 Structure. 6 1-touch stop switch Input 7 Input sor 7 Machine select 2 Input 8 F pump pressure sensor Input 8 Engine stop relay drive Output 9 NC Input 9 Beacon lamp relay drive Output 10 GND (SIG) — 10 NC Input 11 Mode selector switch (Work) Input 11 NC Output 12 Accessory switch Input 12 CAN_SH Muck discharge conveyor pressure 13 Conv. (travel) Input 4 232C_RXD Input 6 NC Input 5 Conveyor OFF switch Input Magnetic separator pressure sen. sensor Input 1 NC Output 2 R pump pressure sensor Input Clearance setting mode select 2 Input 3 Vibrator screen press. function and maintenance standard SEN01355-00 Input and output signals CN-C1 CN-C2 Input/ Input/ Pin No. sensor Input switch (Auto) 4 GND (SIG) — 3 Magnetic separator ON switch Input 5 Mode select sw. Signal name Output Output 1 Secondary conveyor press. Mi position sensor Input Input/ 21 S_NET 21 GND_SIG_A Output 22 POT_PWR0 Output Input/ 22 CAN0_L 23 Start switch (ACC) Input Output 24 Emergency switch Input Input/ 23 CAN1_L *: Never connect to NC or malfunctions or failures will occur. Signal name Pin No. Output 24 PWR_CTR_EXT Input 25 Travel speed select switch 2 Input Muck discharge conveyor OFF 26 Input switch Muck discharge conveyor prohibit 27 Input switch 28 Magnetic separator OFF switch Input 29 GND_SIG_P 30 NC Input 31 GND (S_NET_GND) Input/ 32 CAN0_H Output Input/ 33 CAN1_H Output 34 GND (232C_GND) 35 Travel speed select switch Input Muck discharge conveyor ON 36 Input switch 37 Crusher FWD/REV select switch Input Clearance setting mode select 38 Input switch (SEMI AUTO) 39 GND_SIG_P 40 NC Input *: Never connect to NC or malfunctions or failures will occur. BR380JG-1E0 13 . Hi position sensor Input 13 Input sensor 14 232C_TXD Output 14 Clearance potentio signal Input 15 Conveyor ON switch Input 15 Over feed sensor Input 16 1-touch start switch Input 16 SENS_PWR Output 17 Machine select 1 Input 17 Start switch (C) Input 18 Abnormal pressure relay drive Output 18 Engine stop switch Input 19 Horn relay drive Output 19 Conveyor pressure sensor Input 20 NC Input 20 Conv.

pull relay Output 38 Feeder FWD. EPC Output 37 Lock cyl.SEN01355-00 10 Structure. push relay Output 28 Accessory EPC Output 29 Radio Ctrl travel sig. solenoid relay Output 6 LS EPC Output 7 NC Output 8 Conveyor REV. EPC Output 27 Lock cyl. solenoid relay Output 9 Radio Ctrl work switch Input 10 Feeder ON switch Input 11 PWR_IN_BATT Input 12 PWR_IN_BRY Input 13 GND_ACT — 14 KEY_SIG Input 15 NC Output 16 PC EPC Output 17 Lock cyl. 14 BR380JG-1E0 . EPC Output 39 Radio ctrl. Input 30 Crusher ON switch Input 31 GND_PWR — 32 GND_PWR — 33 GND_PWR — 34 POT_PWR1 Output 35 Travel lock EPC Output 36 Crusher REV. unlock solenoid Output 18 Muck discharge conveyor solenoid Output 19 Radio Ctrl travel switch Input 20 Feeder OFF switch Input 21 GND_PWR — 22 PWR_IN_BRY Input 23 GND_ACT — 24 KEY_SIG Input 25 Magnetic separator solenoid Output 26 Crusher FWD. function and maintenance standard CN-C3 Input/ Pin No. select switch Input 40 Crusher OFF switch Input *: Never connect to NC or malfunctions or failures will occur. Signal name Output 1 PWR_IN_BATT Input 2 PWR_IN_BRY Input 3 GND_ACT — 4 NC Output 5 Conveyor FWD.

10 Structure. BR380JG-1E0 15 . see “Troubleshooting”. function and maintenance standard SEN01355-00 Electronic control system 1 Control function 1 Engine and pump composite control function 2 Pump and valve control function 3 Electronic control system Auto-warm-up and overheat prevention function 4 Travel control function Self-diagnosis function a For the self-diagnosis function.

function and maintenance standard Travel control function 16 BR380JG-1E0 .SEN01355-00 10 Structure.

function and maintenance standard SEN01355-00 BR380JG-1E0 17 .10 Structure.

SEN01355-00 10 Structure. function and maintenance standard Engine and pump compound control function 18 BR380JG-1E0 .

If it happens. q If the pump load increases and the pressure rises.0 kW/1.10 Structure. the pump load decreases and the pressure lowers. On the contrary.800 rpm} trols the pump so that it can absorb all the torque at the output points of the engine q Engine speed is always controlled so that it is depending on the pump absorption torque kept around the matching point specified specified beforehand. 107. BR380JG-1E0 19 . allowing the pump controller to decrease pump delivery (Q). the engine speed is increased to around the matching point. rotation set by the fuel beforehand.800 rpm {143.5 HP/1. the pump controller continues to increase pump delivery until the engine speed reaches around the matching point. control dial. and actual engine speed. function and maintenance standard SEN01355-00 Function q Matching point: q The work equipment and pump controller con. engine speed (N) lowers.

function and maintenance standard Pump and valve control function 20 BR380JG-1E0 .SEN01355-00 10 Structure.

BR380JG-1E0 21 . the start-up time of the pump discharge is optimized and the composite operation and fine control performance is improved. q By this operation.10 Structure. function and maintenance standard SEN01355-00 LS control function q 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.

function and maintenance standard Automatic engine warm-up and overheat prevention function Function q The automatic engine warm-up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts.SEN01355-00 10 Structure. q 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. 22 BR380JG-1E0 .

(Manual reset) BR380JG-1E0 23 . if the engine coolant temperature is low. 1. controller is set to condi- Alarm buzzer: Sounds Min. (Automatic Min. (Automatic Min. or Monitor alarm lamp: Lights up Hydraulic oil temperature: Under above condition. 30°C Auto Automatic engine warm-up operation time: Min. 102° Reduce pump delivery. Under above condition. tion before operation of function.10 Structure. 105°C tion before operation of function. reset) Operating condition Operation/Remedy Resetting condition Coolant temperature: Coolant temperature. Under above condition. or longer 2) Overheat prevention function q This function reduces the pump load and engine speed when coolant or hydraulic oil temperature is too high to protect the engine and hydraulic components from overheating. Operating condition (All of following conditions) Operated Coolant temperature: Below 30°C Engine speed: 1. 10 minutes Engine speed: Any level Fuel control dial: Manual Kept at 70% of full level or above for 3 sec. 100°C reset) Operating condition Operation/Remedy Resetting condition Coolant temperature: Working mode: Coolant temperature. 102°C each mode Below 102°C or Engine speed: Kept as is.200 rpm Engine speed: Max. hydraulic oil temperature: Working mode: each mode Below 105°C Min.200 rpm Resetting condition (Any one of following conditions) Reset Coolant temperature: Min. hydraulic oil temperature: Min. controller is set to condi- Hydraulic oil temperature: Monitor alarm lamp: Lights up tion before operation of function. controller is set to condi- Hydraulic oil temperature: Reduce pump delivery. function and maintenance standard SEN01355-00 1) Automatic engine warm-up function q After the engine is started. the engine speed is raised automatically to warm up the engine. hydraulic oil temperature: Min. q This function starts when coolant temperature or hydraulic oil temperature reaches 100°C. 105°C Engine speed: Low idle Fuel control dial: Return to low idle position once. Operating condition Operation/Remedy Resetting condition Coolant temperature: Coolant temperature. 100°C Working mode: each mode Below 100°C or Engine speed: Kept as is.

function and maintenance standard Travel control function Function q 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.SEN01355-00 10 Structure. 24 BR380JG-1E0 .

0 2. function and maintenance standard SEN01355-00 Travel speed change function 1.10 Structure.8 2. middle or lower position by the con- veyor upper position sensor and conveyor middle position sensor. Radio Travel Position of conveyor Control Mode control speed method Upper Middle Lower selection selection High Middle Hi × speed speed Middle Middle Panel Mi × speed speed Lever Low Low Lo × speed speed Radio — × × × Travel control Panel — × × × High Middle Hi × speed speed Radio control Radio Middle Middle Mi × control speed speed Low Low Lo × speed speed Panel — × × × Lever Radio — × × × control Panel — × × × Work Middle Hi × × speed Radio control Radio Middle Mi × × control speed Low Lo × × speed BR380JG-1E0 25 . ×: Machine cannot travel. Mi and Hi. Max.3 3. 4) The drive signals for the travel lock EPC valv e and LS.EPC v alv e are output according to 1) – 3) and position of the travel speed switch to change the travel interlock and travel speed automatically. the work equipment and pump controller controls the pump capacity at each gear speed as shown below to change the travel speed. Automatic change by selecting conveyor posi- tion and radio control selection mode 1) The conveyor position is judged to be upper. 3) The position of the mode selector switch is judged. 2) The position of the radio control selector switch is judged. Travel speed selector Lo Mi Hi switch Pump capacity (%) 27 77 100 Travel motor capacity Max. Manual change with travel speed selector switch If the travel speed selector switch is changed over Lo. Max. Travel speed (km/h) 0.

1 MPa {5.5 kg/cm2} Function q The travel PPC valve has 2 travel PPC oil pressure switches.5 ± 0. Switch 3.0 ± 1.05 MPa {3.SEN01355-00 10 Structure. which check the travel lever signal and travel differential pressure signal by the output difference of the travel lever and operate the travel alarm and travel junction valve selector solenoid valve. 26 BR380JG-1E0 .0 ± 0.0 kg/cm2} Resetting (OFF) pressure:0.3 ± 0. function and maintenance standard System component parts 1. Plug 2. Connector Specifications Type of contacts: Normally open contacts Operating (ON) pressure: 0.

It converts the in the figure below. This causes a change in the output voltage. q The deformation in the diaphragm causes the resistance of the gauge to change. the diaphragm is deformed. Connector Function q The relationship between the pressure applied q The pump pressure sensor is installed to the to sensors (P) and output voltage (E) is shown inlet circuit of the control valve. Sensor 2. BR380JG-1E0 27 . function and maintenance standard SEN01355-00 Pump pressure sensor 1. pump discharge pressure into voltage and sends it to the work equipment and pump con- troller. q The amplifier magnifies output voltage (E) and transmits it to the pump controller. Operation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part. which is trans- mitted to the amplifier (voltage amplifier).10 Structure.

6. function and maintenance standard Machine monitor system 1 1. Gauge section to display the condition constantly (Coolant temperature.SEN01355-00 10 Structure. Machine monitor 8. Each sensor 5. Monitor section to output alarms when the machine has troubles 2. ately displays the obtained information on the machine monitors notifying the operator of the condition of the machine. It processes and immedi. etc. fuel level signal 7. hydraulic oil tempera. machine control system. 1. Switch 9. Work equipment and pump controller ture. Sensor signal 3. Coolant temperature. fuel level. Caution signal 2. hydrau- lic oil temperature.) 28 BR380JG-1E0 . The panel is roughly divided as follows. Battery q The monitor system monitors the condition of q The machine monitor also has various mode the machine with sensors installed on various selector switches and functions to operate the parts of the machine. Power source 4.

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. and output the information.SEN01355-00 10 Structure. display. 30 BR380JG-1E0 . The monitor display unit consists of LCD (Liquid Crystal Display). The switches are flat sheet switches. The machine monitor has a CPU (Central Process- ing Unit) in it to process.

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 1 NC — 2 Fuel level Input 3 Coolant level Input 4 NC — 5 Air filter Input 6 NC — 7 NC — 8 Engine oil level Input 9 NC — 10 NC — 11 Charge Input 12 Hydraulic oil temp. Signal name output output 1 Key switch (Battery) Input 1 NC — 2 Key switch (Battery) Output 2 NC — 3 NC — 3 NC — 4 Key switch (C) Input 4 NC — 5 NC — 5 NC — 6 GND Output 6 NC — 7 GND Output 7 NC — 8 VB + (24 V) Output 8 NC — 9 NC — 9 NC — 10 NC — 10 NC — 11 NC — 11 NC — 12 NC — 12 NC — 13 NC — 14 CAN_SHIELD Input 15 CAN + Input CN 2 16 CAN – Input Input/ Pin No. (a) Input 13 NC Input 14 Personal code relay Input 15 NC — 16 NC — 17 Reserve — 18 Pre-heating Input 19 Light Input 20 NC — BR380JG-1E0 31 .

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 32 BR380JG-1E0 .

Clearance adjustment execution 24. Inspection mode monitor 22. Hydraulic oil temperature monitor 20. Fuel level gauge 12. Engine oil pressure caution 7. Actual crusher clearance monitor 23. Charge level caution 6. Engine coolant temperature gauge 17. Working mode monitor 15. Maintenance time warning 21. Set crusher clearance monitor BR380JG-1E0 33 . Fuel level monitor 14. Operating condition monitor 16. Engine coolant temperature gauge 5. Travel speed monitor 8. Air cleaner clogging 11. Hydraulic oil temperature gauge 19. Service meter 9. Preheating monitor 2. Fuel level gauge 18. function and maintenance standard SEN01355-00 1. Engine oil level caution 10. Radiator coolant level caution 4.10 Structure. Engine coolant temperature monitor 3. Water separator 13.

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 OFF Engine coolant temperature Hydraulic oil temperature See gauge display on the next page Fuel level 34 BR380JG-1E0 .SEN01355-00 10 Structure.

5 Green C3 200 Green Fuel level (l) C4 100 Green C5 60 Green C6 41 Red BR380JG-1E0 35 .10 Structure. function and maintenance standard SEN01355-00 Temperature or Gauge Range Indicator Buzzer sound volume A1 105 Red Q A2 102 Red Engine coolant A3 100 Green temperature (°C) A4 80 Green A5 60 Green A6 30 White B1 105 Red B2 102 Red Hydraulic oil B3 100 Green temperature (°C) B4 80 Green B5 40 Green B6 20 White C1 289 Green C2 244.

Engine oil Lamp lights up ● — level when abnormal. the hydraulic oil temperature gauge and hydraulic oil temperature monitor are turned OFF and the follow- ing cautions are displayed. The cautions are displayed from the left upper corner in order of the time when they occurred. sounds when abnormal. charge SAP00522 Radiator Lamp lights up Lamp lights up and buzzer ● coolant level when abnormal. then goes off. Air cleaner ● — Lamp lights up when abnormal. if an item which has exceeded the maintenance period lights up. Battery ● — Lamp lights up when abnormal. Displayed Item checked by While engine is Symbol While engine is running item check before starting stopped Engine oil Lamp lights up and buzzer ● — pressure sounds when abnormal. 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. only the symbol is displayed. Maintenance Lamp lights up for only 30 seconds after key is turned ON. separator when abnormal. Lamp lights up when forecast/warning is given. clogging Water Lamp lights up ● Lamp lights up when abnormal. If the hydraulic oil temperature rises or lowers abnormally while the above cautions are displayed.SEN01355-00 10 Structure. Hydraulic oil temperature Colors of symbol Low (Below B6 or equivalent) Black on white background Normal (B6 – B2) Not displayed High (Above B2) White on red background 36 BR380JG-1E0 .

In inspection mode Set crusher clearance is ance monitor (A. In travel mode Travel speed Set mode is displayed. the clearance to be set is displayed. In the semiautomatic (S) mode. *1. A. (*2) Condition of each Displayed in working Condition of each device is device mode displayed. function and maintenance standard SEN01355-00 Display Symbol Displayed item Display range Display method section Working mode In working mode Set mode is displayed. *2. Service Service meter While service meter Lights up while service meter meter indicator is in operation is in operation. S) displayed. the quantity of adjustment of the clearance is displayed. Lo. M Monitor Actual crusher Actual crusher clearance is In inspection mode clearance monitor displayed. If the clearance is set toward the + side (– side).10 Structure. In the automatic (A) mode. (*1) Set crusher clear. it is increased (decreased). The displayed clearance and the measured clearance may not be the same. Mi. BR380JG-1E0 37 . Hi In inspection mode Inspection mode Set mode is displayed. S.

the whole work equipment stops. If engine stop switch (2) is depressed.SEN01355-00 10 Structure. and the items shown below are displayed. 38 BR380JG-1E0 . work equipment stops. Emergency stop switch ON warning If emergency stop switch (1) is depressed. function and maintenance standard When machine is stopped in emergency Engine stop switch ON warning If the machine is stopped in an emergency. the horn sounds. the fol. and the items shown below are displayed. the engine stops. the horn sounds. the whole lowing are displayed.

Operation switch 8. function and maintenance standard Operation section 1. Crusher manual rotation switch 3. Crusher clearance adjustment switch 2. Feeder speed setting screen selector switch 6. Buzzer cancel switch 9. Crusher speed setting screen selector switch 5. Conveyor manual rotation switch 4. Maintenance switch 10. Display brightness and contrast adjustment switch 40 BR380JG-1E0 .SEN01355-00 10 Structure. Crusher load setting screen selector switch 7.

BR380JG-1E0 41 . function and maintenance standard SEN01355-00 q 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. see the section of each function.) q Buzzer cancel switch When the machine detects abnormality and the buzzer of the multi monitor sounds. stop the buzzer with this switch. (For details. q Crusher speed setting screen selector switch This switch is used to set the crusher speed. This switch is effective when the crusher stops in the work/inspection mode. see Mainte- nance function.10 Structure. This switch is effective in the inspection mode. If this switch is depressed. q Display brightness and contrast adjust- ment switch This switch is used to adjust the brightness and contrast of the display. a For the maintenance items. the speed setting screen appears and you can set the crusher speed. q Crusher manual rotation switch This switch is used to rotate the crusher manu- ally. The buzzer sounds when any of the following is detected. q Operation switch This switch is used to use various setting func- tions. q Conveyor manual rotation switch This switch is used to rotate the conveyor man- ually. q Abnormal coolant level q Abnormal engine oil pressure q Overheating of engine coolant q Abnormality in fuel control dial potentiom- eter q Disconnection or short circuit in pump PC- EPC valve q Disconnection or short circuit in governor motor phase A or B q Maintenance switch This switch is used to check the maintenance items.

Conveyor condition lamp 7. Lo (Low-speed travel) or Hi (Hi- speed travel) is displayed. each work equipment and find out the work equip- work mode. Feeder condition lamp 4. Travel mode q If travel mode (A) is selected with mode selec- tor switch (1) on the main panel and speed selector switch (2) on the upper control panel is changed. or inspection mode with mode ment receiving an overload or abnormal load. selector switch (1) on the control panel.SEN01355-00 10 Structure. Crusher condition lamp 5. Secondary conveyor condition lamp 42 BR380JG-1E0 . 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). Side conveyor condition lamp 3. 1. Mode selector switch 2. Vibratory screen condition lamp 8. Magnetic separator condition lamp 6. you can check the operating condition of q The monitor screen is set in the travel mode.

and the lamp is reset. A red lamp lighting because of an abnormal load is reset when "return" switch (9) is depressed or the abnormally loaded work equipment is restarted. Secondary Vibratory Magnetic Conveyor Crusher Feeder veyor conveyor screen separator (If equipped) (If equipped) (If equipped) White lamp White lamp White lamp Stop Transparent Transparent Transparent Transparent lights up lights up lights up White lamp White lamp White lamp Forward drive Transparent Transparent Transparent Transparent lights up lights up lights up White lamp Reverse drive — — — — — — lights up Red lamp Overload — — — — — — flashes (*1) Red lamp Red lamp Red lamp Red lamp Red lamp Red lamp Abnormal load lights up — lights up lights up lights up lights up lights up (*2. function and maintenance standard SEN01355-00 q If an abnormal load is applied and a red lamp lights up (See the table on the next page). *3. An abnormal load on the crusher means that the crusher lock cylinder slips in the clearance increasing direction or the swing tooth moves into the maximum crusher clearance range. Conditions for lighting work equipment lamp Side con. BR380JG-1E0 43 . An overload on the crusher means that an excessive pressure load is applied to the crusher.10 Structure. 3) Stopped under Green lamp — — — — — — overload flashes *1. *2. depress return switch (9) or restart the abnor- mally loaded work equipment.

Semiautomatic (S) 1) Just after this screen appears. (9) flashes. The clearance is increased by the q While clearance opening switch (4) of the value of (12) from current actual monitor is depressed. 4) Depress UP switch (5) or DOWN switch (6) of the monitor to bring the cursor to the clearance set settle monitor and depress the settle switch (7). semiautomatic (S). 44 BR380JG-1E0 . a The input value to crusher clearance set value (12) is so limited that the actual crusher clearance will be in the effective using range of 50 – 150 mm. The clearance is decreased by the a If actual crusher clearance value (10) is value of (12) from current actual smaller than 50 mm or larger than 150 crusher clearance (11). (8) flashes. When crusher clearance set value (12) is increased or decreased and settle switch (7) is depressed.SEN01355-00 10 Structure. and automatic (A) modes. 1. 2) Depress UP switch (5) or DOWN switch (6) of the monitor to bring the cursor to crusher clearance set value monitor (12). the cursor is at clearance set settle monitor (11). function and maintenance standard Inspection mode q If work mode (B) is selected with the mode selector switch (2). 2. mm. monitor (8) flashes and actual crusher q When clearance set value (12) is +: clearance value (10) changes. the crusher clearance set value is returned to the former value. 3) Depress settle switch (7). monitor (9) flashes and actual crusher q When clearance set value (12) is –: clearance value (10) changes. clearance closing explained below. 6) While the crusher clearance is increasing. and clearance set value (12) lights up. it lights up red. if the actual crusher clearance is out of the above range. Manual (M) 5) Clearance set value (12) flashes and the q While clearance closing switch (3) of the clearance is increased or decreased as monitor is depressed. q The inspection mode has the manual (M). you can check the operat- ing condition of each work equipment and find out the work equipment receiving an overload or abnormal load. each which is selected by operating crusher clearance adjustment mode selector switch (2). While the former is decreas- ing. clearance opening crusher clearance (10).

3) Depress settle switch (7). Automatic (A) 1) Just after this screen appears. function and maintenance standard SEN01355-00 a The input range of crusher clearance set value (12) is 50 – 150 mm. 3. (8) flashes.10 Structure. When settle switch (7) is depressed. 5) Clearance set value (12) flashes and the clearance is increased or decreased as explained below. ii The crusher clearance is increased to crusher clearance set value (12). the cursor is at clearance set settle monitor (11). i The crusher clearance is decreased until the swing tooth touches the fixed tooth. 6) While the crusher clearance is increasing. and clearance set value (12) lights up. While the former is decreas- ing. (9) flashes. it is returned to the former value. BR380JG-1E0 45 . 2) Depress UP switch (5) or DOWN switch (6) of the monitor to bring the cursor to crusher clearance set value monitor (12). iii When actual crusher clearance (10) becomes larger than crusher clear- ance set value (12). 4) Depress UP switch (5) or DOWN switch (6) of the monitor to bring the cursor to the clearance set settle monitor and depress the settle switch (7). if the input value is out of the above range. the automatic clearance adjustment is finished.

the original setting is maintained. 2) Depress the operation switch (2) to select the How to use crusher speed. or inspection mode) speed by selecting the feeder speed according is displayed. the original setting is maintained. q This function is used while the ordinary screen The material is sent to the crusher at a proper (travel mode. At input check switch is depressed. 3) After selecting the level. or inspection mode) 1) Depress crusher speed set switch (1) of the is displayed. switch (3). Bar graph extends to right. to the contents of the work. work mode. At the s ame time. the feeder speed changes. the crusher speed level 3) After selecting the level. work mode. switch (4) is depressed to return to the ordinary a The feeder speed does not change until the screen without depressing the input check input check switch is depressed. Operation switch Operation 2) Depress the operation switch (2) to select the feeder speed. depress input check Bar graph retract to left. If return the same time. monitor to display the adjustment screen. switch (3). q This function is used to set the feeder speed. q This function is used while the ordinary screen How to use (travel mode.SEN01355-00 10 Structure. The selected crusher speed level is settled and the ordinary screen appears. The selected feeder speed level is a The crusher speed does not change until the settled and the ordinary screen appears. Bar graph extends to right. 46 BR380JG-1E0 . switch (4) is depressed to return to the ordinary screen without depressing the input check switch. If return switch. depress input check changes. 1) Depress feeder speed set switch (1) of the monitor to display the adjustment screen. function and maintenance standard Crusher mode setting function Feeder speed setting function q This function is used to set the crusher speed. Operation switch Operation Bar graph retract to left.

Bar graph retract to left. by adjusting the crusher pressure switch in proportion to the load level. or inspection mode) is displayed. The material is crushed properly. depress input check switch (3). 3) After selecting the level. the crusher load changes. The selected crusher load level is settled and the ordinary screen appears. q This function is used while the ordinary screen (travel mode. work mode. How to use 1) Depress crusher load set switch (1) of the monitor to display the adjustment screen. BR380JG-1E0 47 . the original setting is maintained. a The crusher load does not change until the input check switch is depressed. function and maintenance standard SEN01355-00 Crusher load setting function q This function is used to set the crusher load. regardless of its type. If return switch (4) is depressed to return to the ordinary screen without depressing the input check switch.10 Structure. At the same time. Operation switch Operation Bar graph extends to right. 2) Depress the operation switch (2) to select the crusher load.

if mainte.000 08 Final drive case oil 2. Depress maintenance switch (1) to display the nance switch (1) is depressed.000 05 Hydraulic tank breather 500 06 Corrosion resistor 1. 48 BR380JG-1E0 .. a The cursor moves and the selected part is inverted. the maintenance items are 30 seconds after the key is turned ON to urge the shown by symbols in a table. the caution lamp maintenance table screen. Warning Remaining time before mainte- (White symbol on nance of 1 or more items is shorter red background) than 0 hour. Display Condition Remaining time before mainte- None nance of every item is longer than 30 hours.000 41 Fuel pre-filter 500 a The above replacement period is set for each item and the remaining time before the mainte- nance is reduced as the machine is operated. of the item to be maintained with operation switch (2) or input it through the numeral keys. the items of remaining time shorter than 30 hours are indicated yellow and those of remaining time shorter than 0 hour are indicated red. The contents of the displayed caution depends on the remaining time as shown below. 1. addition. a Maintenance items No.000 27 Feeder vibrator oil 1. inspection. operator to carry out the maintenance. Forecast Remaining time before mainte- (Black symbol on nance of 1 or more items is shorter yellow background) than 30 hours. Select the No.000 07 Damper case oil 1. etc. replacement. (yellow or red) lights up on the monitor display for a On this screen.SEN01355-00 10 Structure.000 28 Crusher motor case oil 1.000 10 Hydraulic oil 5. Item Replacement period (h) 01 Engine oil 500 02 Engine oil filter 500 03 Fuel filter 500 04 Hydraulic oil filter 1. 2. function and maintenance standard Maintenance function Method of checking condition of maintenance items When each of the 10 maintenance items a Perform the following while the operator approaches the time of maintenance such as screen is displayed. a Similarly to the "relationship between the remaining time and display of caution" on the previous page.

10 Structure. When returning to the maintenance table screen to check the remaining time or when you selected a wrong item. function and maintenance standard SEN01355-00 Maintenance operation 1. depress return switch (4) to return to the mainte- nance table screen. depress input check switch (3) to reset the maintenance time. Check the contents of the maintenance reset screen. the symbol and set time of the maintenance item are dis- played in large size. depress return switch (4). If you made a mistake in selecting the item. After selecting. a If the maintenance time of an item is reset. 3.. If there is no problem. and the maintenance reset screen appears. etc. Check the contents of the check screen. the maintenance table screen appears again. 2. the background of the symbol becomes the same as the background of the screen to show that the maintenance time has been reset. BR380JG-1E0 49 . a On the check screen. depress input check switch (3) to display the check screen. After resetting is completed. depress input check switch (3). If there is no problem.

a Relationship between menu symbol and con- tent. Flow level bar graph retracts to 1) Press display brightness/contrast adjustment the left switch (1) and switch to the adjustment screen.02) to select either contrast or brightness. function and maintenance standard Brightness. contrast of the display. 50 BR380JG-1E0 . or use the 10-key pad to input the number (00 . No. Then press return switch (4) or use the 10-key pad to set to [00] and press input confirmation switch (3) to return to the normal screen.SEN01355-00 10 Structure. After completing the selection. Control switch Actuation Adjustment method Flow level bar graph extends to a Operate as follows when on the operator the right screen. Symbol Content 01 Return mark Return 02 Contrast 03 Brightness 2) Press control switch (2). press input con- firmation switch (3) and return to the adjust- ment screen. contrast adjustment function 3) Press control switch (2) and adjust the bright- This function is used to adjust the brightness and ness and contrast as desired.

9. Depress operation switch (1) or (2) to set valid/ invalid of the password. operation switch (1) is depressed to set "valid". While depressing operation switch (2). not start unless the password is input. 7.10 Structure. 4. and 9 keys on the numeral key pad in order. input the 8- If a password is set in advance. function and maintenance standard SEN01355-00 Password function While the screen is waiting for an input. 2. 2. the engine does digit number "19210513" with the numeral keys. 3. move to valid/invalid of the password appears. the screen to check When setting or changing the password. the password function becomes invalid and ordinary screen (4) appears. This work cannot be carried out until 10 minutes pass after the starting switch is turned ON and the monitor screen changes to the ordinary screen. BR380JG-1E0 51 . In the figure at right. the password function becomes valid and the screen to input a 4-digit number appears. the set screen from the ordinary screen. and the screen to input an 8-digit number appears. If invalid is selected and input check switch (3) is depressed. depress 7. If valid is selected and input check switch (3) is depressed. Setting and changing method Turn the starting switch ON. After the last digit (3) is input.

"2" is dis- played. the password is not settled but the screen to input the number first time appears again. inputting the number second time. function and maintenance standard 5. input a 4-digit num. When switches. Input the display. the ordinary screen appears. 52 BR380JG-1E0 . On the input screen (where symbols of a lock Function of checking service meter and a key are displayed). It takes 3 .5 seconds to display When inputting the number first time. the service meter is indicated on the number again for reconfirmation. a If the number input first time is different from that input second time. th e s e r v i c e m e t e r a ft e r d ep r e s s i ng t h e played at the right top of the screen. the service meter switch (3) to settle it. After the input number is settled. same 4-digit number and depress input check q If the switches are released. "1" is dis. disappears. q 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- system urges you to input the same 4-digit neously.SEN01355-00 10 Structure.

the service code and failure code are displayed. Even if there is a service code/failure code q The ordinary screen (Travel.10 Structure. inspection) which does not cause any user code. BR380JG-1E0 53 . user code is indicated in the part of the hydrau- lic oil temperature gauge. For the method of inputting and setting a phone number. onds. q While the user code is displayed. q If a phone number is set by using the phone number input function of the service menu. if the input check switch is depressed. of the service code/failure code. function and maintenance standard SEN01355-00 Function of displaying user code q If there are multiple service codes/failure q If there is any trouble in operation of the codes which cause the service codes. Spe- cial functions of monitor panel. monitor to urge the operator to take remedy. all of machine. the user codes and a phone symbol can be displayed instead are displayed alternately at intervals of 3 sec. the user code is displayed on the them are displayed at intervals of 3 seconds. it q If there are multiple troubles. work. see Testing and adjusting. it is not changes to the screen shown at right and the displayed by this function.

SEN01355-00 10 Structure. Sub tank 2. Either side of a sensor of contact type is always connected to the chassis ground. function and maintenance standard Sensor 1 q The signals from the sensors are input to the panel directly. Sensor 4. Float 3. Sensor name Type of sensor When normal When abnormal Engine oil level Contact ON (Closed) OFF (Open) Engine oil pressure Contact OFF (Open) ON (Closed) Hydraulic oil temperature Resistance — — Hydraulic oil level Contact ON (Closed) OFF (Open) Coolant temperature Resistance — — Coolant level Contact ON (Closed) OFF (Open) Fuel level Resistance — — Air cleaner clogging Contact OFF (Closed) ON (Open) Coolant level sensor 1. Connector 54 BR380JG-1E0 .

Contact 6. Diaphragm 2. Spring 3. Bracket 4.10 Structure. Plug 4. Contact ring 5. Hydraulic oil level sensor 1 1. Connector 3. Float 2. Switch Engine oil pressure sensor (For low pressure) 1 1. function and maintenance standard SEN01355-00 Engine oil level sensor. Terminal BR380JG-1E0 55 .

Hydraulic oil temperature sensor 1 1. function and maintenance standard Coolant temperature sensor. Body 5. Connector Fuel level sensor 1 1.SEN01355-00 10 Structure. Variable resistor 56 BR380JG-1E0 . Tube 6. Connector 3. Wire 3. Float 2. Thermistor 4. Tube 2. Cover 4.

10 Structure. function and maintenance standard SEN01355-00 Air cleaner clogging sensor 1 BR380JG-1E0 57 .

SEN01355-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 10-06 (01) 58 .SEN01355-00 BR380JG-1E0 Mobile crusher Form No.

.......................................... 2 Standard value table for chassis ......................................................................................... 3 BR380JG-1E0 1 ......... SEN02288-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 20 Standard value table 1 Standard service value table Standard value table for engine ..........................................................................

330 ± 50 2.41 1. 25 35 • Coolant temperature: acceleration Exhaust gas color operating range At high idle % — — Intake valve mm 0. 1. MPa Min.51 0.381 Valve clearance • Normal temperature Exhaust valve mm 0.050 2.69 Compression • Oil temperature: 40 pressure {kg/cm2} {Min.98 1. 147 120 (boost pressure) • At rated output {mmHg} {Min. 98 N{10 kg} 2 BR380JG-1E0 .330 ± 50 • Coolant temperature: Engine speed Low idle rpm 1. High idle {kg/cm2} {Min. 0.0} {0.050 Intake pressure • Coolant temperature: operating range kPa Min.SEN02288-00 20 Standard value table Standard value table for engine 1 Applicable model BR380JG-1E0 Engine SAA6D107E-1 Standard value for new Item Measurement condition Unit Judgement criteria machine High idle rpm 2.100} {900} At sudden % Max.050 ± 25 operating range Rated speed rpm 2. 0.2} pressure – 60°C Engine speed rpm 250 – 280 250 – 280 • Coolant temperature: operating range kPa Max.762 Compression MPa Min.5} SAE10W30DH. Oil pressure SAE15W40DH.96 Blow-by pressure • At rated output {mmH2O} {Max. 24.0} {2.152 – 0.050 ± 25 1. SAE30DH engine oil • Coolant temperature: Low idle MPa Min.6} {17.381 – 0. 0.7} Oil temperature • Whole speed range (inside oil pan) °C 80 – 110 120 • Between fan pulley and alternator pulley Fan belt tension mm 8 6 – 10 • Deflection when pressed with finger force of approx. 100} {200} • SAE0W30E0S. 3.29 0. 2. 1.25 0.10 0.25 SAE5W40E0S.07 operating range {kg/cm2} {Min.

5 ± 0.5 9.4} {Max.20 Standard value table SEN02288-00 Standard value table for chassis 1 Applicable Model BR380JG-1E0 Cate.5 — — ± 0. 5. value up to the stroke end BR380JG-1E0 3 .3} control lever knob and take measurement • Read out the max. 15 Max.5 9.050 ± 100 2.9 • Hook a push-pull scale to the center of the N {kg} in travel {2.0 ± 0.050 ± 100 • Engine running at full throttle condition • Travel circuit in relief condition (locking track shoe) l a b l a b Spool stroke All spools mm 9.6 ± 3.5 ± 0.5 ± 0. value up to the stroke end mm • Stop the engine Play of Control lever • Remove lever play at the neutral position Max.5 Travel • Grip the lever at its knob center 86 ± 9 86 ± 9 control lever Stroke • Read out the max.9 Max.5 9. Standard Permissible Check Item Measurement Condition Unit gory value value • Engine coolant temperature: To be within operating range revolution 2 pumps Engine • Oil temperature: 45 – 55°C in relief rpm 2. 23 control lever Operating effort • Engine running at full throttle • Oil temperature: 45 – 55°C Operating effort 19. 51.

6 ± 1.0 11.98 ± 0.9 ± 1.6 ± 1.0 Unload pressure • Set all levers in neutral {40 ± 10} {40 ± 10} • Pump outlet pressure 38.84 – 3.0 –1.5 Side conveyor motor {150 ± 10} {150 ± 15} Magnetic 19.9 ± 1.5 • Pump outlet pressure elevator cylinder {270 ± 10} {270 ± 15} • Relieve only circuit to be measured 14.2 equipment idle {10 ± 2} {10 ± 2} 4 BR380JG-1E0 .2 +1.04 – 3.SEN02288-00 20 Standard value table Applicable Model BR380JG-1E0 Categ Standard Permissible Check Item Measurement Condition Unit ory value value • Oil temperature: 45 – 55°C • Run engine at full throttle 3.7 ± 1.0 equipment LS differential • Rung engine at full throttle {40 ± 10} {40 ± 10} switches OFF pressure a LS differential pressure = Pump outlet pressure – LS pressure Run all work 0.43 reducing valve {31 – 35} {29 – 35} Turn all work • Oil temperature: 45 – 55°C 3.7 ± 1.5 Left travel {400 +10 –15 } {400 +10 –25 } 39.5 ± 1.98 ± 0.7 ± 1.0 ± 2.5 Belt conveyor motor {235 ± 10} {235 ± 15} 21.9 ± 1.0 3.0 14.5 Right travel {400 +10 –15 } {400 +10 –25 } Self pressure 3.5 38.5 38.0 19.7 ± 1.5 ± 1.0 32.0 Forward {395 ± 15} {395 ± 20} Crusher motor 38.5 ± 1.5 cylinder {330 ± 10} {330 ± 15} Operation of lock 11.5 cylinder • Oil temperature: 45 – 55°C {kg/cm2} {240 ± 10} {240 ± 15} • Run engine at full throttle Side conveyor 26.0 3.7 ± 2.0 ± 1.5 39.43 2.0 23.0 –1.5 21.9 ± 1.0 23.2 +1.0 ± 1.8 ± 1.5 separator motor {200 ± 10} {200 ± 15} 39.8 ± 1.0 26.2 +1.5 39.5 cylinder (Extension. {120 ± 10} {120 ± 15} retraction) Oil pressure Conveyor elevator MPa 23.0 Feeder motor {215 ± 15} {215 ± 20} Release of lock 32.2 0.3 ± 1.2 +1.3 ± 1.5 ± 1.0 –2.0 ± 1.7 ± 2.0 –2.0 Reverse {395 ± 15} {395 ± 20} 23.

measure travel deviation in travel of 20 m.0 72. 200 Max.2 20. Hi 20.20 Standard value table SEN02288-00 Applicable Model BR380JG-1E0 Categ Standard Permissible Check Item Measurement Condition Unit ory value value Hydraulic drift of mm 0 0 travel • Stop engine • Hydraulic oil temperature: 45 – 55°C • Stop machine on 12° slope with sprocket side up • Measure hydraulic drift of travel in 5 minutes Leakage from travel l/mm Max.0 – 120. a Test on hard and level ground. 300 a Measure dimension x.9 – 28. 27.0 – 120.9 – 28. 13.2 – 36. BR380JG-1E0 5 . 27.2 – 36.8 27.2 • Run engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Set primary conveyor in travel posture • Travel at Hi • After approach run of at least 10 m on flat ground. Travel deviation mm Max.6 Max.2 motor • Run engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Lock shoe with lock pin (1) and relieve travel circuit Lo 72.0 Travel • Run engine at full throttle • Hydraulic oil temperature: 45 – 55°C • Set primary conveyor in travel posture Travel speed • After approach run of at least 10 m on flat Mi Sec. measure time required to travel 20 m.8 ground.

100 MAX 950 – 1.150 3) Feeder vibration cpm MIN 468 – 632 MIN 440 – 660 4) Primary conveyor 102 – 138 96 – 144 belt speed 5) Side conveyor m/min 95 – 129 90 – 135 belt speed 6) Magnetic separator belt 70 – 100 66 – 108 speed 6 BR380JG-1E0 .SEN02288-00 20 Standard value table Applicable Model BR380JG-1 Cate Check Item Measurement Condition Unit Standard value Permissible value gory MAX 297 – 363 MAX 280 – 380 Standard pulley MIN 153 – 187 MIN 136 – 204 1) Crusher speed (Forward) MAX 261 – 319 MAX 246 – 334 Small (torque up) pulley • Run engine at full throttle MIN 135 – 165 MIN 120 – 180 • Hydraulic oil temperature: 45 – 55°C rpm Work equipment speed MAX 238 – 322 MAX 224 – 336 Standard pulley MIN 144 – 196 MIN 136 – 204 2) Crusher speed (Reverse) MAX 209 – 283 MAX 196 – 295 Small (torque up) pulley MIN 127 – 173 MIN 120 – 180 MAX 1.000 – 1.

20 Standard value table SEN02288-00 Cate Discharge amount of main piston pump (each 1 pump) gory Piston pump performance Pump speed: At 2050 rpm.) (l/min. The error is large near the point where the graph curves. a When measuring with the pump mounted on the machine. Discharge pres. bring pump discharge pressures. Standard value for Judgement stan- Check Average pressure charge pressure sure of other pump discharge amount dard lower limit Q point (MPa {kg/cm2}) (MPa {kg/cm2}) 2 (MPa {kg/cm }) Q (l/min. take the pump discharge amount and the engine speed at the point of measurement and use them as a base for calculating the pump discharge amount at the specified speed. P1 and P2 as close as possible to the average pressure when measuring. if it is impossible to set the engine speed to the specified speed with the fuel control dial. BR380JG-1E0 7 . so avoid measuring at this point. PC current 310 mA Test pump dis.) As P1 + P2 P1 P2 See graph See graph desired 2 a As far as possible.

SEN02288-00 BR380JG-1E0 Mobile crusher Form No. SEN02288-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01) 8 .

...................................................................................................................................................................................................................................................................................................................................11 Measuring blow-by pressure.................................................................................................................................................................. 9 Measuring compression pressure........................................................................................................................................... 23 Measuring and adjusting oil pressure in work equipment and travel circuits ........................................................... 18 Bleeding air from fuel circuit........................ 3 Measuring engine speed................................... 20 Checking fuel circuit for leakage .......................................................................................................................................................................................................... SEN02303-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting 1 Testing and adjusting....................... 14 Handling fuel system parts.......... 16 Measuring fuel return rate and leakage ...................... 15 Measuring fuel pressure ................................................................................................................................................................................................................................ 8 Adjusting valve clearance .............................. adjusting................. 15 Releasing residual pressure from fuel system ... 7 Checking exhaust gas color................................................................... 13 Measuring engine oil pressure.......................................................................................................................... Part 1 Tools for testing.................................................. 22 Checking and adjusting track shoe tension .................... 25 BR380JG-1E0 1 .......................................................................................................... 6 Measuring intake air pressure (boost pressure) ............................................................... and troubleshooting......................................................

... 46 2 BR380JG-1E0 ... 30 Measuring and adjusting oil pressure in pump LS control circuit ................................................................................. 33 Measuring solenoid valve output pressure...................................................................................................................................... 41 Bleeding air from each part ..................... 40 Measuring oil leakage ..................................................................................................................................................................................................................................................................................................... 45 Adjusting mirrors .............................. 42 Testing travel deviation......................... 37 Measuring PPC valve output pressure................................................... 29 Measuring and adjusting oil pressure in pump PC control circuit ............SEN02303-00 30 Testing and adjusting Measuring control circuit basic pressure.......................................................................................................................................................................................................................................................................................................................

0 mm o R1/8 6215-81-9710 O-ring 1 Pressure gauge: 0. swing. 60.8 MPa 1 {25. Pressure gauge: 58. 58.9.98 MPa 2 799-401-2320 Hydraulic gauge 1 {10 kg/cm2} Pressure gauge: 799-101-5002 Hydraulic tester 1 2.9. 5.25 mm 07002-11023 O-ring 2 BR380JG-1E0 3 .8 MPa 790-261-1204 Digital hydraulic tester 1 Measuring fuel pressure G {600 kg/cm2} 6732-81-3170 Adapter 1 2 10 × 1.2. 600 kg/cm2} oil pressure in work equip. 39. 400. 5. – 101 – 200 kPa A 799-201-2202 Boost gauge kit 1 sure (boost pressure) {– 760 – 1.98 MPa 3 799-401-2320 Hydraulic gauge 1 {10 kg/cm2} 1 795-790-4700 Tester kit 1 2 795-790-6700 Adapter 1 6754-71-5340 Connector 1 3 Measuring fuel return rate 6754-71-5350 Washer 1 H and leakage Commercially 4 Measuring cylinder 1 available Commercially 5 Stopwatch 1 available Pressure gauge: 799-101-5002 Hydraulic tester 1 2. 39.9. 600 kg/cm2} Pressure gauge: 58.500 mmHg} 1 799-201-9001 Handy smoke checker 1 Checking exhaust gas B Commercially Bosch index: 0 – 9 color 2 Smoke meter 1 available 1 795-799-1131 Gear 1 Adjusting valve clearance C Commercially 2 Clearance gauge 1 Intake: 0. Part name Remarks bol Measuring intake air pres. adjusting. 58. 39. 58.5.5. Exhaust: 0. 60. 5.8 MPa J 790-261-1204 Digital hydraulic tester 1 ment. 400. and troubleshooting 1 Sym- Q'ty Testing/Adjusting item Part No.30 Testing and adjusting SEN02303-00 Tools for testing.2.2. and travel {600 kg/cm2} circuits 799-101-5220 Nipple 2 2 Size: 10 × 1.9 MPa {0 – 70 kg/cm2} Measuring compression 2 795-799-6700 Puller 1 For 107E-1 engine D pressure 795-790-4410 Adapter 1 For 107E-1 engine 3 6754-11-3130 Gasket 1 For 107E-1 engine Measuring blow-by pres. Pressure gauge: 58.8 MPa Measuring and adjusting 1 {25. 1 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O} E sure 2 795-790-3300 Blow-by tool 1 For 107E-1 engine Pressure gauge: 799-101-5002 Hydraulic tester 1 2.8 MPa 1 {25.8 MPa F sure 790-261-1204 Digital hydraulic tester 1 {600 kg/cm2} Pressure gauge: 0.51 mm available 1 795-502-1590 Compression gauge 1 0 – 6. 600 kg/cm2} Measuring engine oil pres. 400. 60.5.25 mm.

39. 400. 39.8 MPa 790-261-1204 Digital hydraulic tester 1 {600 kg/cm2} 2 799-401-3100 Adapter 1 Size: 02 Pressure gauge: 799-101-5002 Hydraulic tester 1 2.5.9. 5.25 mm 07002-11023 O-ring 4 Pressure gauge: 799-101-5002 Hydraulic tester 1 2.SEN02303-00 30 Testing and adjusting Sym- Q'ty Testing/Adjusting item Part No. 400. 600 kg/cm2} Measuring PPC valve out.5 3 07002-11423 O-ring 1 Commercially Measuring oil leakage Q Measuring cylinder 1 available Measuring coolant tem- perature and oil tempera. 60.9. 60.5. 60. Pressure gauge: 58. Commercially — Stopwatch 1 ment speed available Measuring voltage and Commercially — Circuit tester 1 resistance available Removal and installation Commercially 3. 600 kg/cm2} Measuring and adjusting Pressure gauge: 58.2. 39.2. 5. 39.9. 58.8 MPa P 790-261-1204 Digital hydraulic tester 1 put pressure {600 kg/cm2} 2 799-101-5230 Nipple 1 Size: 14 × 1.8 MPa 1 {25. Part name Remarks bol Pressure gauge: 799-101-5002 Hydraulic tester 1 2.299°C ture Measuring operating effort 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg} — and depressing force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg} Measuring stroke and Commercially — Ruler 1 hydraulic drift available Measuring work equip. 58. 5. 5.26 mm torque wrench of boost pressure and — Torque wrench 1 available (KTC Q4T15 or equivalent) temperature sensors Removal and installation of engine oil pressure sen. 58. 60.8 MPa 790-261-1204 Digital hydraulic tester 1 oil pressure in pump LS M {600 kg/cm2} control circuit 799-101-5220 Nipple 4 2 Size: 10 × 1.9. 39. 58. 58. 600 kg/cm2} Measuring and adjusting oil pressure in pump PC L Pressure gauge: 58. — (Not set yet) Deep socket 1 27 mm deep socket sor 4 BR380JG-1E0 .2. 600 kg/cm2} N output pressure Pressure gauge: 58.2. 60.8 MPa 790-261-1204 Digital hydraulic tester 1 control circuit {600 kg/cm2} 799-101-5220 Nipple 4 2 Size: 10 × 1.8 MPa K 790-261-1204 Digital hydraulic tester 1 of control circuit {600 kg/cm2} 799-401-3100 Adapter 1 2 Size: 02 07002-11023 O-ring 1 Pressure gauge: 799-101-5002 Hydraulic tester 1 2.25 mm 07002-11023 O-ring 4 Differential pressure 3 799-401-2701 1 49 MPa {500 kg/cm2} gauge Pressure gauge: 799-101-5002 Hydraulic tester 1 2. 400. 400.8 MPa 1 {25.9 – 1.2. 400. — 799-101-1502 Digital thermometer 1 – 99. 5.8 MPa Measuring solenoid valve 1 {25.5.9.8 MPa 1 {25.5.5. 600 kg/cm2} Measuring basic pressure Pressure gauge: 58.8 MPa 1 {25.

Part name Remarks bol Removal and installation Commercially 21 mm deep socket of engine coolant temper. controllers. electrical equipment. sensors. List of T-boxes and T-adapters”. actuators. of the T-boxes and T-adapters used for troubleshooting for the machine monitor. and wiring harnesses.30 Testing and adjusting SEN02303-00 Sym- Q'ty Testing/Adjusting item Part No. — Socket 1 available (MITOLOY 4ML-21 or equivalent) ature sensor a For the model names and part Nos. see “Trou- bleshooting (General information on troubleshooting). BR380JG-1E0 5 .

and set the conveyor height to Hi (Travel operation position). a Measure the engine speed under the following condition. 4. 2) Set the machine in the travel mode.SEN02303-00 30 Testing and adjusting Measuring engine speed 1 a Measure the engine speed with the monitoring function of the machine monitor. see “Special functions of machine monitor”. 3) Operate the travel control lever to relieve the travels (Right and left) and measure the engine speed. select travel speed Hi. Measuring high idle speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position. q Engine coolant temperature: Within oper- ating range q Hydraulic oil temperature: Within operat- ing range 1. 3. a For the operating method of the machine monitor. Preparation work Operate the machine monitor so that the engine speed can be monitored. 6 BR380JG-1E0 . 2) Set the machine in the operation mode and turn the all work equipment switches OFF. a Monitoring code: 01002 Engine speed 2. Measuring low idle speed 1) Start the engine and set the fuel control dial in the low idle (MIN) position. 2) Set the machine in the operation mode and turn the all work equipment switches OFF. Measuring 2-pump relief speed 1) Start the engine and set the fuel control dial in the high idle (MAX) position.

ing range 5. Install nipple [1] of boost gauge kit A and con- nect it to gauge. 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. Accordingly. 2. a If Pm kit (A) is available. 6. be sure to drain the oil. Open the engine hood and remove intake air the travel lever. remove the mea- suring tools and return the removed parts. Part name oil will be drained. relieve the travels (Right and pressure pickup plug (1) from the intake air left) and measure the intake air pressure. lowing condition. and the Symbol Part No.30 Testing and adjusting SEN02303-00 Measuring intake air pressure 3. Set the machine in the travel mode. After finishing measurement. and set the conveyor height to q Hydraulic oil temperature: Within operat- Hi (Travel operation position). connector. a If oil is left in the hose. the gauge does not a Measure the intake air pressure under the fol- work. BR380JG-1E0 7 . While running the engine at high idle. q Engine coolant temperature: Within oper- 4. k Stop the machine on a level ground. Run the engine at middle or higher speed and (boost pressure) 1 bleed oil from the hose. select ating range travel speed Hi. you use the air- A 799-201-2202 Boost gauge kit bleeding coupling (790-261-1130) in that kit. operate 1.

filter paper will absorb the exhaust gas. remove the mea. remove the checking tools and return the removed parts.4 ± 0. Checking with smoke meter B2 7) Place the contaminated filter paper on the 1) Insert probe [1] of smoke meter B2 in the clean filter paper (at least 10 sheets) in the outlet of the exhaust pipe and fix it to the filter paper holder and read the indicated exhaust pipe with a clip. 4) Loosen the cap nut of the suction pump 3) Start the engine and accelerate it sud. exhaust pipe. use a Limit the supplied air pressure to 1. 3) Connect the power cable to an AC recep- 1. use handy smoke meter B2. a Check the exhaust gas color under the follow- ing condition. and air hose to smoke are not available in the field. collect the exhaust gas into the filter paper. 4) Remove the filter paper and compare it 6) Start the engine and accelerate it sud- with the attached scale. k Be careful not to touch any hot part when removing or installing the checking tools. checker B1. accelerator pedal of smoke meter B2 and suring tools and return the removed parts. check checker B1. receptacle of the a If an air source and an electric power source accelerator switch.SEN02303-00 30 Testing and adjusting Checking exhaust gas color 1 a Checking tools for exhaust gas color Symbol Part No. value. Measuring with handy smoke checker B1 tacle. denly or run it at high idle and operate the a Fit the filter paper securely so that the handle of smoke checker B1 so that the exhaust gas will not leak. denly or run it at high idle and depress the 5) After finishing checking. Part name 1 799-210-9001 Handy smoke checker B Commercially 2 Smoke meter available k Stop the machine on a level ground. q Engine coolant temperature: Within oper- ating range 2) Connect the probe hose. 1) Stick a sheet of filter paper to smoke a Before connecting the cable.2 sec B2.5 smoke meter B2. 8) After finishing checking. that the power switch of the smoke 2) Insert the exhaust gas intake pipe in meter is turned OFF. 5) Turn on the power switch of smoke meter a Absorbing time: 1. When recording official data. MPa {15 kg/cm2}. 2. and fit the filter paper. 8 BR380JG-1E0 .

a Measure the valve clearance under the follow- the piston in the No. is not set to the compression top dead q Engine coolant temperature: Normal tem- center (TDC). C Commercially 2 Clearance gauge a If you can see the yellow marks of projec- available tion top (a) and wide slit (b). pull it together with the cylinder head cover. a If you can move the rocker arms of exhaust valves (EX) with the hand by the valve clearance. Stop the machine on a level ground. 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. Part name a Projection top (a) must be within the range of wide slit (b) when it is seen from the fan 1 795-799-1131 Gear side. a Valve arrangement drawing BR380JG-1E0 9 . 5. adjust the valves marked with Q in the valve arrangement drawing. 6 cylinder ing condition. k k When the crankshaft is set as above. motor and insert gear C1. Remove cylinder head cover (1). Open the engine hood and remove the bracket for the fan guard and engine step. 1 cylinder to judge the valve to be adjusted. a Since the breather connector on the rear side of the cylinder head cover is con- nected to the flywheel housing through the O-ring.30 Testing and adjusting SEN02303-00 Adjusting valve clearance 1 4. Symbol Part No. Remove plug (2) from the top of the starting with q in the valve arrangement drawing. 2. perature 1. Check the movement of the rocker arm of the No. 1 or No. Take care. adjust the valves marked 3. a If you can move the rocker arms of air intake valves (IN) with the hand by the valve clearance. you may set them to each other.

tighten locknut (4). check the valve clearance again. Adjust the other valve clearances according to steps 5. 8. 3) While fixing adjustment screw (3). and 6. 1) While fixing adjustment screw (3). Rotate the crankshaft forward by 1 turn and set wide slit (b) to projection top (a) according to step 4.41 kgm} a After tightening the locknut. and 6. adjust the valves marked with q. Adjust the valve clearance according to the fol- lowing procedure. 7. adjust the valves marked with Q. a With the clearance gauge inserted. and 6. remove the adjust- ing tools and return the removed parts.SEN02303-00 30 Testing and adjusting 6. After finishing adjustment. 9. 2) Insert clearance gauge C2 in the clearance between rocker arm (5) and crosshead (6) and adjust the valve clearance with adjustment screw (3). loosen locknut (4).45 ± 0. turn the adjustment screw to a degree that you can move the clearance gauge lightly. 3 Locknut: 24 ± 4 Nm {2. a If the valves marked with q in the valve arrangement drawing were adjusted in steps 5.41 kgm} 10 BR380JG-1E0 . 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.45 ± 0. k Remove gear C1 without fail. a If the valves marked with Q in the valve arrangement drawing were adjusted in steps 5.

BR380JG-1E0 11 . engine step and cylinder head cover (1).04 kgm} 2nd time: 75 ± 5° (Angle tightening) a If a little quantity of engine oil is applied to the joint of the adapter and gauge. a Measuring tools for compression pressure Symbol Part No. a The inlet connector is connecting the fuel tube to the injector. Remove the mounting bolts of rocker arm assembly (2) on the exhaust side. 3. 5. 2.36 ± 0. Install rocker arm assembly (2) on the exhaust side and adjust the valve clearance. 3 Injector clamp mounting bolt: 1st time : 3. and then remove inlet connector (7) in the cylinder head. q Engine oil temperature: 40 – 60°C 1. Part name 1 795-502-1590 Compression gauge 2 795-799-6700 Puller D 795-790-4410 Adapter 3 6754-11-3130 Gasket k Stop the machine on a level ground. Disconnect injector wiring harness.35 Nm {0.5 ± 0.30 Testing and adjusting SEN02303-00 Measuring compression pressure1 4. pull it together with the cylinder out fail. and then remove rocker arm assembly (2). 6. a See “Adjusting valve clearance”. Using tool D2. air does not leak easily. you do not need to remove the rocker arm assembly on the intake side. Install adapter D3 to the injector mounting part a Since the breather connector on the rear with the injector clamp and connect compres- side of the cylinder head cover is con. nected to the flywheel housing through the a Install the gasket to the adapter end with- O-ring. sion gauge D1. Open the engine hood and remove the fan guard bracket. a Measure the compression pressure under the following condition. Remove fuel tube (3). remove injector (4). head cover. a When removing the injector.

fault. After finishing measurement. For details. cover the connector on the directed to the air intake manifold.5 kgm} 8.8 Nm {0.SEN02303-00 30 Testing and adjusting 7. ment and it will be dangerous. 3 Inlet connector retainer: 50 ± 5 Nm {5. 5) Tighten the mounting bolt of injector clamp (6) securely.1 ± 0.026 kgm} 3 Fuel tube sleeve nut: 35 ± 3. machine side with a vinyl sheet. 3 Injector wiring harness nut: 1. suring tools and return the removed parts. 4) Install inlet connector (7) and tighten inlet connector retainer temporarily.4 kgm} 3 Rocker arm assembly mounting bolt: 36 ± 6 Nm {3. a Tighten the bolts and nuts other than the injector and inlet connector to the follow- ing torque. to 3) Install injector clamp (6) and tighten the prevent electric leakage and ground mounting bolt by 3 – 4 threads. 1) Apply new engine oil (SAE15W-40) to the k Since the CE03 connector is a part of O-ring of injector (4) and cylinder head.6 kgm} a Adjust the valve clearance. etc.5 Nm {3.41 kgm} 12 BR380JG-1E0 . the power supply circuit of the engine 2) Install injector (4) with the fuel inlet hole controller.08 kgm} 6) Tighten inlet connector retainer (8) securely. Rotate the engine with the starting motor and measure the compression pressure.7 ± 0. 3 Injector clamp mounting bolt: 8 ± 0. a Read the gauge when the pointer is stabi- lized.25 Nm {0. a Install the injector and inlet connector the engine will start during measure.8 ± 0.15 ± 0.45 ± 0. according to the following procedure. 3 Cylinder head cover mounting nut: 24 ± 4 Nm {2.6 ± 0. k If the connector is not disconnected. remove the mea- controller. see “Adjusting valve clearance”. Disconnect CE03 connector (5) of the engine 9.5 ± 0.

30 Testing and adjusting SEN02303-00 Measuring blow-by pressure 1 4. 1 799-201-1504 Blow-by checker E 2 799-790-3300 Blow-by tool k Stop the machine on a level ground. and select travel speed Hi. Start the engine and lock the travel. Symbol Part No. remove the mea- suring tools and return the removed parts. set the machine in the travel mode. a Measure the blow-by pressure under the fol- lowing condition. Part name a Read the gauge when the pointer is stabi- lized. After finishing measurement. q Engine coolant temperature: Within oper- ating range q Hydraulic oil temperature: Within operat- ing range 1. relieve the travels (Right and left) and measure the a Measuring tools for blow-by pressure blow-by pressure. 2. Install tool and adapter of blow-by checker E1 or blow-by tool E2 to breather hose (1) and connect gauge. BR380JG-1E0 13 . 3. While running the engine at high idle. Start the engine. k Insert pin [2] between the sprocket and the track frame to lock the travel securely. set the conveyor height to Hi (Travel operation position). 5.

Remove oil pressure pickup plug (1) from the top of the engine oil filter. a Measure the engine oil pressure under the fol- lowing condition. q Engine coolant temperature: Within oper- ating range 1. 14 BR380JG-1E0 .SEN02303-00 30 Testing and adjusting Measuring engine oil pressure 1 3. Install nipple [1] of hydraulic tester F1 and con- nect hydraulic gauge F2. a Measuring tools for engine oil pressure Symbol Part No. 2. Part name 799-101-5002 Hydraulic tester 1 F 790-261-1204 Digital hydraulic tester 2 799-401-2320 Hydraulic gauge k Stop the machine on a level ground. Run the engine and measure the engine oil pressure at high idle and low idle. remove the mea- suring tools and return the removed parts. 4. After finishing measurement.

If a filter stopping the engine until the residual pres- other than the genuine one is used.30 Testing and adjusting SEN02303-00 Handling fuel system parts 1 Releasing residual pressure from a Precautions for checking and maintaining fuel fuel system 1 system a Pressure is generated in the low-pressure cir- The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys- consists of more precise parts than the con. a The pressure in both low-pressure circuit and sticks to any part. High-pressure circuit: When checking and maintaining the fuel sys.) BR380JG-1E0 15 . observe the following. take care more than the past. Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is checked and its parts cartridge. the fuel sure in the fuel circuit is released. Supply pump – Common rail – Injector tem. Accord- (CRI) consists of more precise parts than the ingly. If for. automatically 30 seconds after the engine is a Precautions for replacing fuel filter cartridge stopped. never start the work just after stopping the engine use such a filter. etc. (Do not system may have a trouble. conventional fuel injection pump and nozzle. wash that part thoroughly high-pressure circuit lowers to a safety level with clean fuel. since there is residual pressure. ventional fuel injection pump and nozzle. it can cause a Feed pump – Fuel main filter – Supply pump trouble. the residual pressure in the fuel Since the common rail fuel injection system circuit must be released completely. Low-pressure circuit: eign matter enters this system. ing its parts. If dust. wait at least 30 seconds after vent foreign matter from entering it. Accordingly. it k Before checking the fuel system or remov- employs a high-efficiency special filter to pre. are removed. tem while the engine is running.

1 – 13.3 MPa main filter. 3 Fuel pressure pickup plug: 10 ± 2 Nm {1 ± 0. however. it 3) Run the engine at low idle and measure cannot be measured. 1. k Since the pressure in the high-pressure cir- cuit from the supply pump through the common rail to the injector is very high. Measuring pressure in fuel low-pressure a If the pressure in the fuel low-pres- circuit sure circuit is in the following range. Do not rotate for more than 20 seconds continu- ously. you may measure the fuel pressure while rotating the engine with the starting motor. the pressure in the fuel low-pressure cir- cuit.1 – 11. it 1) Open the engine hood and remove fuel is normal. 799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester Adapter G 6732-81-3170 2 (10 × 1. 4) After finishing measurement.2 kgm} 16 BR380JG-1E0 . pressure pickup plug (1) from the fuel 0. Symbol Part No. At low idle {5. Part name a Use the oil pressure gauge of 2. a Measure only the fuel pressure in the low-pres- sure circuit from the feed pump through the fuel main filter to the supply pump and the return circuit from the supply pump/common rail/injector to fuel tank. remove the measuring tools and return the removed parts.3 – 1.5 MPa {25 kg/cm2}.3 kg/cm2} k If the engine cannot be started.1 MPa During cranking {3.SEN02303-00 30 Testing and adjusting Measuring fuel pressure 1 2) Install adapter G2 and nipple [1] of hydraulic tester G1 and connect them to a Measuring tools for fuel pressure oil pressure gauge [2]. for protection of the starting motor.0 mm o R1/8) 6215-81-9710 O-ring 3 799-401-2320 Hydraulic gauge k Stop the machine on a level ground.5 – 1.3 kg/cm2} 0.

02 MPa During cranking {Max. remove the 1) Open the engine hood and remove fuel measuring tools and return the removed pressure pickup plug (2) from the fuel parts. it is normal.4 kgm} 2) Install nipple [3] of hydraulic tester G1 and nipple [1] and connect them to hydraulic tester G3. 3 Fuel pressure pickup plug: 24 ± 4 Nm {2. BR380JG-1E0 17 . a Nipple [3]: 790-301-1181. 0. At low idle Max. 07002-11223 3) Run the engine at low idle and measure the pressure in the fuel return circuit.4 ± 0. however. for protection of the starting motor. Measuring pressure in fuel return circuit 4) After finishing measurement. a If the pressure in the fuel return circuit is in the following range. Do not rotate for more than 20 seconds continu- ously.30 Testing and adjusting SEN02303-00 2. you may measure the fuel pressure while rotating the engine with the starting motor. 0. return block.19 kg/cm2} k If the engine cannot be started.

SEN02303-00 30 Testing and adjusting Measuring fuel return rate and leakage 1 a Measuring tools for fuel return rate and leakage Symbol Part No. a When measuring the leakage from the injector: Leave the removed parts as they are and keep the hose end in the receiving pan. measuring tools and return the removed parts. remove the ing pan. 1. however. Measuring return rate from supply pump 1) Open the engine hood and disconnect At low idle 1. pump is in the following range. a When measuring the leakage from the pressure limiter or finishing the measurement: Return the removed parts to their original positions. pre- cylinder H4. Do not rotate for more than 20 seconds continu- ously. 5) After finishing measurement. 3) Connect test hose [2] of tester kit H1 to the supply pump. During cranking 140 cc/min a The return hose is connected by a k quick coupler. If the engine cannot be started. k a If the return rate from the supply Stop the machine on a level ground. you may measure the fuel return rate while rotating the engine with the starting motor. pare receiving pan of about 20 liters. for protection of the starting motor. Part name 1 795-790-4700 Tester kit 2 795-790-6700 Adapter 6754-71-5340 Connector 3 H 6754-71-5350 Washer Commercially 4 Measuring cylinder available Commercially 5 Stopwatch available 4) Run the engine at low idle and measure the return rate in 1 minute with measuring a Since some fuel flows out during check. 18 BR380JG-1E0 .000 cc/min return hose (1) of the supply pump. 2) Install connector H3 and cap nut [1] of tester kit H1 to the return hose to stop the fuel from flowing out. it is normal. a Lay the test hose so that it will not slacken and put its end in the receiv.

before 3) Install connector H3 to the common rail measuring the leakage from the injector.4 ± 0. supply pump”. slacken and put its end in the receiv. a Install the seal washer to the connec- tor bolt. 2) Disconnect return hose (4) of the return block. At low idle 0 cc (No leakage) BR380JG-1E0 19 . Measuring leakage from pressure limiter 1) Open the engine hood and disconnect return hose (2) of the pressure limiter. 5) After finishing measurement. keep the test hose end in the receiving pan. k The fuel returning from the supply pump flows out during measure- ment of the return rate from the injector. remove the mea- suring tools and return the removed parts. a Install the seal washer to the return hose. 3 Joint bolt: 24 ± 4 Nm {2.4 kgm} 3. and connect test hose [2] of tester kit H1. set the supply pump for testing. Measuring return rate from injector 2) Install removed connector bolt (3) and cap a The leakage from the injector is measured nut [1] of tester kit H1 to the return hose to while the return hose of the pressure lim- stop the fuel from flowing out. 1) Referring to “Measuring return rate from ing pan. a If the leakage from the pressure limiter is in the following range. it is normal. 4) Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder H4. Accordingly. Accordingly.30 Testing and adjusting SEN02303-00 2. iter is connected. check that the leakage from the pressure a Lay the test hose so that it will not limiter is normal.

ously. 4) Run the engine at low idle and measure the return rate in 1 minute with measuring cylinder H4. ing pan.4 ± 0. it is normal. Fill the fuel tank with fuel. and connect test hose [4]. a Add fuel until the float of the sight gauge reaches the maximum position. a If fuel is used up or if a fuel circuit part is a Lay the test hose so that it will not removed and installed. circuit according to the following procedure. remove the measuring tools and return the removed parts. At low idle 180 cc/min During cranking 90 cc/min k If the engine cannot be started. a Move the knob until it becomes heavy. a The plug at the top of the fuel main filter does not need to be removed. bleed air from the fuel slacken and put its end in the receiv. 4. Do not rotate for more than 20 seconds continu. 2. push in and tighten knob (1). 1. After bleeding air. 3 Joint bolt: 24 ± 4 Nm {2. a If the return rate from the injector is in the following range. you may measure the fuel return rate while rotating the engine with the starting motor.SEN02303-00 30 Testing and adjusting 3) Install connector bolt [3] of adapter H2 Bleeding air from fuel circuit 1 instead of the removed connector bolt. Loosen knob (1) of the feed pump and pull it out. 3. however. and then operate it forward and backward. Open the under cover of the pump room. k Stop the machine on a level ground.4 kgm} 20 BR380JG-1E0 . 5) After finishing measurement. for protection of the starting motor.

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 21 .

a If any fuel leakage is detected. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. 5. a Check mainly around the high-pressure pressure circuit of the fuel system. 7. Check the fuel piping and devices for fuel leak- age. repair it and check again from step 2. repair it and check again from step 2. Run the engine at speed below 1. Check the fuel piping and devices for fuel leak- age.000 rpm and stop it after its speed is stabilized. Spray color checker (developer) over the fuel supply pump. a Check around the high-pressure circuit parts coated with the color checker for fuel leakage. it is dan. repair it and check again from step 2. a If any fuel leakage is detected. k Stop the machine on a level ground.SEN02303-00 30 Testing and adjusting Checking fuel circuit for leakage 1 9. gerous since it can catch fire. common rail. check it for fuel leakage according a If no fuel leakage is detected. 2. its parts. completed. 4. Run the engine at low idle. If fuel circuit parts coated with the color checker leaks while the engine is running. Check the fuel piping and devices for fuel leak- age. check is to the following procedure. a If any fuel leakage is detected. and joints of the high-pressure piping. fuel injector. a Relieve the travels (Right and left). 6. repair it After checking the fuel system or removing and check again from step 2. 1. 22 BR380JG-1E0 . Check the fuel piping and devices for fuel leak- age. a Clean and degrease the engine and the parts around it in advance so that you can check it easily for fuel leakage. a Check mainly around the high-pressure circuit parts coated with the color checker for fuel leakage. k Very high pressure is generated in the high. Run the engine at high idle and load it. Run the engine at high idle. 8. for fuel leakage. a If any fuel leakage is detected. 3.

Checking 1. If the tension is still low. q Standard maximum clearance (a): 10 – 30 mm a You may add grease until dimension (b) between the idler guide and track frame end becomes 0 mm. check the track shoe ten- sion again according to the above proce- 3. run 2. a grease gun.30 Testing and adjusting SEN02303-00 Checking and adjusting track Adjusting shoe tension 1 a If the track shoe tension is abnormal. reverse or replace the pins and bushings. etc. machine forward by the length of track on a As the steel bar. 2) To check that the tension is normal. BR380JG-1E0 23 . Increasing tension machine forward by the length of track on 1) Add grease through grease fitting (1) with ground. 3) After adjusting. Measure maximum clearance (a) between dure. In this case. Place steel bar [1] on the track shoe between the engine at low idle and move the the idler and the 1st carrier roller. adjust it according to the following procedure. the pins and bushings are worn much. then stop slowly. Run the engine at low idle and drive the 1. which will be deflected less. use an angle steel. ground. steel bar [1] and track shoe. and then stop slowly.

k Do not loosen the valve more than 1 turn. 3) After adjusting. check the track shoe ten- sion again according to the above proce- dure. Decreasing tension 1) Loosen valve (2) to discharge grease. 2) To check that the tension is normal.SEN02303-00 30 Testing and adjusting 2. 24 BR380JG-1E0 . then stop slowly. run the engine at low idle and move the machine forward by the length of track on ground. it may jump out because of the high-pres- sure grease in it. If it is loosened more. and then tighten it.

a Measuring and adjusting tools for oil pressure 1) Remove oil pressure pickup plugs (1) and in work equipment and travel circuits (2). q Monitoring code: 01100 F pump pressure q Monitoring code: 01101 R pump pressure 2) Install nipples J2 and connect oil pressure gauges of hydraulic tester J1.25 mm) 2 07002-11023 O-ring k Stop the machine on a level ground. a Use the oil pressure gauge of 58. too (For details. see “Special functions of machine monitor”). Preparation work k Stop the engine and gradually loosen pressure in work equipment and the oil filler cap of the hydraulic tank to travel circuits 1 release the air from the tank. q (1): Front pump discharge pressure Symbol Part No. q Hydraulic oil temperature: Within operat- ing range BR380JG-1E0 25 .30 Testing and adjusting SEN02303-00 Measuring and adjusting oil 1.8 MPa {600 kg/cm2}. Measuring a The oil pressure in the work equipment and travel circuits (pump discharge pressure) can be checked with monitoring function of the machine monitor. Part name pickup plug 799-101-5002 Hydraulic tester q (2): Rear pump discharge pressure 1 790-261-1204 Digital hydraulic tester pickup plug J 799-101-5220 Nipple (10 × 1. a Measure the oil pressure in the work equip- ment and travel circuits under the following condition.

block the piping of the motor inlet cir- cuit or the valve outlet circuit. Measuring travel relief pressure a When the oil from the pumps is divided. and measure the oil always relieved at high pressure.SEN02303-00 30 Testing and adjusting 2. primary conveyor. The travel circuit is trol lever to neutral. turn OFF the relief valve of the control valve is work equipment switch. nism. relieved is indicated. pressure. pendently on each actuator as shown in k Put pin [2] between the sprocket the table below. a When measuring the relief pressure of each motor drive circuit of the griz- zly feeder. and magnetic separator. and select travel speed Hi. set the travel con. operate the Primary conveyor Safety valve travel lever to relieve the travel motor. and track frame to lock the travel tors relieve different valves. set the machine in the Safety valve travel mode. Measuring main relief pressure 1) Run the engine at high idle. a The pressure measured when the main 2) Run the engine at high idle. Pump Actuator Valve relieved Crusher motor safety Crusher valve Front Right travel F main relief valve Lock cylinder reset Safety valve (Unload) F unload valve (Unload) R unload valve Magnetic separator Safety valve Side conveyor Safety valve Primary conveyor Safety valve elevator Side conveyor Rear Safety valve 2) Set the conveyor height to Hi (Travel oper- elevator Lock cylinder extension ation position). Combination of pump. actuator. 4. and valve 5. mechanism securely. Feeder Safety valve k Before operating the travel lever. 26 BR380JG-1E0 . 2) Relieve each actuator and measure the oil pressure. and retraction 3) Run the engine at high idle. Accordingly. check the position and locking direction of the locked sprocket 3. Note that different actua. the relief pressure of each safety valve is measured. measure the oil pressure when the crusher motor is started. 1) Start the engine. and Left travel R main relief valve measure the oil pressure. 1) Run the engine and lock the travel mecha- the front pump and rear pump act inde. a The pressure measured when the unload valve is unloaded is indicated. side conveyor. a The set pressures of the safety valves of the actuators other than the travel motor are lower than the set pressure of the main relief valve. a As the relief pressure of the crusher motor. Measuring unload pressure again.

3 MPa {Approx. a Quantity of adjustment per turn of a Quantity of adjustment per turn of adjustment nut: adjustment screw: Approx.30 Testing and adjusting SEN02303-00 Adjusting 2. loosen 1) Loosen locknut (12). adjust safety valves (7). Turn adjustment nut (13) to adjust the 2) Turn adjustment screw (5) to adjust the pressure. tighten locknut (12). check again that the oil pressure is normal according to the above described measurement procedure. (8). q Turned to the left.2 Nm {3 – 4 kgm} 4) After finishing adjustment. tighten 3) While fixing adjustment screw (5). the set pres- q Turned to the right. q (8) : For side conveyor motor q (3): Rear (R) main relief valve q (10) : For feeder motor q (4): Front (F) main relief valve q (11) : For resetting lock cylinder 1) While fixing adjustment screw (5). 3 Locknut: 3 Locknut: 39 – 49 Nm {4 – 5 kgm} 29. set pressure. locknut (6). 25. locknut (6). a If the work equipment safety valves are abnormal. adjust main relief valves (3) and (4) q (7) : Motor for magnetic separator according to the following procedure. the set pres. 12. according to the following procedure. 128 kg/cm2} 2) While fixing adjustment nut (13). sure is decreased. sure is increased. a If the adjustment nut is a If the adjustment screw is q Turned to the right. Adjusting work equipment safety valves a The unload valve cannot be adjusted. Adjusting main relief pressure (Travel) (10) and (11) of the work equipment a If the main relief pressure is abnormal. the set pres. 1.4 – 39.6 MPa {Approx. BR380JG-1E0 27 . sure is increased. 258 kg/cm2} Approx. sure is decreased. the set pres- q Turned to the left.

2] While fixing holder (17). too. applied when the 2-stage relief valve is a Adjusting relief pressure (Low pressure turned OFF and the pilot pressure is not setting side) applied to the selector port. the pres- sure rises. the pres- 93 – 123 Nm {9. check q The solenoid selector valve drives again that the oil pressure is normal actuators of 3 kinds. 3 Locknut: q turned to the left.SEN02303-00 30 Testing and adjusting q (9): Accessory valve 4] After finishing adjustment. a Quantity of adjustment per turn of holder: Approx. 2] While fixing holder (15). q Lock cylinder (Extension and retrac- 1] Disconnect 2-stage selector pilot tion) hose (14). setting side) a If the high pressure setting side is q Primary conveyor motor adjusted. q turned to the left. a If the holder is q turned to the right. 28 BR380JG-1E0 . 1] Disconnect 2-stage selector pilot hose (14).3 MPa {258 kg/cm2} 3 Locknut: 78 – 93 Nm {8 – 9. the pres- Approx. Accordingly. q The low relief pressure is the pressure applied when the 2-stage relief valve is turned ON and the pilot pressure is applied to the selector port. nut (18). a Quantity of adjustment per turn a If the holder is of holder: q turned to the right.3 MPa {258 kg/cm2} sure rises. adjust the q The high relief pressure is the pressure low pressure setting side. loosen lock- sure lowers. the low pressure setting q Conveyor elevator cylinder side changes.5 kgm} 3] Connect pilot hose (14). 25. the pres.5 kgm} sure lowers. according to the above described a Adjusting relief pressure (High pressure measurement procedure. 25. loosen lock- nut (16).5 – 12.

a Measure the control circuit basic pressure under the following condition.9 MPa {60 a Measuring tools for control circuit basic pres. and set the work equipment lock lever in the LOCK position. a Use the oil pressure gauge of 5. 6. oil pressure. remove the mea- suring tools and return the removed parts. While running the engine at high idle. loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Install nipple [2] and oil pressure gauge [1] of pressure 1 hydraulic tester K1. k Stop the engine. the operation switches OFF and measure the noid valve. range 5. q Hydraulic oil temperature: Within operating 4.30 Testing and adjusting SEN02303-00 Measuring control circuit basic 3. After finishing measurement. Part name 799-101-5002 Hydraulic tester 1 K 790-261-1204 Digital hydraulic tester 2 799-401-3100 Adapter: 02 k Stop the machine on a level ground. a Do not adjust the relief valve for control circuit basic pressure. 2. Disconnect inlet hose (1) of the 5-spool sole. turn all 1. BR380JG-1E0 29 . sure Symbol Part No. Connect adapter K2 to hose (1) and install the hose again. kg/cm2}. Start the engine.

and (4).8 piston inlet pressure) MPa {600 kg/cm2}. k Stop the engine. 1. Part name 799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester L 799-101-5220 Nipple (10 × 1. 1) Remove oil pressure pickup plugs (1). Measuring a Before measuring the oil pressure in the pump PC control circuit.SEN02303-00 30 Testing and adjusting Measuring and adjusting oil pressure in pump PC control circuit 1 a Measuring and adjusting tools for oil pressure in pump PC control circuit Symbol Part No. q Hydraulic oil temperature: Within operating range 2) Install nipple L2 and connect it to oil pres- sure gauge [1] of hydraulic tester L1. q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug q (3): Front PC valve output pressure pickup plug q (4): Rear PC valve output pressure pickup plug 30 BR380JG-1E0 . (3).25 mm) 2 07002-11023 O-ring k Stop the machine on a level ground. a Measure the PC valve output pressure (servo piston inlet pressure) and pump discharge pressure simultaneously and compare them. (2). Measuring PC valve output pressure (servo a Use the oil pressure gauge of 58. check that the oil pressure in the work equipment and travel circuits and the basic pressure of the control circuit are normal. a Measure the oil pressure in the pump PC con- trol circuit under the following condition. loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. and set the work equipment lock lever in the LOCK position.

Pump discharge 1 pressure Travel relief PC valve output Approx. 3/5) a If the PC valve or the servo piston is abnormal. run the engine at high idle and low idle. 4) Turn OFF all the work equipment mal. 2) Install nipples L2 and connect them to oil pressure gauges [1] of hydraulic tester L1. Measuring PC-EPC valve output pressure 1) Remove oil pressure pickup plug (5). following ratio. remove the measuring tools and return the removed parts. BR380JG-1E0 31 . 0. and measure the oil pressure at Measured oil Ratio of oil pressure Condition pressures each speed.30 Testing and adjusting SEN02303-00 2. a Measuring condition and method of judgment: If the pressures are in the 3) Start the engine. the PC valve is nor. 5) After finishing measurement.9 MPa {60 kg/cm2}. 3) Start the engine. 4) While running the engine at high idle.6 pressure (Approx. relieve the travel circuit and measure the pump discharge pressure and PC valve output pressure (servo piston inlet pres- sure) simultaneously. a Use the oil pressure gauges of 5. switches. the PC valve output pres- sure (servo piston inlet pressure) is “the same as the pump discharge pressure” or “almost 0”.

check again that the PC valve output pressure (servo piston inlet pressure) is normal according to the above described measurement procedure. so that you can see the position of the locknut before the adjustment (and you All work Engine equipment Output pressure can return the locknut to its original posi- switches tion after turning it in reverse). Approx.8 – 3. a If either of the following phenomena occurs 3 Locknut: and the PC valve seems to be defective. Loosen locknut (8). the engine speed lowers remarkably. q The engine speed is normal but the work equipment speed is low. Adjusting Adjusting pump PC valve 3. 2. q (6): Front pump PC valve q (7): Rear pump PC valve 4. 32 BR380JG-1E0 . 0 MPa a Turn the adjustment screw High idle {0 kg/cm2} q Clockwise when the work equipment speed is low (to in crease pu mp 5) After finishing measurement. the PC-EPC counter mark at the adjustment screw end valve is normal. make in the following range. Tighten locknut (8).9 MPa Low idle 2.SEN02303-00 30 Testing and adjusting a Measuring condition and method of 1.3 Nm {2. 30 kg/cm2} OFF terclockwise to adjust. adjust 27. judgment: If the output pressures are a Before loosening the locknut.5 kgm} PC valves (6) and (7) according to the proce- dure shown below. After finishing adjustment. Turn adjustment screw (9) clockwise or coun- {Approx. q As the working load increases. speed lowers (to decrease pump absorption torque).5 – 34. remove the absorption torque) and measuring tools and return the removed q Counterclockwise when the engine parts.

(2). and (4). pickup plug k Stop the engine and loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Measuring a Before measuring the oil pressure in the pump LS control circuit. 1) Remove oil pressure pickup plugs (1).25 mm) q (2): Rear pump discharge pressure 2 pickup plug 07002-11023 O-ring q (3): Front LS valve output pressure 3 799-401-2701 Differential pressure gauge pickup plug q (4): Rear LS valve output pressure k Stop the machine on a level ground. 799-101-5002 Hydraulic tester q (1): Front pump discharge pressure 1 790-261-1204 Digital hydraulic tester pickup plug M 799-101-5220 Nipple (10 × 1. q Hydraulic oil temperature: Within operating range BR380JG-1E0 33 . a Measure the oil pressure in the pump LS con- trol circuit under the following condition. Part name (3).30 Testing and adjusting SEN02303-00 Measuring and adjusting oil 1. Symbol Part No. Measuring LS valve output pressure (servo pressure in pump LS control piston inlet pressure) a Measure the LS valve output pressure circuit 1 (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. check that the oil pressure in the work equipment and travel circuits and the basic pressure of the control circuit are normal.

SEN02303-00 30 Testing and adjusting 2) Install nipple M2 and connect them to oil 3) Start the engine. a Measuring condition and method of judgment: If the pressures are in the following ratio. 2. (2). the LS valve is normal.6 pressure (Approx. 4) While running the engine at high idle. Ratio of oil Condition pressures Measured oil All work pressure All work equip- equipment ment switches switches ON OFF (No load) Pump discharge 1 pressure Almost same LS valve output Approx. q (1): Front pump discharge pressure pickup plug q (2): Rear pump discharge pressure pickup plug 34 BR380JG-1E0 .8 measure the pump discharge pressure MPa {600 kg/cm2}. remove the measuring tools and return the removed parts. a Use the oil pressure gauges of 58. (3). Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure (actuator load pressure) simultaneously and calculate the differ- ence between them. and LS valve output pressure (servo pis- ton inlet pressure) simultaneously under the condition in the following table. 3/5) 5) After finishing measurement. 1) Remove oil pressure pickup plugs (1). pressure gauge [1] of hydraulic tester M1. and (4). 0.

2) Install nipple M2 and connect it to differen.9 ± 1. BR380JG-1E0 35 . remove the by installing the same gauge to the measuring tools and return the removed pickup plugs alternately. 4) While running the engine at high idle tial pressure gauge M3 or the oil pressure under the condition shown in the table. q (4): Rear LS pressure pickup plug 3) Run the engine.0} ferential pressure is about 3. Connect the pump discharge pres. a Calculation of LS differential pressure: sure to the high pressure side (back LS differential pressure = Pump dis- side) and connect the LS pressure to charge pressure – LS pressure the low pressure side (lower side). Since the dif.9 MPa {40 kg/cm2} at maximum.98 MPa {10 kg/cm2}. measure it 5) After finishing measurement. {10 ± 1. connect it (MPa {kg/cm2}) to a battery. LS differential Since the differential pressure gauge All work equipment switches pressure needs a 12V power source.30 Testing and adjusting SEN02303-00 q (3): Front LS pressure pickup plug q The figure shows the LS pressure side. gauge [1] of hydraulic tester M1. 3.8 MPa {600 kg/cm2} having the unit of 0.1 ON (No load) 0.0 a When using oil pressure gauge (in M1): OFF {40 ± 10} Use the oil pressure gauge of 58. measure the pump discharge pressure a When using differential pressure gauge and LS pressure (actuator load pressure) M3: simultaneously. parts. q The figure shows the pump discharge pressure side.98 ± 0.

Measuring LS-EPC valve output pressure Adjusting 1) Remove oil pressure pickup plug (5). 4. 13. the differential pressure is decreased. Turn adjustment screw (9) to adjust the differ- ential pressure. Adjusting LS valve a If the LS differential pressure is abnormal. 30 kg/cm2} 5) After finishing measurement. the LS-EPC valve is normal.6 Nm {5 – 7 kgm} the work equipment switches. loosen lock- nut (8). 36 BR380JG-1E0 . a Measuring condition and method of judgment: If the output pressures are in the following range.9 MPa OFF {Approx. All work equipment Output pressure switches Approx. and mea- sure the output pressure. While fixing adjustment screw (9). remove the measuring tools and return the removed parts. q Turned to the left. a Quantity of adjustment (LS differential pressure) per turn of adjustment screw: Approx. adjust the LS valve according to the following procedure.3 kg/cm2} 3) Start the engine.3 MPa {Approx. After finishing adjustment. a Use the oil pressure gauges of 5. q (6): Front pump LS valve q (7): Rear pump LS valve 2) Install nipple M2 and connect it to oil pres- sure gauge of hydraulic tester M1. 2. 1. the differential pressure is increased. 3 Locknut: 49 – 68. a If the adjustment screw is q Turned to the right. Turn OFF all nut (8).9 MPa {60 kg/cm2}. 1. check again that the LS differential pressure is normal according to the above described measurement procedure. While fixing adjustment screw (9). 3. 2.SEN02303-00 30 Testing and adjusting 3. tighten lock- 4) Run the engine at high idle.

9 MPa {60 9 Crusher reverse EPC solenoid valve kg/cm2}. q Hydraulic oil temperature: Within operating range 1.30 Testing and adjusting SEN02303-00 Measuring solenoid valve output pressure 1 a Measuring tools for solenoid valve output pres- sure Symbol Part No. Solenoid valve to be measured 1 Travel junction/2-stage relief solenoid valve a The hoses to be measured are installed to 2 Magnetic separator solenoid valve the right side of the main valve. Install adapter N2 and connect the discon- 5 Travel lock EPC solenoid valve nected hose again. Install nipple [1] of hydraulic tester N1 and con- 7 Feeder forward EPC solenoid valve nect it to oil pressure gauge [2]. 8 Crusher forward EPC solenoid valve a Use the oil pressure gauge of 5. Start the engine. BR380JG-1E0 37 . k Stop the engine and loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. 6 Accessory EPC solenoid valve 3. No. a Measure the solenoid valve output pressure under the following condition. Disconnect outlet hoses (1) – (15) of the sole- noid valves to be measured. Part name 799-101-5002 Hydraulic tester 1 N 790-261-1204 Digital hydraulic tester 2 799-401-3100 Adapter (Size 02) k Stop the machine on a level ground. check that the basic pressure of the control circuit is normal. Radio control left travel forward solenoid 10 valve (if equipped) Radio control left travel reverse solenoid 11 valve (if equipped) Radio control right travel forward solenoid 12 valve (if equipped) Radio control right travel reverse solenoid 13 valve (if equipped) 14 Vibratory sieve solenoid valve (if equipped) Secondary belt conveyor solenoid valve (if 15 equipped) 4. a Before measuring the solenoid valve output pressure. 3 Side conveyor solenoid valve 4 Lock cylinder reset solenoid valve 2.

2.6 ON Operating condition Operation (Signal is ON for conveyor in {26} operation when primary con- When travel steering signal is veyor ON switch is pressed) OFF 0 {0} ON In travel ON mode When travel steering signal is OFF OFF Operation table of crusher forward EPC valve When crusher clearance ON Output: Left In testing reducing switch is ON Operating condition MPa {kg/cm2} mode When crusher clearance OFF Approx 2. forward.9 reducing switch is OFF Crusher forward signal ON {30} (Crusher speed: MAX) OFF 0 {0} Operation table of side conveyor solenoid valve Operating condition Operation Operation table of radio control travel (Right. see “Special functions of machine monitor”). Side conveyor signal left.9 MPa {30 kg/cm2} ON (Excitation) (Exclude EPC solenoid ON during operation) valve) 6. After finishing measurement. 2. remove the mea. Operation table of accessory EPC valve suring tools and return the removed parts. operate the control Operation table of magnetic separator solenoid levers and switches to turn the solenoid valve valve ON or OFF. Operation table of lock cylinder reset solenoid a If the output pressure is as follows.5} (Feeder speed: MAX) OFF 0 {0} Inspection mode 0 {0} 38 BR380JG-1E0 .SEN02303-00 30 Testing and adjusting 5. see the operation Magnetic separator signal ON ON table of each solenoid valve.9 {30} Operating condition Hi MPa {kg/cm2} Conveyor Travel top mode Travel speed Approx 1. Output Operating condition pressure Operation table of travel junction/2-stage relief MPa {kg/cm2} solenoid valve Primary conveyor signal Approx. the valve solenoid valve is normal.8 Feeder forward signal ON Min. and measure the oil pressure. Run the engine at high idle.0 {20} position Lo {18. (Magnetic separator ON switch a The operating condition of the solenoid is pressed and magnetic sepa- rator operating signal is ON) OFF OFF valve can be checked with the monitoring function of the machine monitor (For details. and reverse) solenoid valve ON ON (Side conveyor ON switch is (if equipped) pressed and side conveyor operating signal is ON) OFF OFF Operating condition Operation Radio control travel signal ON ON (Signal is ON for radio control Operation table of travel lock EPC solenoid valve travel in operation) OFF OFF Output Operating condition pressure Operation table of feeder forward EPC valve MPa {kg/cm2} Travel speed Output: Left Approx 2. a For the conditions for turning the solenoid Operating condition Operation valve ON and OFF. Operating condition Operation Solenoid valve Output pressure Lock cylinder reset signal (Crusher clearance increase or ON ON OFF 0 MPa {0 kg/cm2} decrease switch is pressed in (Demagnetization) inspection mode and signal is OFF OFF 2.

2.30 Testing and adjusting SEN02303-00 Operation table of crusher reverse EPC valve Output: Left Operating condition MPa {kg/cm2} Approx. OFF OFF nal is ON) BR380JG-1E0 39 .9 Crusher reverse signal ON {30} (Crusher speed: MAX) OFF 0 {0} Operation table of vibratory sieve solenoid valve (if equipped) Operating condition Operation Vibratory sieve signal ON ON (Vibratory sieve ON switch is pressed and vibratory sieve operating signal is ON) OFF OFF Operation table of secondary belt conveyor solenoid valve (if equipped) Operating condition Operation Secondary belt conveyor signal (Secondary belt conveyor ON ON ON switch is pressed and second- ary belt conveyor operating sig.

Run the engine at high idle and measure the oil pressure with the control lever in neutral and moved to the stroke end. the PPC valve is normal. Output pressure Operation of lever MPa {kg/cm2} Neutral 0 {0} Stroke end Approx. a Before measuring the PPC valve output pres- sure. q Hydraulic oil temperature: Within operat- ing range 4. Open cover (1). a If the output pressure is as follows. 1. 2. After finishing measurement.9 {30} 6.5) 3 07002-11423 O-ring k Stop the machine on a level ground.SEN02303-00 30 Testing and adjusting Measuring PPC valve output 3. Part name 799-101-5002 Hydraulic tester 1 790-261-1204 Digital hydraulic tester P 2 799-101-5230 Nipple (14 × 1. Remove PPC oil pressure switches (2) and (3) of the circuits to be measured.9 MPa {60 a Measuring tools for PPC valve output pressure kg/cm2}. a Use the oil pressure gauge of 5. Install nipple P2 and connect it to oil pressure pressure 1 gauge [1] of hydraulic tester P1. a Measure the PPC valve output pressure under the following condition. 2. 5. remove the mea- suring tools and return the removed parts. check that the basic pressure of the con- trol circuit is normal. Symbol Part No. q Switch (2): Travel signal (Black) q Switch (3): Steering signal (Red) 40 BR380JG-1E0 . Start the engine.

After finishing measurement. a Use the following part to block the hose side. Accordingly. check a Measuring tools for oil leakage Symbol Part No. a Measure several times. 2. k Wrong operation of the lever can cause Commercially Q Measuring cylinder available an accident. condition. return the and stop the engine. Disconnect drain hose (1) of the travel motor and block the hose side with a plug. relieve the travel circuit. k Put pin [1] between the sprocket and removed parts. Run the engine at high idle. Remove the travel motor cover. 07376-70422 (Plug #04) BR380JG-1E0 41 . make signs a Measure the oil leakage under the following and checks securely. 3. moving the motor Measuring oil leakage from travel motor a little (changing the position of the valve plate and cylinder and that of the cylinder 1. and measure the oil leakage. and piston) each time. k Before operating the travel lever. onds after relieving is started and mea- ing range sure for 1 minute. a Start measuring the oil leakage 30 sec- q Hydraulic oil temperature: Within operat. Run the engine.30 Testing and adjusting SEN02303-00 Measuring oil leakage 1 4. 5. track frame to lock the travel mecha- nism securely. Part name the position and locking direction of the locked sprocket again. lock the travel mechanism.

1. tighten air bleeder (1).SEN02303-00 30 Testing and adjusting Bleeding air from each part 1 Air bleeding procedure Air bleeding item 1 2 3 4 5 6 7 Bleeding Bleeding Checking Bleeding Bleeding Bleeding air from air from oil level air from Starting air from air from grizzly belt con. Bleeding air from hydraulic pump 1) Loosen air bleeder (1) and check that oil oozes out through the air bleeder. 3 Air bleeder: 7.8 – 9. and start- hydraulic engine crusher travel feeder veyor ing opera- pump motor motor motor motor tion • Replacing Contents ofhydraulic work oil q q q q q o q • Cleaning strainer (See note) • Replacing return filter element q o o o o q • Replacing and repairing hydrau- lic pump q q q q q o q • Removing suction piping • Replacing and repairing control valve q q q q o q • Removing control valve piping • Replacing and repairing grizzly feeder motor q q o o o q • Removing grizzly feeder motor piping • Replacing and repairing crusher motor q o q o o q • Removing crusher motor piping • Replacing and repairing travel motor q o o q o q • Removing travel motor piping • Replacing and repairing belt conveyor motor q o o o q q • Removing belt conveyor motor piping Note: Bleed air from the travel motor only when the oil in the motor cases is drained.0 kgm} a Do not use an impact wrench to tighten the air bleeder. 42 BR380JG-1E0 .8 Nm {0.8 – 1. 2) After the oil oozes out.

3.0 kgm} 2. tighten air bleeder (2). stop the 3) Leave bleeder (1) loosened.5 – 35.3 Nm {2. the motor case with oil. disconnect engine.30 Testing and adjusting SEN02303-00 a If the oil does not flow out of the air bleeder: 2) If the oil does not flow out. Bleeding air from grizzly feeder motor 3 Air bleeder: 1) Run the engine at low idle. tighten the drain hose. tighten the drain hose. Bleeding air from crusher motor 1) Run the engine at low idle. and fill drain hose (2). stop the engine temporarily and motor slowly. loosen drain 27. and the automatic warm-up opera.8 – 1. and fill 1. and remove elbow (3). loosen drain hose (1). (2). reset the automatic warm-up operation with the fuel control dial (Set the starting 5. stop the When running the engine after performing step engine. control dial in the MAX position for 3 sec. 3 Bleeder: 9JH05861 7. 4) Run the engine at low idle to rotate the 5) Install elbow (3) and connect drain hose motor slowly. a If the engine coolant temperature is low 3) After bleeding air. and check that oil flows out of the drain port.6 kgm} hose (1). tion is reset). BR380JG-1E0 43 . keep its speed at low idle for 10 minutes. until it flows out of the bleeder (1). Bleeding air from travel motor switch in the ON position and hold the fuel 1) Run the engine at low idle. and check that oil flows out of the drain port.8 – 3.8 Nm {0. disconnect the drain hose. 4. 4) Add oil through the elbow mounting hole 3) After bleeding air. disconnect the drain hose. the motor case with oil.8 – 9. oozes out through the air bleeder. 2) Loosen air bleeder (2) and check that oil onds. 3) After the oil oozes out. 6) Tighten air bleeder (1). Starting engine 2) If the oil does not flow out. and the automatic warm-up operation is 4) Run the engine at low idle to rotate the started.

tighten the drain hose. loosen drain hose (1). stop the engine. 3) After bleeding air. 2) If the oil does not flow out. 4) Run the engine at low idle to rotate the motor slowly. and fill the motor case with hydraulic oil. Bleeding air from conveyor motor 1) Run the engine at low idle. 44 BR380JG-1E0 .SEN02303-00 30 Testing and adjusting 6. and check that oil flows out of the drain hose.

raise the primary belt conveyor and hitch mount hook (1) in fixing position for travel (a) securely. 2. a Install an oil pressure gauge and measure the pump discharge pressure during the measurement of the travel deviation. Make run up for 10 m.30 Testing and adjusting SEN02303-00 Testing travel deviation 1 a When traveling on flat ground 1. a To set the machine in the travel posture. a Run the engine at full throttle for measure- ment. BR380JG-1E0 45 . and then measure the travel deviation in 20 m. Set the machine in the travel posture.

SEN02303-00 30 Testing and adjusting Adjusting mirrors 1 46 BR380JG-1E0 .

adjust so that it is possible to see any persons at the front left and right edges of the machine (both sides of the conveyor) or objects of a height of 1 m and diameter of 30 cm.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. Adjusting mirrors (b1) and (c1) Loosen bolts (2) and (3) of the mirrors and adjust the mirrors so that the operator can see a person (an object 1 m high and 30 cm in diameter) stand- ing in the left side of the machine which is a blind corner from the operator's seat. q Mirror (a1) : Hatched part (a2) must be seen q Mirror (b1) : Hatched part (b2) must be seen q Mirror (c1) : Hatched part (c2) must be seen BR380JG-1E0 47 . Adjusting view Adjust each mirror so that the operator can see the following ranges. a When installing the mirror.

SEN02303-00 BR380JG-1E0 Mobile crusher Form No. SEN02303-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01) 48 .

....... SEN02304-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting 1 Testing and adjusting............................................ Part 2 Special functions of machine monitor . 2 BR380JG-1E0 1 ...........................................................

SEN02304-00 30 Testing and adjusting Special functions of machine monitor 1 [1]: Figure input switch 1 [ ]: Return switch [2]: Figure input switch 2 [E]: Upward move switch [3]: Figure input switch 3 [R]: Downward move switch [4]: Figure input switch 4 [ ]: Input confirmation switch [5]: Figure input switch 5 [6]: Figure input switch 6 [7]: Figure input switch 7 [8]: Figure input switch 8 [9]: Figure input switch 9 [0]: Figure input switch 0 2 BR380JG-1E0 .

30 Testing and adjusting SEN02304-00 Ordinary functions and special functions of machine monitor The machine monitor has the ordinary function and special functions and displays information of various types on the multi-display. ment [07] Initialization of clearance poten- 12 tion tiometer 13 Check of maintenance information function Option registration 14 Service meter display function 27 Function of cylinder cut-out operation [08] 15 Caution generation display function 28 Function of no injection cranking [09] 16 Function of displaying user code 29 Function of crusher clearance record [10] Function of displaying error code and failure 17 30 Function of lock cylinder slip record [11] code 18 Function of monitoring emergency stop 19 Function of displaying conveyor location BR380JG-1E0 3 . Adjustment of crusher speed 26 Display's brightness and contrast adjusting func. Operator menu Service menu 1 Password input and setting function 20 Function of monitoring [01] 2 KOMATSU logo display screen Function of abnor. q Ordinary functions: Operator menu The functions in this mode are displayed ordinarily. Display and setting of these functions are available from the operator's switch operations. q Special functions: Service menu The functions in this mode are not ordinarily displayed. Some items are displayed automatically and others are displayed through the switch operations according to the internal setting of the machine monitor. This mode is used for special setting. Display and setting of these functions are avail- able from the serviceman's operations of the special switches. testing. Electrical systems 21 3 Check before starting function mality record [02] Mechanical systems 4 Maintenance display function 22 Function of maintenance record [03] 5 Caution items display function 23 Function of maintenance mode change [04] 6 Function of travel mode 24 Function of phone number entry [05] 7 Function of working mode Function of default Language 25 8 Function of testing mode [06] Unit 9 Function of setting feeder speed Pump absorption torque 10 Function of setting crusher speed Adjustment of feeder speed 11 Function of setting crusher load Function of adjust. adjusting or troubleshooting.

For details on the contents and Check before starting screen is displayed for 2 operation steps of each menu. a maintenance mark appears for 30 seconds pointing the oil or filter whose specified maintenance time has already expired or going to expire soon. 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. a Above display is available only when the password function is selected. function and mainte- nance standard” in this shop manual. Password input and setting function Password input screen is displayed as the starting switch is turned ON. 4 BR380JG-1E0 . 1. refer to the seconds succeeding to display of KOMATSU “Operation and maintenance manual” or the logo. Check before starting function operator menu. a Above display is available only when the maintenance function is selected.SEN02304-00 30 Testing and adjusting Operation of operator menu and display (outline) a This section introduces only the outline of the 3. Maintenance display function Succeeding to display of the check before starting screen. 2. 4. chapter of “Structure.

the appears pointing a check before starting item operator can check the operating condition of on which a problem was found. Function of working mode Succeeding display of the check before start. an ap plica ble caution m ark selector switch of the main control box. q If the hydraulic oil temperature is abnor- mally high. each work equipment unit and specify the work equipment that is overloaded or loaded abnor- mally. Function of travel mode If the travel mode is selected with the mode selector switch of the main control box. the travel mode is selected forcibly. the Hi. Caution items display function 7. or Auto (A) selected with the crusher clearance adjustment mode selector switch of the main control box. the screen changes according to the position of Manual (M). Semiauto (S). 6. 8.30 Testing and adjusting SEN02304-00 5. Function of testing mode If the testing mode is selected with the mode selector switch of the main control box. the travel mode is selected forcibly. then the operator can adjust the crusher clearance in each mode. q If the hydraulic oil temperature is abnor- mally high. Mi or Lo speed is displayed according to the setting of the travel speed selector switch of the upper control box. If the working mode is selected with the mode ing scre en. BR380JG-1E0 5 .

Display's brightness and contrast adjusting The operator can adjust the crusher speed with function the crusher speed setting switch of the The screen adjustment switches allow adjust- machine monitor. Function of setting feeder speed 11. ing the display brightness and contrast. A: Speed is minimum B: Speed is maximum 6 BR380JG-1E0 . A: Feeding speed is minimum A: Load is set to minimum. Function of setting crusher speed 12.SEN02304-00 30 Testing and adjusting 9. 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. monitor. 10. B: Feeding speed is maximum B: Load is set to maximum.

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). nance. (Simultaneous operation) BR380JG-1E0 7 . is on the screen. smaller size until the trouble is eliminated. an applica- ble user code is automatically displayed depending on the seriousness of the trouble in 14. Caution generation display function The maintenance switch allows checking If a caution is warned for a caution item. switch the failure code q Switch operation: [ ] + [E] display screen (see Item 17). 16. User code display function If a trouble occurs on the machine. Check of maintenance information function 15.30 Testing and adjusting SEN02304-00 13. It also allows resetting after the mainte. Service meter display function order to alert the operator to take an appropri- Display of the service meter alone becomes ate action. available by operating the following switches a Operating any switch while an user code after the starting switch is turned OFF. a Setting and resetting of the maintenance function as well as setting of the mainte- nance time is done from the service menu.

error 8 BR380JG-1E0 .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 E02 PC-EPC valve error immediately. Engine sensor (coolant temperature. Operate machine to a safe posture and have inspection car- E14 Throttle system error ried out immediately. but have inspection carried out E15 temperature and oil pressure) system immediately. error (engine stopped) Engine controller system error Operate machine to a safe posture and have inspection car- E11 (Output reduced to protect engine) ried out immediately. error Network error Operate machine to a safe posture and have inspection car- E0E Pump controller solenoid power source ried out immediately. Engine controller power source error Engine controller drive system circuit E10 Have inspection carried out immediately. fuel Operations are possible.

(2) Telephone symbol mark BR380JG-1E0 9 . q Switching operation: ( ) E02 a The telephone mark and telephone num- ber are displayed only when the telephone number is registered to the machine moni- BJZ13828 tor. Registration. a For detailed information of failure codes. correction or deletion of a a The screen display sequentially changes telephone number is done from the ser- as shown below.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. (1) Failure code see the “Failure code table”. sequentially displays the failure code. the phone mark (if registered) and phone number (if registered). vice menu.

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 W/E Electrical system — 7RC2KA Disconnection in conveyor OFF switch W/E Electrical system — 7RC5KB Short circuit in feeder ON switch W/E Electrical system — 7RD2KB Short circuit in conveyor reverse relay W/E Electrical system — 7RD2KZ Disconnection or short circuit in conveyor reverse relay W/E Electrical system — 7RE1KB Short circuit in crusher ON switch W/E Electrical system — 7RE2KA Disconnection in crusher OFF switch W/E Electrical system — 7RE6KB Short circuit in muck conveyor ON switch W/E Electrical system — 7RE7KA Disconnection in muck conveyor OFF switch W/E Electrical system — 7RE8KB Short circuit in magnetic separator ON switch W/E Electrical system — 7RE9KA Disconnection in magnetic separator OFF switch W/E Electrical system — 7REAKB Short circuit in accessory Input circuit W/E Electrical system — 7REDMA Abnormality in conveyor pressure sensor W/E Electrical system — 7REEMA Abnormality in muck conveyor pressure sensor W/E Electrical system — 7RENKZ Abnormality in clearance potentiometer W/E Electrical system — 7REPKA Disconnection in feeder OFF switch W/E Electrical system — 7RESKB Short circuit in one-touch start switch W/E Electrical system — 7RETKA Disconnection in one-touch stop switch W/E Electrical system — 7RF2KA Disconnection in crusher forward EPC solenoid W/E Electrical system — 7RF2KB Short circuit in crusher forward EPC solenoid W/E Electrical system — 7RF2KY Short circuit in crusher forward EPC solenoid W/E Electrical system — 7RF3KA Disconnection in crusher reverse EPC solenoid W/E Electrical system — 7RF3KB Short circuit in crusher reverse EPC solenoid W/E Electrical system — 7RF3KY Short circuit in crusher reverse EPC solenoid W/E Electrical system — 7RF4KA Disconnection in feeder forward EPC solenoid W/E Electrical system — 7RF4KB Short circuit in feeder forward EPC solenoid W/E Electrical system — 7RF4KY Short circuit in feeder forward EPC solenoid W/E Electrical system — 7RFAKY Short circuit in engine stop relay W/E Electrical system — 7RFAKZ Disconnection or short circuit in engine stop relay W/E Electrical system — 7RFBKB Short circuit in muck conveyor solenoid W/E Electrical system — 7RFBKZ Disconnection or short circuit in muck conveyor solenoid W/E Electrical system — 7RFCKA Disconnection in magnetic separator solenoid W/E Electrical system — 7RFCKB Short circuit in magnetic separator solenoid W/E Electrical system — 7RFCKY Short circuit in magnetic separator solenoid W/E Electrical system — 7RFHKB Short circuit in conveyor forward relay W/E Electrical system — 7RFHKY Short circuit in conveyor forward relay W/E Electrical system — 7RFKKB Short circuit in lock cylinder pull relay W/E Electrical system — 7RFKKY Short circuit in lock cylinder pull relay W/E Electrical system — 7RFLKA Disconnection in accessory EPC solenoid W/E Electrical system — 7RFLKB Short circuit in accessory EPC solenoid W/E Electrical system — 7RFLKY Short circuit in accessory EPC solenoid W/E Electrical system — 7RFMKY Short circuit in abnormal pressure relay W/E Electrical system — 7RFMKZ Disconnection or short circuit in abnormal pressure relay W/E Electrical system — 7RFNKA Disconnection in lock cylinder unlock solenoid valve W/E Electrical system — 7RFNKB Short circuit in lock cylinder unlock solenoid valve W/E Electrical system — 7RFNKY Short circuit in lock cylinder unlock solenoid valve W/E Electrical system — 7RFPKB Short circuit in lock cylinder push relay W/E Electrical system — 7RFPKY Short circuit in lock cylinder push relay W/E Electrical system — 7RGAMA Abnormality in 2nd conveyor pressure sensor W/E Electrical system — 7RJAKA Disconnection in travel lock EPC solenoid valve W/E Electrical system 10 BR380JG-1E0 .

1 q ENG Electrical system E11 CA323 Disconnection or short circuit in injector No.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 W/E Electrical system — 7RJAKY Short circuit in travel lock EPC solenoid valve W/E Electrical system — 7RJMMW Lock cylinder slipping W/E Mechanical system — 7RJNMA Abnormality in vibration screen pressure sensor W/E Electrical system — 7RJPKB Short circuit in radio control work-mode switch W/E Electrical system — 7RJQKB Short circuit in radio control travel-mode switch W/E Electrical system — 7RJRKB Short circuit on travel signal W/E Electrical system — 7RJSMA Abnormality in magnetic separator pressure sensor W/E Electrical system — AA10NX Air cleaner Clogging MON Mechanical system — AB00KE Charge voltage too low MON Mechanical system — B@BAZG Engine oil pressure too low e ENG Mechanical system — B@BAZK Engine oil level reduction MON Mechanical system — B@BCNS Radiator coolant overheat e ENG Mechanical system — B@BCZK Radiator coolant level reduction e MON Mechanical system — B@HANS Hydraulic oil overheat e MON Mechanical system E10 CA111 Abnormality in engine controller q ENG Electrical system E10 CA115 Abnormality in engine NE and Bkup speed sensors q ENG Electrical system E11 CA122 Charge pressure sensor too high q ENG Electrical system E11 CA123 Charge pressure sensor too low q ENG Electrical system E14 CA131 Throttle sensor too high q ENG Electrical system E14 CA132 Throttle sensor too low q ENG Electrical system E15 CA144 Coolant temperature sensor too high q ENG Electrical system E15 CA145 Coolant temperature sensor too low q ENG Electrical system E15 CA153 Charge temperature sensor too high q ENG Electrical system E15 CA154 Charge temperature sensor too low q ENG Electrical system E11 CA155 Charge temperature too high and engine speed derated q ENG Electrical system E15 CA187 Sensor power source 2 too low q ENG Electrical system E11 CA221 Ambient pressure sensor too high q ENG Electrical system E11 CA222 Ambient pressure sensor too low q ENG Electrical system E15 CA227 Sensor power source 2 too high q ENG Electrical system — CA234 Engine overspeed q ENG Mechanical system E15 CA238 Abnormal power source for Ne speed sensor q ENG Electrical system E10 CA271 Short circuit in fuel pump actuator q ENG Electrical system E10 CA272 Disconnection in fuel pump actuator q ENG Electrical system E11 CA322 Disconnection or short circuit in injector No.2 q ENG Electrical system E11 CA332 Disconnection or short circuit in injector No.3 q ENG Electrical system E11 CA325 Disconnection or short circuit in injector No.4 q ENG Electrical system E10 CA342 Abnormality in engine controller data consistency q ENG Electrical system E10 CA351 Abnormality in injector drive circuit q ENG Electrical system E15 CA352 Sensor power source 1 too low q ENG Electrical system E15 CA386 Sensor power source 1 too high q ENG Electrical system E15 CA428 Water detection sensor too high q ENG Electrical system E15 CA429 Water detection sensor too low q ENG Electrical system E15 CA435 Abnormality in engine oil pressure switch q ENG Electrical system E10 CA441 Power source voltage too low q ENG Electrical system E10 CA442 Power source voltage too high q ENG Electrical system E11 CA449 Common rail pressure sensor too high (2) q ENG Electrical system E11 CA451 Common rail pressure sensor too high q ENG Electrical system E11 CA452 Common rail pressure sensor too low q ENG Electrical system BR380JG-1E0 11 .5 q ENG Electrical system E11 CA324 Disconnection or short circuit in injector No.6 q ENG Electrical system E11 CA331 Disconnection or short circuit in injector No.

SEN02304-00 30 Testing and adjusting User Failure Alarm Applicable History Failure contents code code buzzer equipment classification E11 CA488 Charge temperature too high and torque derated q ENG Electrical system E15 CA553 Common rail pressure sensor too high (1) q ENG Electrical system E15 CA559 Supply pump no pressure q ENG Electrical system E15 CA689 Abnormality in engine Ne speed sensor q ENG Electrical system E15 CA731 Abnormal phase in engine Bkup speed sensor q ENG Electrical system E10 CA757 Loss of all engine controller data q ENG Electrical system E15 CA778 Abnormality in engine Bkup speed sensor q ENG Electrical system E0E CA1633 CAN communication error (engine controller) q ENG Electrical system E14 CA2185 Throttle pedal sensor power source too high q ENG Electrical system E14 CA2186 Throttle pedal sensor power source too low q ENG Electrical system E11 CA2249 Supply pump no pressure (2) q ENG Electrical system E11 CA2311 Abnormal resistance in pump regular valve q ENG Electrical system E15 CA2555 Disconnection in air intake heater relay q ENG Electrical system E15 CA2556 Short circuit in air intake heater relay q ENG Electrical system — D162KY Short circuit in horn relay W/E Electrical system — D162KZ Disconnection or short circuit in horn relay W/E Electrical system E0E DA22KK Solenoid power source too low q PUMP Electrical system — DA25KP Abnormality in pressure sensor power source PUMP Electrical system E0E DA2RMC CAN communication error (pump controller) q PUMP Electrical system — DA2SKQ Abnormality in model code input PUMP Electrical system E0E DAFRMC CAN communication error (monitor controller) q MON Electrical system — DDA6KA Disconnection in engine stop switch W/E Electrical system — DGH2KB Short circuit in hydraulic oil temperature sensor MON Electrical system — DHPAMA Abnormality in F pump pressure sensor PUMP Electrical system — DHPBMA Abnormality in R pump pressure sensor PUMP Electrical system — DUB0KY Short circuit in beacon solid state relay W/E Electrical system — DUB0KZ Disconnection or short circuit in beacon solid state relay W/E Electrical system E02 DXA0KA Disconnection in PC-EPC Solenoid q PUMP Electrical system E02 DXA0KB Short circuit in PC-EPC Solenoid q PUMP Electrical system E02 DXA0KY Short circuit in PC-EPC Solenoid q PUMP Electrical system — DXE0KA Disconnection in LS-EPC solenoid PUMP Electrical system — DXE0KB Short circuit in LS-EPC solenoid PUMP Electrical system — DXE0KY Short circuit in LS-EPC solenoid PUMP Electrical system 12 BR380JG-1E0 .

a User code Attached : If the failure code is detected. the machine monitor does not notify the operator of the abnormality. PUMP: The pump controller is in charge of detection of abnormality. W/E: The work equipment and pump controller is in charge of detection of abnormality. a Category of record Mechanical system: Abnormality information is recorded in the mechanical system abnormality record. ENG: The engine controller is in charge of detection of abnormality. failure code. Electrical system: Abnormality information is recorded in the electrical system abnormality record. and telephone No. the buzzer sounds (The operator can stop the buzzer with the alarm buzzer cancel switch). a Alarm buzzer q : When occurrence of an error is notified to the operator. e: Since the caution monitor is also turned ON. BR380JG-1E0 13 . Not attached: Even if the failure code is detected.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). the user code. a Component in charge MON: The machine monitor is in charge of detection of abnormality. (if regis- tered) are displayed on the ordinary screen to notify the operator of the abnormality. its function sounds the buzzer.

the machine cannot travel. mode selector switch of the main control q The whole work equipment stops and box. q The whole work equipment and engine stop and the horn sounds. 2) Conveyor position display in travel mode If the travel mode is selected with the mode selector switch of the main control box. Function for conveyor position display 1) Warning for turning emergency stop 1) 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.SEN02304-00 30 Testing and adjusting 18. 14 BR380JG-1E0 . At this time. the work equipment can operate. At this time. the color of mode monitor (b) changes according to the conveyor posi- tion. the color of mode monitor (a) the horn sounds. q When conveyor position is “Middle” or “Lower” Mode monitor (a) becomes yellow. q When conveyor position is “Lower” Mode monitor (b) becomes red. At this time. the machine can travel. Function of monitoring emergency stop 19. q When conveyor position is “Upper” Mode monitor (a) becomes red. changes according to the conveyor posi- tion. 2) Warning for turning engine stop switch ON When the engine stop switch installed to the upper operation box is depressed. At this time. the whole work equipment stops. q When conveyor position is “Middle” or “Upper” Mode monitor (b) becomes yellow.

30 Testing and adjusting SEN02304-00 Service menu operation and display 3) Displaying menu screen The display is changed to the initial display of Switching to service menu Service Menu program. Select an appropriate a When using the service menu. q Press [ ] switch (enables every screen). Service menu 00 Return (Ends the service menu) 01 Monitoring 02 Abnormality record 03 Maintenance record 04 Maintenance mode change 2) Switch operation Do the following switch operation. 1) Confirmation of display Make sure that the conventional display is turned on. screen through the following special operation. 05 Phone number entry q Switch operation: 06 Default [E] + [1] o [2] o [3] 07 Adjustment (Enter the numbers while holding E down) 08 Cylinder cut out 09 No injection cranking 10 Crusher clearance record 11 Lock cylinder slip record 4) Ending the menu and function When ending the operation from the service menu screen or respective menu screens. q When “RETURN” switch is displayed. q When “Return” menu is displayed. a Changing to Service Menu is usually avail- able only from this conventional display. No. switch the item from among the menu. press the applicable switch. select the menu and press [ ] switch. BR380JG-1E0 15 . select either of the following operations.

If truly real time monitoring is required. to the monitoring information screen. If you press [R] switch again in this condi- tion. confirm the monitored informa- tion operating the machine. Thus the Select “01 Monitoring” in the initial display number of selected items can impact of Service Menu and depress [ ] switch. etc. switch sensor actuators on various machine a When you have registered all the parts. move to the monitoring information screen through any of the following switch operations after the registra- tion work has been completed. q [Hold down [ ] switch (for about 3 seconds).. Monitoring [01] function q Select menu “99999” and press The machine monitor monitors signals from the [ ] switch. 3) Operation for monitoring As the monitoring information screen is displayed. a For details on the monitoring items. display unit. the max. number can be less than four) a In case of monitoring 1 to 3 items. 16 BR380JG-1E0 . refer to the “Monitor- ing Items table”. screen will be automatically switched tions. a Monitored information are transmitted 1) Menu selection via communication circuits. the monitored information through following opera. It allows displaying and checking the items that can be registered. reduce the selected items to the minimum.SEN02304-00 30 Testing and adjusting 20. the currently held information will be released. the communication speed. 2) Setting a monitoring item Select and register an item to be moni- tored through the following switch opera- tion. q [E] switch: Selection q [R] switch: Selection q [ ] switch: Registration 4) Monitored information holding function You can hold every monitored information by pressing [E] while monitoring is contin- ued. a A monitoring item can be set from 1 to 4 at maximum (Depending upon the selected item.

Curr. mA mA mA PUMP 03200 Battery Voltage V V V PUMP 03203 Battery Power Supply V V V ENG 04300 Battery Charge Vol. V V V MON 37401 Ambient Press Sens Volt V V V ENG 18501 Charge Temp Sens Volt V V V ENG 36501 Charge Press Sens Volt V V V ENG 36401 Rail Pressure Sens Volt V V V ENG 17500 Engine Power Mode — — — ENG 31701 Throttle Position % % % ENG 31706 Final Throttle Position % % % ENG 18600 Inject Fueling Command mg/st mg/st mg/st ENG 36200 Rail Press Command MPa kg/cm2 psi ENG 36300 Injection Timing Command CA CA CA ENG BR380JG-1E0 17 . V V V MON 2 36400 Rail Pressure MPa kg/cm psi ENG 2 37400 Ambient Pressure kPa kg/cm psi ENG 18500 Charge Temperature °C °C °F ENG 2 36500 Boost Pressure kPa kg/cm psi ENG 36700 Engine Torque Ratio % % % ENG 18700 Engine Output Torque Nm Nm kgfm ENG 03000 Fuel Dial Pos Sens Volt V V V ENG 04200 Fuel Level Sensor Vol. Pressure MPa kg/cm2 psi PUMP 2 25801 Vibrator Screen Pressure MPa kg/cm psi PUMP 04107 Coolant Temperature °C °C °F ENG 04401 Hydr. V V V MON 04105 Eng. Oil Temperature °C °C °F MON 01300 PC-EPC Sol. Speed Command r/min rpm rpm PUMP 2 01100 F Pump Pressure MPa kg/cm psi PUMP 01101 R Pump Pressure MPa kg/cm2 psi PUMP 2 24300 Conv. Curr. mA mA mA PUMP 25705 Acc. Temp. mA mA mA PUMP 25900 Crusher FWD EPC Curr. mA mA mA PUMP 24700 Feeder FWD EPC Curr. Pressure MPa kg/cm psi PUMP 2 24400 Muck Conv. mA mA mA PUMP 28801 Travel Lock EPC Curr. Sensor Vol. Lo V V V ENG 04402 Hydr. Vol. Pressure MPa kg/cm psi PUMP 24402 2nd Conv.30 Testing and adjusting SEN02304-00 Monitoring items table Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks No ISO meter inch charge 00200 Controller Model Select — — — PUMP 00201 Machine ID — — — ENG 01002 Engine speed r/min rpm rpm ENG 01601 2nd Eng.(F) mA mA mA PUMP 01500 LS-EPC Sol. EPC Curr. Water Temp. Pressure MPa kg/cm psi PUMP 2 24401 Mag. mA mA mA PUMP 26000 Crusher REV EPC Curr.

Sw. FWD/REV ON•OFF PUMP Machine Select1 PUMP Machine Select2 PUMP Emergency Sw. OFF Sw. PUMP Overfeed Sensor PUMP Radio Sel. PUMP MuckConv. MON Feeder OFF Sw. Input PUMP 18 BR380JG-1E0 . PUMP Conv.ON Sw. MON Feeder ON Sw. Speed Command % % % PUMP 13113 Main Pump Absorb Torque Nm kgm lbft PUMP Key Switch PUMP Start PUMP 04500 Monitor input 1 Preheat ON•OFF PUMP Light PUMP Rad. Work Sw.1 PUMP 25005 Switch Input 5 TravelSpeed Sw. ON Sw. Trv.OFF Sw. ON•OFF MON R-Ctrl. Hi Sensor PUMP Conv. PUMP MuckConv. PUMP Acc. PUMP TravelSpeed Sw. MON R-Ctrl. Travel PUMP 25002 Switch Input 2 Crush. Level PUMP Air cleaner MON 04501 Monitor Input 2 Eng. On Trv. PUMP 25006 Switch Input 6 Mag. ON Sw. Oil Level ON•OFF MON Battery Charge MON 18800 Water In Fuel — — — ENG Conv. MON 25001 Switch Input 1 R-Ctrl.2 ON•OFF PUMP Clearance F-auto PUMP Clearance Auto. ON•OFF PUMP Mag. MON Crusher ON Sw. PUMP 25003 Switch Input 3 ON•OFF 1-touch start Sw PUMP 1-touch stop Sw. MON 25000 Switch Input 0 ON•OFF Crusher OFF Sw.SEN02304-00 30 Testing and adjusting Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks No ISO meter inch charge 37300 Fuel Rate l/h l/h l/h ENG 01602 2nd Eng. Mi Sensor PUMP 25004 Switch Input 4 ON•OFF MuckConv. Work PUMP Mode Sel. Sen. PUMP Engine Stop Sw. Sw. MON Mode Sel. MON Conv. OFF Sw.

Cyl. Prog. BR380JG-1E0 19 . Sep. V V V PUMP 20216 ECM Build Version — — — ENG 20217 ECM CAL Data Ver — — — ENG 18900 ECM Internal Temp °C °C °F ENG 20400 ECM Serial No. Version — — — PUMP 20230 Pump Con. — — — ENG 20200 Monitor Prog. V V V PUMP 26200 Clearance Angle rad ° ° PUMP 26300 Last 0 Clearance Vol. P/N PUMP 20229 Pump Con. Unlock ON•OFF PUMP Muck Conv. or inch freely (Set it with “Unit selecting” in “Initialization” of the service menu). PUMP Eng. PUMP: The pump controller is in charge of detection of monitoring information. Prog. FWD Relay PUMP 25602 Relay Drive 1 ON•OFF Conv. PUMP Horn Relay PUMP Becon Relay PUMP Abno. a Unit The display unit can be set to ISO. ENG: The engine controller is in charge of detection of monitoring information. Version — — — MON 20227 Monitor Ass'y P/N MON 20402 Monitor Serial No MON 20212 Pump Con. Serial No PUMP a Entry order of items in table The items are entered in the order of display on the monitoring selection menu screen. a Component in charge MON: The machine monitor is in charge of detection of monitoring information. Sol. Ass'y P/N PUMP 20403 Pump Con. PUMP 25500 Solenoid Valve Lock. PUMP LockCyl.30 Testing and adjusting SEN02304-00 Unit (Initial setting ISO) Com- Code Monitoring item (Display on screen) pornent Remarks No ISO meter inch charge 02202 Switch Input 7 Key Switch(ACC) ON•OFF PUMP Mag.Push Re. “CA” in the display unit is an abbreviation for crankshaft angle. Sol.Press Relay PUMP 25601 Relay Drive 0 ON•OFF LockCyl. “mg/st” in the display unit is an abbreviation for milligram/stroke. meter. REV Relay PUMP 26100 Clearance Potentio Vol. Stop Relay PUMP Conv.Pull Re.

following operations. Pheomena: 2 digits) (4): Total number of occurrences (5): Service meter reading at first occur- rence a See the operator menu “Failure codes table”. Function of abnormality record [02] 3) 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.SEN02304-00 30 Testing and adjusting 21. the first occurrence tial display of Service Menu and depress (4): Contents of trouble [ ] switch. It allows display. records ing and checking the information through the (2): Failure code (Equipment: 4 digits. 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. a See the operator menu “Failure codes table”. (1): Record number (2): Contents of trouble (3): Failure code (Equipment: 4 digits. Phenomena: 2 digits) 1) Menu selection (3): Elapsed time on service meter from Select “02 Abnormality Record” in the ini. 2) Sub menu selection Select the sub menu from the abnormality 4) Contents of display of mechanical system record menu screen and then press [ ] abnormality record information screen switch. Number Sub menu of abnormality record 00 Return (End of abnormality record) 01 Electrical systems 02 Mechanical systems 20 BR380JG-1E0 .

switch or [R] switch. 1] Following switch operation from the electrical system abnormality record screen opens the reset screen. implement the the information to be displayed following procedure. be the mechanical system cannot be sure to display the subject infor- reset. on the screen can be any. do the switch record operation according to the screen a Resetting abnormality record (dele. mation in the abnormality record of a When resetting all information. tion) is possible only with the electri. mation on the screen using [ E] a When resetting individual or all infor. BR380JG-1E0 21 .30 Testing and adjusting SEN02304-00 5) Resetting electrical systems abnormality 2] From the reset screen. a When a specific individual infor- cal system. q Switch operation: [E] + [1] o [2] o [3] a Above is the same as that done when switching to the service menu. The abnormality record in mation alone is to be reset. instructions. the electrical systems.

2) Information to be displayed q Oil and filter names q Replacement time elapsed up to 2) Selection of item to be changed present Select the item to be changed from the q Time elapsed on service meter up to “Maintenance Mode Change” Selection the last replacement Menu screen. Function of maintenance record [03] 23..SEN02304-00 30 Testing and adjusting 22. 22 BR380JG-1E0 . oils. q Set function effective or ineffective 1) Menu selection q Change set replacement interval Select “03 Maintenance Record” from the initial display of Service Menu and then 1) Menu selection depress [ ] switch. which the rently set operating conditions of the mainte- operator can display and check by the follow. etc. nance display function. ing operations. Select “04 Maintenance Mode Change” from the Service Menu and then depress [ ] switch. Function of maintenance mode change [04] The machine monitor records the maintenance Following procedure allows changing the cur- information of the filters.

The main- 03 Engine oil filter change int. 12 Hydraulic oil change int. function for this item is disabled. 13 Fuel pre-filter change int. 11 Crusher motor case oil change int. individually set information. 09 Final drive case oil change int. tion for this item is enabled. (Irrespec- tive of whether “On” or “Off” set for 5) Description of “Initialize all items” individual items. this setting prevails) Select this menu and then press [ ] q Not use (Off): The maintenance dis. decreased in multiple of 50 hours by 05 Hyd oil filter change int.30 Testing and adjusting SEN02304-00 4) Description of individual setting items Number Items of the maintenance mode change (1): Default value: The maintenance time set in the monitor (recommended by Return (End of change in the maintenance 00 the manufacturer and cannot be mode) changed). 06 Hyd tank breather change int. BR380JG-1E0 23 . hours. related items is disabled (prece- dence is given to this setting over the “On” or “Off” selected for an individual items). (4): Not use (Off): Maintenance display 08 Damper case service int. 01 Maintenance mode on/off (2): Set value: Denotes the maintenance 02 Engine oil change int. (3): Use (On): Maintenance display func- 07 Corrosion resistor change int. time that can be freely set. switch to restore the default value for the play function of all oils and filter. 14 Initialize all items a 01 and 14 menus are provided for setting the whole maintenance mode. tenance mode operates based on this time (the time can be increased or 04 Fuel main filter change int. while those from 02 through 13 are for setting individual items. 3) Contents of Maintenance Mode On/Off q Use (On): The maintenance display function of all oil and filter-related items are turned effectual. use of [E] and [R] switches). a The lower limit of this setting is 50 10 Feeder vibration oil change int.

to the “Phone Number Entry” display. (Entry automatically with the failure code. Function of phone number entry [05] 3) Entry and setting phone number When the user code is displayed. a When entered a wrong number. 1] Using the numerical keypad. screen changes to entry screen shown above. inputted. enter the number starting with the cursor position situated at the left end. procedure allows entering or correcting the entry a phone number in the “Phone Num- phone numbers to be displayed alternately ber Entry” display. 2] Depress [ ] switch when all the num- a Even if a Phone number is already bers have been entered. the input is normal. a Numbers can be entered up to the max. 12 di gits . 1) Menu selection Select “05 Phone Number Entry” menu from the Service Menu initial screen and then depress [ ] switch. the “Phone Number Entry” screen.SEN02304-00 30 Testing and adjusting 24. it is deleted if you switch the a As the input is finished. 2) Changing the display depress [B] switch to return the Select “Entry” next to change the display cursor by one digit. 24 BR380JG-1E0 . the phone number screen is not displayed. If the entered phone number is shown on this display. but omit unnecessary digits. begins with a cursor at the left end) a If a telephone number is not input. following Following the method explained below.

modifications as needed. a SI unit system is the default setting of the machine monitor. which is a spare part. change and then press [ ] switch. Function of default [06] 3) Language setting function Following machine monitor. a The default language of the machine monitor is English. a When using the machine monitor. 4) Unit selection function You can select 1 from the 3 units to be 2) Selecting sub menu used in the monitoring function display of Select the target sub menu of setting Service Menu. q Language used in the service menu q Unit to be displayed in relation to the mon- itoring function 1) Menu selection Select “06 Default” menu from the Service Menu initial screen and then press [ ] switch. switch this function from English to Japanese. Service Menu allows switching the lan- related settings are modifiable. Number Sub menu of default value 00 Return (End of default) 01 Language 02 Unit BR380JG-1E0 25 .30 Testing and adjusting SEN02304-00 25.or machine. in the Japa- nese-speaking sphere. Do necessary guage between Japanese and English.

0 225 –1.SEN02304-00 30 Testing and adjusting 26. speed 250 – 650 Number Adjustment of sub menu 00 Return (Ends the adjustment) 01 Pump absorption torque 02 Feeder speed adjustment 03 Crusher speed adjustment 04 Clearance potentiometer initialization 05 Option register 26 BR380JG-1E0 . Function of adjustment [07] 3) 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. Torque adjust. Adjust.0 change is to be done and then press [ ] switch.0 4) Function for feeder speed adjustment The maximum and minimum feeder speed can be adjusted within the range shown in the table below by adjusting the feeder EPC current. Torque adjust- ment ment value ment ment value value (kgm) value (kgm) 2) Sub menu selection 220 +4. Adjust.0 228 –4. 222 +2.0 224 0.0 223 +1. speed 750 – 910 Min.0 Select the sub menu on which setting 221 +3.0 227 –3. adjusted within the range shown in the 1) Menu selection table below.0 226 –2. Select “07 Adjustment” menu from the Service Menu initial screen and then press [ ] switch. Item Input range (mA) Max.

as well as the maximum crusher speed. the value before inputting is dis- played again. change. value input window is displayed. a If the LS-EPC solenoid current is adjusted. then adjust the other speeds.30 Testing and adjusting SEN02304-00 1] Move the cursor to the current to 1] Move the cursor to the current to adjust with [ ] switch and [ ] switch adjust with [ ] switch and [ ] switch and depress [ ] switch. and depress [ ] switch. 5) Function for crusher speed adjustment q Maximum speed adjustment Adjust the LS-EPC current. speed 6) Function for clearance potentiometer ini- 600 – 1000 tial adjustment (LS-EPC solenoid current) When the tooth plate is replaced. a If a value out of the proper range is a If a value out of the proper range is input. When adjust- ing the crusher and feeder speeds. speed Forward 250 – 650 the clearance potentiometer. and depress [ ] switch. adjust the maximum crusher speed first. (EPC current) Reverse 250 – 650 BR380JG-1E0 27 . q Minimum speed adjustment Adjust the crusher forward/reverse EPC current. the value before inputting is dis. Input range Item (mA) Max. played again. initialize Min. the minimum crusher speed and maximum and minimum feeder speeds. 2] The adjusted current flashes and the 2] The adjusted current flashes and the value input window is displayed. 3] Input a value with the numeral keys 3] Input a value with the numeral keys and depress [ ] switch. input.

position. 6] Select the service menu to display the 2] The screen changes to the use (on)/ clearance potentiometer initialization disuse (off) setting screen for the screen. Use/Disuse of the options of the machine 2] Set mode selector switch (1) of the can be set. 28 BR380JG-1E0 . the manual mode position.SEN02304-00 30 Testing and adjusting 1] Check that the display is in the ordi. main control box in the testing mode 1] On the option setting menu screen. 7] Depress “1” (SET) on the clearance Move the cursor with the [E] switch potentiometer initialization screen. 03 Overfeed sensor 5] Depress crusher clearance closing switch (5) of the machine monitor to 04 2nd conveyor press the swing jaw of the crusher 05 Vibrator screen against the fixed jaw (and the monitor 06 Travel lever buzzer sounds). the monitor buzzer sounds for 3 seconds and then the screen returns to the previous screen. 7) Function for option registration nary display mode. move the cursor with the [E] switch 3] Set clearance adjustment selector and [R] switch to an option to be switch (2) of the main control box in adjusted and press the [ ] switch. selected option. 3] When the option is set normally. Number Option registration menu 4] Rotate the crusher with crusher man- ual forward switch (3) and reverse 00 Return (Finish adjustment) switch (4) of the machine monitor to 01 Magnetic separator bring mark (B) of the flywheel to the 02 Muck discharge conveyor center of adjustment range (A). and [R] switch to “Use”/“Disuse” and press the [ ] switch.

30 Testing and adjusting SEN02304-00 27. 1) Selecting menu Select “08 Cylinder cut out” menu from the Service Menu initial screen and press [ ] switch. “Cylinder cut out” operation means to run the engine with 1 or more fuel injectors disabled electrically to reduce the number of effective cylinders. a If pressing the switch changes the cylinder number on the screen to a white letter enclosed in the white frame. 2) Selecting cylinder to be cut out Press a switch corresponding to the cylin- der No. a If pressing the switch changes the cylinder number on the screen to a black letter enclosed in the black frame. to be cut out from switches [1] to [6] of the machine monitor. Function of cylinder cut out operation [08] The operator can perform the engine on cylin- der cut out operation with the machine monitor. This operation is used to find out a cylinder which does not output power normally (combustion in it is abnormal). press the correct switch again). 3) Resetting cut out cylinder Press the switch corresponding to the cut out cylinder number from switches [1] to [6] of the machine monitor to be reset. the cylinder is reset. a Number of cylinders to be reduced is any. the cylinder is cut out (when a wrong number is selected. BR380JG-1E0 29 .

the (1) Run the engine from the normal operation held speed is displayed in the lower mode (no cylinder cut out) and then hold the space along with ( ) and the upper speed of that time. enabling or speed is newly displayed in the lower disabling of the cylinder cut out mode does not space. out. a If the holding function is used. In other words. when identifying a failed cylinder quicker. (5) Repeat above steps (2) to (4) and then com- pare the results against that obtained from other cylinders. 30 BR380JG-1E0 . a If the diagnosis identified a cylinder on which there was no decrease in the engine speed or the decrease was small. Then compare the engine speed at the cylinder cut out or not. it can be safely judged that there must be some abnormalities in its combustion. (3) Run the engine under the same condition as pendent of the currently set mode – that for (1).SEN02304-00 30 Testing and adjusting 4) 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. that time and the held speed being displayed to diagnose the cylinder. Thus. (4) Reset a cut out cylinder independent of the fluctuations in the engine speed. Pressing [ R ] switch during holding can. space continuously displays the cur. fol- cels the holding function and deletes the lowing operation is effective. a The holding function is usable inde. affect the display. display in the lower space. (2) Specify the cylinder to be diagnosed as the cut rent speed.

No injection cranking denotes stopping injec- tion of fuel from the injector even if the engine is run from the starting motor.30 Testing and adjusting SEN02304-00 28. a The letters “Under Preparation” are displayed in red. BR380JG-1E0 31 . a “Check Communication” will be dis- played in red. from the machine monitor. for instance. 2) The initial screen for the no injection cranking will appear. This mode is used. “Under Preparation” will be displayed on the screen. a This setting must be done after stopping the engine. for measurement of com- pressive pressure. following screen No injection cranking of the engine is available appears. 1) Selecting menu Select “09 No Injection Cranking” from the Service Menu initial screen and press [ ] switch. Function of no injection cranking [09] 3) As the checkup is over. 4) Select “No Injection” and press [ ] switch.

to protect the starting motor. 32 BR380JG-1E0 . display remains on the screen even 6) From this state. press [ ] switch from the previous screen and the letters “End” will be displayed for 3 seconds. crank the engine using after the engine is stopped. the service menu screen alone a Limit the cranking time to 20 seconds deletes the display. a The letters “End” are displayed in green.SEN02304-00 30 Testing and adjusting 5) As the preparation for no injection crank. inadvertently selected while the ration” is replaced with “After No engine is running. 7) After the no injection cranking is over. a If the no injection cranking function is ing is completed. Restoring the starting motor. This “Engine Running” displayed in green. will appear as No Injection in step 4) a The letters “After No Injection” are is selected. 8) Press “Return” when ending the no injec- tion cranking. “Engine Running” Injection”. display of “Under Prepa.

After recording 10 times. about the past slip of the crusher lock cylinder q The machine monitor records the informa. and depress [ ] switch. q The total number of the recorded slips if the crusher clearance saved previous above 10 is counted and recorded up to time is different from the current crusher 999. tion up to 10 times.30 Testing and adjusting SEN02304-00 29. 1) Selection of menu Select “10 Crusher Clearance Record” in the initial display of Service Menu. clearance. Function for lock cylinder slip record [11] The machine monitor records the information The machine monitor records the information about the crusher clearance setting. the machine monitor saves the current crusher clearance. Function for crusher clearance record [10] 30. After recording 10 q The machine monitor records the slips up times. order from the oldest one and keeps the q When the mode selector switch is changed newest ones. 1) Selection of menu Select “11 Lock Cylinder Slip Record” in the initial display of Service Menu. the machine monitor discards the to 10 times. the data in order from the oldest one and machine monitor discards the data in keeps the newest ones. (service meter reading). from the “testing mode” to “another mode”. and depress [ ] switch. 2) Information shown in display 1] Crusher clearance 2] Service meter reading at which crusher clearance was saved BR380JG-1E0 33 .

input numbers] 34 BR380JG-1E0 .SEN02304-00 30 Testing and adjusting 2) Deletion of data [ ] + [1] o [2] o [3] (While pressing [ ].

SEN02304-00 BR380JG-1E0 Mobile crusher Form No. SEN02304-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01) 36 .

.................................................................... 46 List of companies which handles radio controllers............... 4 Adjusting tension of crusher drive V-belt............................................................. 56 Procedure for testing diodes ........................................................................................... 2 Check and adjustment of outlet clearance................................................................................................................................................. Part 3 Check and adjustment of jaw crusher................................. 60 BR380JG-1E0 1 ................................................................................. 38 Inspection and maintenance of magnetic separator .......................................................................... 49 Procedure for turning on KOMTRAX terminal.... 44 Check and adjustment of muck discharge conveyor ...... SEN02305-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 30 Testing and adjusting 1 Testing and adjusting.......... 37 Check and adjustment of primary conveyor.................................................................................................................................................................................................................................................................................................................................................................................................... 50 KOMTRAX terminal lamp indications................................................................. 53 Preparation work for troubleshooting for electrical system ............................ 48 Handling voltage circuit of engine controller ..................................................................................................

then remove the key and keep it with him. then lock the control box. One worker should stand in front of the control box to prevent any other person from turning the starting switch ON by mistake. 2 BR380JG-1E0 . Always carry out operations with 2 or more workers. there is danger that this may lead to serious personal injury.SEN02305-01 30 Testing and adjusting Check and adjustment of jaw 3. One worker should turn the key in the starting switch to the OFF position (A). 2. always follow the procedure below when carrying out the operation. If the work equipment is actuated by mis- take. k When entering the top of the feeder or the inside of the crusher to carry out inspec- tion and maintenance of the crusher. Hang a warning tag on the horn switch of the crusher control box. 1. or replacement of consumable parts.

put stand (2) of a height of approx.30 Testing and adjusting SEN02305-01 4. When moving from the deck on the right side of the machine to the top of the feeder. Press work equipment lock switch (1). BR380JG-1E0 3 . 300 mm on top of the deck. then go up to the feeder from stand (2). 5.

(A) Crusher outlet clearance (B) Lock cylinder (C) Fixed jaw plate (D) Swing jaw plate 4 BR380JG-1E0 . it is con- venient to use a jig as shown in the example below. a When measuring outlet clearance A. 1500 mm. (Example) Length = approx. Weld a rod of the commonly used outlet clearance dimension (for example: 50 mm) to an H- shape. Measure at three places (both ends and the center) and take the value for the smallest clearance as the representative value.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. diame- ter of rod = φ6 to 10 mm at both ends.

remarkably worse than when the clearance was so adjust the discharge clearance to the last adjusted. ing or retracting the lock cylinder.30 Testing and adjusting SEN02305-01 Outlet clearance adjusting method k Before starting operations. k O. k Be sure to attach a warning tag to the start- ing switch in the control box.). and the size of the particle k When the machine is shipped from the fac- will become coarser. (If the input value is (+). If the crushed particles are tory.) M (Manual): It is possible to adjust the clearance manually by using the panel switch. S. adjusted according to the set value sand. ance to become larger. the clearance is set to 50 mm (O. When adjusting the outlet clearance. opened. means the condition when the On this machine. rounding area. check that there When the machine is used continuously. the clear- ance becomes larger. k Start the engine. S. set the travel lever lock to the LOCK position without fail. or soil stuck to the teeth. adjust the clearance as follows. S. being crushed. desired size or size suitable for the material The crusher outlet clearance is adjusted by extend. if the input value is (–). use the inch- ing operation to bring the position of the flywheel to the center of the adjustment range on the right to position it before adjusting the outlet clearance. there are three types of clearance c r u s h e r d i s c h a r g e c l e a ra n c e i s f u l l y adjustment function. the clearance becomes smaller. (A): Adjustment range (B): Flywheel marking (red painted part) BR380JG-1E0 5 . see the sections of “Check before starting engine” and “Start- ing engine” in Operation of OPERATION in Operation and maintenance manual. S. S (Semi-automatic): The clearance is automatically adjusted by inputting the desired value for change on the clearance set moni- tor. wear of is no one inside the crusher or in the sur- the addendum will cause the crusher outlet clear. A (Automatic): k Always be sure to check that the crusher The clearance is automatically chamber is empty and that there is no mud. k For starting the engine. input on the clearance set monitor. For adjusting the outlet clearance.

Set mode selector switch (2) to INSPECTION (c) position. 3) Use UP switch (4) or DOWN switch (5) to increase or decrease the value on the dis- play and adjust to give the desired set value. of the machine monitor is set to (A) (automatic) mode. 2) Press input confirmation switch (6). 6 BR380JG-1E0 . the set value will increase or decrease in units of 10 mm . The machine monitor switches to the normal inspection screen. Set clearance adjustment selector switch (3) to 1. 2. 1) Use UP switch (4) or DOWN switch (5) to move the cursor on the screen display to position (A). Start the engine. Set fuel control dial (1) to the low idle (MIN) 5. (A) starts flashing and numeral input window (B) is displayed at the top left of the screen. then input the OSS clearance (A) to be adjusted to the machine monitor in the follow- ing order. If the UP switch (4) or DOWN switch (5) is kept pressed continuously. 3.SEN02305-01 30 Testing and adjusting Adjusting clearance in A (automatic) mode 4. Check that clearance adjustment monitor (D) position. position (A) (automatic). The numerical value can be set in units of 1 mm in a range of 50 to 150 mm.

ance monitor display value (F) is as 1) Use UP switch (4) or DOWN switch (5) to shown as 0. q Automatic adjustment is carried out with the following procedure.S. to set the input value.S. there is no need to input the set value again. When this happens. clear. fixed tooth. “|” lamp (C) goes out to show that the clear- ance. “|” lamp (C) lights up and the automatic adjustment is carried out.S. Adjust the clearance. press return switch (7). If that value is to be used as it is. This will 2) When the swing jaw plate contacts the return the set value to the original setting. 7. 1) The movable swing jaw plate to the fixed tooth side and the crusher clearance closes. 3) Press input confirmation switch (6) again to carry out the adjustment. move the cursor on the screen display to position (C). a The set value is saved and is displayed when the next adjustment is made to the clearance. clearance.S. 2) Press input confirmation switch (6) to complete the preparations. “|” lamp (C) flashes.30 Testing and adjusting SEN02305-01 4) After inputting the desired O. and crusher actual clear- 6. BR380JG-1E0 7 . portion (E) on the machine monitor flashes. press input confirmation switch (6) ance adjustment is completed. a If it is desired to abort the setting of the O. the buzzer inside the machine monitor sounds.

S. measure the clearance and adjust with S (semi-automatic) mode or M (manual) mode. the monitor panel and selector and the outlet clearance adjusted in the A (automatic) mode may be different because of the wear of the tooth plate and the condition of installation. 4) When the crusher clearance reaches the desired O. machine monitor 1. While the mode clearance is opening.S. completed. 8 BR380JG-1E0 . Measure the present crusher outlet clearance portion (G) flashes.SEN02305-01 30 Testing and adjusting 3) The swing jaw plate acts in the direction to Adjusting clearance in S (semi-automatic) open the crusher clearance. 3. to understand how much to increase or decrease the value to reach the target value for the clearance. clearance set value (H). the automatic clearance adjustment is 2. Set fuel control dial (1) to the low idle (MIN) a The value for the outlet clearance displayed on position. In such cases. Start the engine.

mode. the set value will increase or decrease in units of 10 mm .30 Testing and adjusting SEN02305-01 4. Set mode selector switch (2) to INSPECTION 6. 3) Use UP switch (4) or DOWN switch (5) to increase or decrease the value on the dis- play and adjust to give the desired set value. (A) starts flashing and numeral input window (B) is displayed at the top left of the screen. The machine monitor switches to monitor has changed to S (semi-automatic) the normal inspection screen. BR380JG-1E0 9 . press input confirmation switch (6) to set the input value. Check that mode monitor (D) of the machine (c) position. 2) Press input confirmation switch (6). + display: Adjustment to open clearance – display: Adjustment to close clearance If the UP switch (4) or DOWN switch (5) is kept pressed continuously. 1) Use UP switch (4) or DOWN switch (5) to move the cursor on the screen display to position (A). then input clearance value (A) for the amount to change the present clearance on the machine monitor as follows. 4) After inputting the set value for the adjust- ment. Set clearance adjustment selector switch (3) to the S (semi-automatic) position. 5. The numerical value can be set in units of 1 mm in a range of 50 to 150 mm.

decrease the value to reach the target value 2) Press input confirmation switch (6) to for the clearance. Set fuel control dial (1) to the low idle (MIN) position. 3. 10 BR380JG-1E0 . 3) Press input confirmation switch (6) again to carry out the adjustment. “|” lamp (C) goes out to show that the clear- ance adjustment is completed. 2. complete the preparations.SEN02305-01 30 Testing and adjusting 7. Start the engine. Measure the present crusher outlet clearance move the cursor on the screen display to to understand how much to increase or position (C). Adjusting clearance in M (manual) mode 1) Use UP switch (4) or DOWN switch (5) to 1. “|” lamp (C) flashes. 8. Adjust the clearance. “|” lamp (C) lights up.

30 Testing and adjusting SEN02305-01 4. keeping crusher clearance decrease switch (4) pressed to bring the teeth into contact with the fixed jaw plate. the teeth become worn. 5. a Depending on the wear of the teeth. 6. Using crusher clearance decrease switch (4) actual clearance monitor (A) changes to 0. For details. even if the mode selector switch is turned to the OPERATION mode. the crusher cannot be started while the crusher status lamp is lighted up the yellow (period that crusher operation is prohibited after adjusting clearance: approx. (4) Crusher clearance decrease switch Action to close crusher clearance contin. the movable teeth and fixed jaw plate are in contact. 10 seconds. so the value displayed on clearance dis- play monitor (A) gradually becomes different from the actual clearance. When the value (A) shows no more change. 1. Check that mode monitor (D) of the machine 3. become exactly 0. the value on crusher 7. The machine monitor switches to the normal inspection screen. cate any abnormality. a After the operation for adjusting the ues while switch is being pressed. 30 seconds). After bringing the movable teeth and fixed jaw plate into contact. When this happens. the adjust so that crusher actual clearance monitor value after compensation may not (A) for the amount to change the present clear. When this happens. and crusher clearance increase switch (5). keep crusher clearance decrease switch (4) pressed for approx. 4. BR380JG-1E0 11 . completed. crusher clearance is completed. Press crusher clearance increase switch (5) and ues while switch is being pressed. Action to open crusher clearance contin. Keep crusher clearance decrease switch (4) pressed to bring the movable teeth and fixed jaw plate into contact. 2. The buzzer sounds and the compensation is monitor has changed to M (manual) mode. but this does not indi- ance reaches the target value. see “Operation status display lamp in Operation and maintenance man- ual”. Set clearance adjustment selector switch (3) to it is possible to compensate for the value by the M (manual) position. a As the crusher is operated. adjust so that the value on crusher actual clear- (5) Crusher clearance increase switch ance monitor (A) becomes the target value. Set mode selector switch (2) to INSPECTION (c) position.

As shown in the diagram. tension spring adjust it if there is any problem. If there is play in the tooth plate. because of the fitting of parts together dur- ing the first 50 hours (time shown on the service meter). If tension spring set length is greater than dimension shown below: q Knocking occurs between the toggle plate and toggle seat. so carry out inspection and control thoroughly. and this will reduce the life of the toggle plate and toggle seat. from around the crusher. or if the toggle plate has fallen out. pa r ts h a v e b e e n t u r n e d o r r e p l a c e d . fixed jaw wedge bolt spring is not suitable: q There may be play in the jaw plate and breakage of the wedge bolt.SEN02305-01 30 Testing and adjusting Check and adjustment of tooth plate wedge bolt Check that the spring set length is correct and spring case. q The toggle plate may fall out. 12 BR380JG-1E0 . the spring set length and tightening torque of the nuts and bolts may change. and the inset is within 2 mm. Fixed jaw plate wedge bolt spring stop operations immediately and carry out the fol. knocking noise from the toggle plate. If tension spring set length is less than dimension shown below: q The tension rod or tension spring may break. abnormal noise The spring set length is as follows. A = 0 – 2 mm lowing check and adjustment. face (a) (collar face) does k With new machines or with machines not extend to the outside from face (b) (plate sur- where the jaw plate or other consumable face). If swing jaw.

Check that there is no deformation of the spring. measure at 4 places 90° apart around the circumference. 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. rotate the spring to change the seating position of the spring. k This machine uses cover assembly (1) with springs built into the fixed jaw plate wedge portion and swing jaw plate wedge portion. BR380JG-1E0 13 . If the difference in the spring set length of the ten- sion spring is more than 3 mm. When measuring the set length of the tension spring. then tighten again. there is dan- ger that the internal parts will fly out and cause injury.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. If bolts (2) of the front face of the cover are removed during disassembly.

stop the crusher. eventually resulting in damages on the jaw plates on account of the worsened partial wear. rocks may not be discharged smoothly. (1): Hypothetical wear range (hatched portion) (2): Tooth plate (3): Frame New Wear limit part height (mm) (mm) Height from mount. premature partial wear will develop on the tips of jaw plates. k If a work is continued with the partially worn jaw plates. 14 BR380JG-1E0 . Fixed 44 34 ing face of tooth jaw (A) plate to groove in Swing tooth plate 75 65 jaw (B) a Even if dimension (A) and (B) have not reached the wear limit.SEN02305-01 30 Testing and adjusting Check of wear on major wearing parts Jaw plate k When checking the wear. turn the tooth plate or replace it. if position (C) (100 – 300 mm from the bottom end) is the same as the bottom end portion and the protrusion of the tooth has been worn and the tooth has become flat. k If the machine is used continuously with the crusher chamber excessively charged. then stop the engine and check the wear. a serious damage will be inflicted on the jaw crusher main body itself. k If jaw plates are used beyond their wear limit. Replace the partially worn jaw plates with new ones.

(B) 50 mm 10 mm (wear amount: 10 mm). 15 mm) at the bottom. replace the cheek plate mounting bolts also at the same time. a When replacing the cheek plate.30 Testing and adjusting SEN02305-01 Cheek plate Swing jaw plate wedge Carry out replacement when the remaining dimen. pro- ceed with the replacement. (A) Wear amount: 10 mm (B) Protector thickness: 19 mm BR380JG-1E0 15 . Protector (A) Wear amount: 5 mm Replace when the remaining dimension is approx. 10 mm (wear amount: (B): 10 mm). 15 mm (wear amount: 10 tom of the wedge is approx. Replace when remaining dimension (A) at the bot- sion reaches approx. 79 mm (wear amount mm) at the top. Toggle seat If the wear dimension reaches approx. Replace also if part of the wedge is worn unevenly. (C) 30 mm Replace also if part of the protector is worn unevenly. 5 mm. and approx.

see “Check of jaw crusher and related accessories in Operation and maintenance manual”. see “Toggle seat”. a When replacing toggle plate (1). 2. (For details of the tension spring set length. a If noise is generated between toggle seat (2) and toggle plate (1). replace the toggle plate dust cover also at the same time. For details of the amount of wear of the toggle seat. If a knocking noise is generated.SEN02305-01 30 Testing and adjusting Toggle plate 1.) 16 BR380JG-1E0 . the noise made when tog- gle plate (1) rolls on the surface of the toggle seat has no effect on the machine itself. Replace also if there is more wear of the one side as shown in the diagram. remove the toggle plate and measure the amount of wear (A) of the toggle plate. Replace if wear amount (A) is approx. Wear limit (D): 390 mm When new (E): 400 mm a Use the wear tolerance of toggle seat (2) and toggle plate (1) as a guideline for the above dimension. check if tension spring set length (B) is the specified value. 5 mm on one side. If distance (C) between the tip of the flange and the bottom of the toggle seat is 278 mm.

when its remaining dimension reaches 10 mm (wear amount of 9 mm).30 Testing and adjusting SEN02305-01 3. replace the Liner plate (1) needs to be replaced with a new one toggle plate with a new one. the side comes in (Crusher feeder portion) contact with the tip of rod pin (2). When wear develops on the side of toggle Liner plate plate (1) and as a result. BR380JG-1E0 17 .

SEN02305-01 30 Testing and adjusting Replacement of cheek plate 1. 1 nance volume of the operation and maintenance manual. 5 Wrench: Accessory tool No. see Tools to use “Crusher accessory tool” in Mainte- Wrench: Accessory tool No. 3 Extension: Accessory tool No. 8 k For details of the accessory tool. an angle. Handle: Accessory tool No. Tools to use 2. it may be difficult to remove. then lift up vertically. 10 with the bolt loosened. k For details of the accessory tool. Next. Fit the tool supplied with the machine to the lift- sand or soil clogging lifting hole (3) of top ing hole. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. If the load is at cheek plate (1). 18 BR380JG-1E0 . 7 Pipe: Accessory tool No. 4 Socket: Accessory tool No. Use an air gun or wire brush to remove the 3. tighten locknut (5) again. Hook: Accessory tool No. Loosen cheek plate mounting bolt (4).

rear. 4 Socket: Accessory tool No.30 Testing and adjusting SEN02305-01 4. Repeat the same procedure to lift up bottom cheek plate (2). 3 Extension: Accessory tool No.) the side frame. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. 17 k For details of the accessory tool. completely remove the soil and sand from the cheek plate fitting surfaces (front. After removing all the cheek plates. While lifting. BR380JG-1E0 19 . see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. Tighten the cheek plate lock bolts.0 kg 6. 5. Insert new cheek plates in order from the plate with a medium-sized hammer. When cheek plate (1) comes free. Top cheek plate (1): M24 x 2 (each side) Bottom cheek plate (2): M24 x 1 (each side) Tools to use Wrench: Accessory tool No. 9. In particular. right and left). Tool to use Hammer: Accessory tool No. 4 Bottom cheek plate (2): 36. 7 Pipe: Accessory tool No. remove the soil and sand clog- ging both sides of the fixed jaw.0 kg 7. 4 Top cheek plate (1): 74. 5 Wrench: Accessory tool No. 1 Handle: Accessory tool No. hit the area around the cheek 8. underside along the fixed jaw and a guide of (Hit the places marked q in the diagram. remove the mounting bolts and lift up. 8 k For details of the accessory tool.

2. 5 Wrench: Accessory tool No. Unless removed completely. sand. k After removing the fixed jaw plate. For details. etc. which likely leads to premature wear or partial wear on the jaw plates. 1 Handle: Accessory tool No. 7 Pipe: Accessory tool No. fixed jaw wedge bolt. from the fixed jaw fitting surfaces (front frame and mount stopper upper surface). 13 k For details of the accessory tool. there is dan- ger that the internal parts will fly out and cause injury. they may cause a backlash on the fixed jaw plate. see “Replacement of cheek plate”. If bolts (2) of the front face of the cover are removed during disassembly. 1. Remove the fixed jaw wedge bolt spring cover assembly. Tools to use Wrench: Accessory tool No. 12 Wrench: Accessory tool No. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. and fixed jaw wedge block.SEN02305-01 30 Testing and adjusting Reversal or replacement of fixed jaw plate k This machine uses cover assembly (1) with springs built into the fixed jaw plate wedge portion and swing jaw plate wedge portion. 8 Adjustable wrench: Accessory tool No. com- pletely remove soils. If the clearance is not even on the right and left sides. there will be a slippage from the swing jaw plate tip. Remove the cheek plate. 20 BR380JG-1E0 . 3 Socket: Accessory tool No.

Lift up the fixed jaw plate with a wire rope. lower it on to a block once. 3. BR380JG-1E0 21 . Then lift up a new fixed jaw plate with a wire rope and insert it into the crusher frame. Then hook a wire rope on the other side to lift it up and insert it into the crusher frame. and washer (9). lower it on to a block once. 3) Remove spring cover assembly (10) and raise it with wire. 2) Remove wedge bolt locknut (7). nut (8). q When reversing the fixed jaw plate.30 Testing and adjusting SEN02305-01 Remove the fixed jaw wedge bolt spring cover assembly as follows. 1) Loosen locknut (4) and tighten until spring holder push bolt (5) contacts spring holder (6). q When replacing the worn fixed jaw plate.

SEN02305-01 30 Testing and adjusting 4. Push out swing jaw (12) and push fixed jaw (13) against the front frame. and position the fixed jaw plate and the crusher frame so that both centers are aligned. insert wooden block (11) (or equivalent object) between fixed jaw (13) and swing jaw (12). For details. 22 BR380JG-1E0 . 6. see “Outlet clearance adjusting method”. 5. Take measurements of the clearance on both sides of fixed jaw plate. If fixed jaw (13) is not in tight contact with the frame.

D > C BR380JG-1E0 23 . fixed jaw wedge bolt. q Condition of wedge sitting (1): Unstable q Condition of wedge sitting: After initial running-in period of crushing operation Spring set length increases.30 Testing and adjusting SEN02305-01 7. If it is left unstable with burrs remaining. Install the fixed jaw wedge. In that case. remove the burrs before install- ing the wedge. the wedge securing bolt may loosen during the initial running-in period of crushing operation and the machine may be damaged. 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.

secure nut (8) so that it will not rotate together with wedge bolt locknut (7).) wire and insert into the wedge bolt. 2) Install wedge bolt nut (8) and washer (9). do not apply the tightening torque to nut (8).SEN02305-01 30 Testing and adjusting Install the fixed jaw wedge bolt spring cover assem. so that it will not rotate together with wedge bolt locknut (7) and interfere with the swing jaw. 4) Tighten wedge bolt locknut (7). At this time. too. If it is not being pushed in to the correct position. In addition. 24 BR380JG-1E0 . 1) Raise spring cover assembly (10) with (The width of (A) should be 0 – 2 mm. 3) Check that spring holder (6) is being bly as follows. turn 2 bolts (5) to adjust the holder. pushed into the correct position. secure spring cover assembly (10). At this point.

then tighten locknut (4). If it is not the specified value. adjust again. Install the cheek plates. BR380JG-1E0 25 . 8.30 Testing and adjusting SEN02305-01 5) Loosen spring holder push bolt (5) so that dimension (B) becomes 15 mm. 6) Repeat the procedure in Step 3) to check that spring holder (6) is being pushed in to the correct position.

8 Adjustable wrench: Accessory tool No. 1. Wrench: Accessory tool No. 7 Pipe: Accessory tool No. k When pushing out the swing jaw plate wedge from the rear of the swing jaw. Remove the swing jaw wedge bolt spring cover k This machine uses cover assembly (1) with assembly (2 places).SEN02305-01 30 Testing and adjusting Reversal or replacement of swing jaw plate 2. 26 BR380JG-1E0 . After removing the portion and swing jaw plate wedge portion. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. 1) Lift the spring cover assembly lightly with wire. always leave one of the swing jaw plate wedge bolts inserted. fit the If bolts (2) of the front face of the cover are nut and leave the bolt inserted. 1 Hook: Accessory tool No. to prevent the movable wedge from falling. 6 Wrench: Accessory tool No. Remove the swing jaw wedge bolt spring cover assembly as follows. there is dan- ger that the internal parts will fly out and Tools to use cause injury. taking care not to drop it. then remove 1 swing jaw springs built into the fixed jaw plate wedge wedge bolt on one side. Secure the crusher inspection hatch in the open position. swing jaw wedge spring cover assembly. 13 k For details of the accessory tool. 12 Wrench: Accessory tool No. removed during disassembly.

nut (8). fit lifting wire (A) to the center portion. push the swing jaw plate wedge out approximately 30 mm. 3) Remove wedge bolt locknut (7). and raise the wedge. a To make it easier to fit lifting wire (A) to the and washer (9). 4) Remove spring cover assembly (10) and raise it with wire.30 Testing and adjusting SEN02305-01 2) Loosen locknut (4) and tighten until spring holder push bolt (5) contacts spring holder (6). Check that the swing jaw wedge is completely loose. BR380JG-1E0 27 . swing jaw plate wedge. 3. then remove the temporarily installed bolts and nuts.

If not removed completely. sand. Lift up a new swing jaw plate with a wire rope and insert it into the crusher frame. q When replacing the swing jaw plate. Fit swing jaw lifting hook (B) to the top surface of the swing jaw. each upper surface of swing jaw plate mount stopper and transverse stopper piece). lower the worn plate on to a block once.SEN02305-01 30 Testing and adjusting 4. from the swing jaw plate fitting surfaces (swing jaw. etc. q When turning over. then fit the wire to the hook on the opposite side. 4 Swing jaw: 735 kg k After removing the swing jaw plate. they may cause a backlash on the swing jaw plate. and insert again in the crusher frame. 28 BR380JG-1E0 . then raise it. com- pletely remove soils. lower the swing jaw plate on top of a stand.

Install the swing jaw wedge and swing jaw wedge bolt. In that case. When the swing jaw wedge is installed to the swing jaw plate. the wedge securing bolt may loosen during the initial running-in period of crushing operation and the machine may be damaged. If it is left unstable with burrs remaining. D > C BR380JG-1E0 29 . the wedge may not sit well with the plate due to burrs remaining on the contact face of either parts.30 Testing and adjusting SEN02305-01 5. remove the burrs before install- ing the wedge. q Condition of wedge sitting (1): Unstable q Condition of wedge sitting (2):After initial running-in period of crushing operation Spring set length increases.

In addition. too. secure nut (8) so that it will not rotate together with wedge bolt locknut (7). 30 BR380JG-1E0 . turn 2 bolts (5) to adjust the holder. 1) Raise spring cover assembly (10) with (The width of (A) should be 0 – 2 mm. If it is not being pushed in to the correct position. At this point.) wire and insert into the wedge bolt. do not apply the tightening torque to nut (8). 2) Install wedge bolt nut (8) and washer (9). secure spring cover assembly (10).SEN02305-01 30 Testing and adjusting Install the swing jaw wedge bolt spring cover 3) Check that spring holder (6) is being assembly as follows. so that it will not rotate together with wedge bolt locknut (7) and interfere with the swing jaw. 4) Tighten wedge bolt locknut (7). pushed into the correct position. At this time.

then start the engine. Attach a warning tag to announce to those concerned that the machine is now worked on. 5. adjust again. and move the fixed link for- ward until the fixed jaw plate contacts the fixed jaw plate. If it is not the specified value. Remove the dust prevention rubber plate at the side of the crusher. 6) Repeat the procedure in Step 3) to check that spring holder (6) is being pushed in to the correct position. then sling it. 2. Replacement of toggle plate 1.30 Testing and adjusting SEN02305-01 5) Loosen spring holder push bolt (5) so that 3. Check that there is no one inside the machine. tighten locknut (4). Wrap a nylon sling around toggle plate (1) and dimension (B) becomes 15 mm. Secure the crusher inspection hatch in the open position. 7. (left and right) 4. Set mode selector switch (3) to the inspection position. BR380JG-1E0 31 . 6. Press crusher clearance decrease switch (4) on the control box.

Attach a warning tag to announce to those concerned that the machine is now worked on. (1) Wrench: Accessory tool No. 32 BR380JG-1E0 . and pull back the fixed link slowly. Stop the engine. 9. Loosen tension spring (2) (both ends: M42) completely. Check that there is no one inside the machine. k It is extremely dangerous if you go on to the next work without completely 11. Set mode selector switch (3) to the inspection position. 14. 8 k For details of the accessory tool. 13. then use a chain block to pull the crusher case and the track frame and fix them in position. loosening tension spring (2). the swing jaw. so then start the engine. 2 (2) Pipe: Accessory tool No. remove tension spring nut (M42) from the rod. Press crusher clearance increase switch (5) on the control box. 15. If the tooth plates come into contact with each 10.SEN02305-01 30 Testing and adjusting 8. stop the engine. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. 12. Pass the wire through the hole in the bottom of other.

25. 21. Loosen the chain block fixed in Step 10. Install the dustproof rubber plate to the side of the crusher. 24. For adjusting the crusher outlet clearance. 23. 18. Close the crusher inspection hatch. be careful not let rubber cover (6) on top of the toggle plate get caught. When doing this. Lower the toggle plate and align it with the cen. the section of “Check and adjustment of outlet clearance”. 22. Loosen the chain block installed to the bottom of the swing jaw and remove the wire. 20. Set tightening length (C) of the tension spring so that it is 258 – 260 mm when the lock cylin- der length = Min (maximum clearance at crusher addendum). then position it so that the center of the swing jaw contact face of the toggle plate is aligned with the center of the swing jaw toggle seat contact face. Take out the toggle plate. Install the tension spring and tighten it to the specified tightening length. Wrap a nylon sling around the new toggle plate. 17. 19. BR380JG-1E0 33 . see ter of the seat at the fixed link end.30 Testing and adjusting SEN02305-01 16. Check crusher outlet clearance and adjust it to a desired clearance. Remove the nylon sling fitted to the toggle 4 Toggle plate: 144 kg plate.

Insert eyebolts into both ends of the lock link toggle seat. follow the 4 Toggle seat at swing jaw end: 44. In this case. take action with the gasket or other part as necessary. After long use. if necessary. 34 BR380JG-1E0 . Screw in an eyebolt (M12) on the side from which a holding plate has been removed and lift up the toggle seat provisionally. then raise the toggle seat. (Bolts to use: M20 x 8) 6. weld a hook to the center of the toggle seat and pull out the worn toggle seat. 5. referring to the section dealing with replacement of the toggle plate in this manual. k To prevent the lock link toggle seat from falling. Remove only one toggle seat holder plate (3) 1.7 kg 9. When the work of lifting up the toggle seat pro- 3. be careful not to mistake the assembly combinations. Start with removing the toggle plate before. Insert new toggle seats in the reverse order of the works explained above. 8. Screw in eyebolts (M12) into tap hole (2) at visionally has been completed. taking care not to let it fall. 7. so it may get stuck to the fixed link or swing jaw. hand. the toggle seat becomes deformed. carry out the operation with the lock cylinder extended to the maximum. In addition. at the fixed link end. Raise the toggle seat. 4 Lock link toggle seat: 41. 2. proceed to both ends of the toggle seat and fit the wire.5 kg items below without fail. Remove toggle seat holder plates (1) of the swing jaw at both ends.SEN02305-01 30 Testing and adjusting Replacement of toggle seat 4. so when installing. k Before replacing the toggle seat. remove a toggle seat holding plate on the opposite side. (Toggle seat material: Carbon steel) k There is no commonality of the toggle seats.

BR380JG-1E0 35 . 11 k For details of the accessory tool.30 Testing and adjusting SEN02305-01 Replacement of crusher driving V-belt 4. remove motor cover (2). Loosen locknuts (4) and (5) of crusher V-belt adjustment turnbuckle (3). 1 Wrench: Accessory tool No. 3. Turn the crusher V-belt adjustment turnbuckle 1. open position. 2. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. Secure the crusher inspection hatch in the (3) to reduce distance (L) between the yokes.) Tools to use Wrench: Accessory tool No. and at the same time. (Locknut (5) turns in the opposite direction to normal. Loosen the bolts of flywheel cover (1) at the side of the top step to release it.

SEN02305-01 30 Testing and adjusting 5. and bottom of the flywheel cover on the left. (For details of the method of adjusting the V- belt tension. starting from the outside. Loosen the bolts of covers (6) at the top. then remove them from the opening at the top of the crusher motor. see “Adjusting tension of crusher drive V-belt”. then turn crusher V-belt adjustment turnbuckle (3) to extend distance (L) between the yokes and adjust the V-belt tension. 6. rear. 36 BR380JG-1E0 .) 7. tighten locknuts (4) and (5). Remove the V-belts. Return the cover to its original position. 8. After completing adjustment of the V-belt ten- sion. Fit new belts to the flywheel in the opposite order from removal.

and shorten the service life of the V belts drastically. measured tension loads for 9 V-belts. then adjust the turnbuckle so that tension load (F) for 1 V-belt is 63. (Locknut (5) turns in the opposite direction to B A BJZ13807 normal. 3. Turn crusher V-belt adjustment turnbuckle (3) to extend distance (L) between the yokes.5 kg}. 1 4. Tighten locknuts (4) and (5).) Tools to use Wrench: Accessory tool No. 15 mm when 1 belt Tension load (F) is the average value of the is pressed with a finger force of approx. Open the V-belt inspection window. 14 or 15 Box wrench: Accessory tool No. (a) is 15 mm. 1.) 6. 11 k For details of the accessory tool.6 N {6. see 5.) The deflection should be approx. If the V-belt makes a slipping sound when the crusher is started or stopped. 6 – 7 kg. Tools to use Handle: Accessory tool No. L V belt tension adjusting method The V belt tension may be changed by adjusting a L/2 the turnbuckle located behind the crusher motor. Wrench: Accessory tool No.7N nance volume of the operation and {6. deflection maintenance manual. BR380JG-1E0 37 .6 – 73.5 – 7. use the following pro- cedure to adjust to the correct belt tension. Start and stop the crusher 2 – 5 times. see “Crusher accessory tool” in Mainte- nance volume of the operation and maintenance manual. Open the V-belt inspection cover. 16 k For details of the accessory tool. Guideline when checking V-belt tension (When this is done. be sure to tighten the locknut. Loosen locknuts (4) and (5) of crusher V-belt adjustment turnbuckle (3).0 – 7. (When this is done. check that the measured value is 58.0 kg). F After the adjustment. 2. then adjust the V- belt tension as follows. deflection (a) is 15 mm. the V belts will likely slip when the crusher starts or stops.30 Testing and adjusting SEN02305-01 Adjusting tension of crusher drive V-belt k If the V belt tension is not normal. Measure tension load (F) for 1 V-belt again and “Crusher accessory tool” in Mainte.7 – 68.

Check and adjustment of primary conveyor 8. Be sure to start the work only after stopping the belt conveyor. ing to Step 5 above. it emits a loud noise. then check the tension accord. k When inspecting and cleaning the primary Next. conveyor belt start and stop the crusher 2 – 5 times to k If it becomes necessary to work on the remove the difference in tension between the adjust bolts. Close the V-belt inspection window. 38 BR380JG-1E0 . revolving parts.SEN02305-01 30 Testing and adjusting 7. If the belt starts snaking. and after adjustment. turn adjustment bolt (1) to adjust the left and right tension. Start the engine and turn the fuel control dial to the MAX position. remove the stop- per plate to adjust. After adjusting Check and adjustment of snaky movement of the V-belt tension according to Step 3 above. start with the work only after top and bottom. If the always the danger that you are caught in a V-belt slips. stopping the engine. When turning the adjustment bolt. install it to its original position without fail. a There may be a difference in the V-belt tension at the top (A) and bottom (B). start and stop the crusher and check that conveyor and its surrounding. there is there is no slipping sound from the V-belt.

3. Measure the maximum deflection of the con- veyor belt top surface from the bottom surface of the wooden block.30 Testing and adjusting SEN02305-01 Check tension of conveyor belt 1. 2. Standard value for deflection Deflection (a) should be 170 to 175 mm. BR380JG-1E0 39 . 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.

Loosen nuts (5) and (6).SEN02305-01 30 Testing and adjusting Adjustment of conveyor side rubber Adjustment of scraper If the conveyor side rubber has been worn out. gram. Loosen nuts (1) and bolts (2).e. 1. 3. (Standard clearance 0 mm. i. Driving pulley side ating a clearance between the rubber and belt. then set cleaner plate (4) so that it is at right angles to belt (3). 40 BR380JG-1E0 . then move the cleaner up so that the tip (7) of the cleaner contacts the belt. cre. close contact) 2. The default condition is as shown in the dia- loosen the adjustment bolt.

5. Tighten nuts (5) and (6). (4) is at right angles. BR380JG-1E0 41 . then rotate the cleaner plate 7.3 Nm {3. then tighten bolt (2) and nut (1).5 kgm} 6. 8. Raise the cleaner 5 mm. move the cleaner up. Rotate cleaner shaft (8) so that cleaner plate as shown in the diagram. Loosen bolts (2). If the angle of the tip of the cleaner and the belt is less than 60°. Check that cleaner tip (7) and the belt are at the 60° position. 3 Bolt M12: 34.30 Testing and adjusting SEN02305-01 4.

(It is in even contact with the belt across the width) 42 BR380JG-1E0 .SEN02305-01 30 Testing and adjusting Driven pulley side If the scraper rubber has been worn out. replace it by loosening the securing bolts.

or any of the parts was removed and installed in the past. a This sideways sway can be visually confirmed when an amount of sway is over 3 mm.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. and if the frame is found to sway sideways. 1. Operate the belt conveyor without load. Check the frame at portion (A) visually. carry out the following inspection and make adjustments or replace a parts. it means the frame needs to be replaced with a new one. if nec- essary. there is no need for the replacement. If the frame does not show such sway. 2. BR380JG-1E0 43 .

q Are debris stuck to the backside of the belt? k The magnetic force will attract metal tools q Has the belt surface been scratched or peeled and pieces of steel. mm at both ends from the inner surface of k If there is any misalignment or snaking of the flange at the end of the pulley. damaged or cut. or other precision instruments close to the magnetic separator. 1) In case the belt is deflected or makes a netic separator. tighten the lock bolt again. so do not approach the magnetic separator Adjust the position of the take-up unit. Do not allow any person base plate and adjust the position of the wearing a pacemaker to approach within a take-up unit with the tap bolt. There is danger of injury. and there is danger of off? getting your fingers or hands caught q Has the belt scraper not been damaged? between such objects and the attracting q Have metal parts or bolts at the connection of surface. a pillow block and magnetic separator. cause malfunction of pacemakers. the belt the belt. After the range of 5 m from the magnetic separator. k When conduction a trial run of the machine. accelerated by the metal piece discharging belt. k There is danger of the magnetic field caus- ing damage. adjustment. since they can damage the conveyor belt. If anything unusual is found. The take-up unit k When storing this machine or removing the consists of a base plate. k If metal pieces are drawn by the magnetic separator. or other cards with magnetic strips when approach- ing the magnetic separator. so do not approach the magnetic the belt end not been damaged or fallen off? separator when carrying metal tools or pieces of steel. 44 BR380JG-1E0 . check that there When there is a clearance more than 10 is no misalignment or snaking of the belt. k Before starting operations.SEN02305-01 30 Testing and adjusting Inspection and maintenance of The discharging belt for this machine has the same magnetic separator structure as that for the conventional belt conveyor. be sure to run the motor at low speed and check that the conveyor belt does not make a snaky movement. they will be ejected. As that poses a big danger. when starting k There is danger that the magnetic field may the day's work or daily inspection. referring to the figure. k There is danger of the stored data being damaged by the magnetic field. Pay attention to the following points. take the following k Use a steel object removal belt to remove actions. set up cones and make a tap bolt. cellu- lar phones. Loosen the lock bolt on the a no entry area. so do not bring watches. while it is being operated. snaky movement. credit cards. so do not carry bank cards. so per. there is danger that the belt will be is at a proper position. provide a safety cover at the discharging outlet to prevent the metal pieces from flying off. any pieces of steel attracted to the mag. k Do not feed concrete debris containing reinforcing bars larger than 13 mm in diam- eter and longer than 600 mm. q Has the belt been biased or does it make a sons wearing pacemakers should not snaky movement? approach within a range of 5 m from the q Is the belt tension appropriate? magnetic separator.

charge clearance and condition. 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. and fit on magnetic separator frame hook (2). since fixed position for crushing reinforced concrete. At that time. Rear (Q): Change position of magnetic separator bracket hole (5) and magnetic separator frame hole (4) to adjust. Front (P): Change position of magnetic separator replace it immediately. position for crushing reinforced concrete. 350 mm at both (A) and 40 mm from the lower surface of the mag. BR380JG-1E0 45 . Adjusting clearance from conveyor Adjust the belt tension in the same way as The clearance between the surface of the conveyor mentioned above. 4) If the belt or any related part is broken. see they can cause a damage on the belt or “Preparations for primary conveyor in Operation the pulley. 3) In case debris are stuck at the backside of Change as necessary according to the crusher dis- the belt. and maintenance manual”. chain (1) to adjust. then secure with pin (3). For details of the Remove them as soon as found. (B) when the primary conveyor height is at the fixed net on the main body.30 Testing and adjusting SEN02305-01 2) In case the belt tension is not appropriate.

If the belt is not slackened k Stop the engine first and start to work on the adjusting bolt (1).SEN02305-01 30 Testing and adjusting Check and adjustment of muck 2. wire shred. or inside the hopper rubber and belt. while inspecting or cleaning it. Be sure to stop the engine before starting the work. Adjust the belt ten- sion by turning the adjusting bolts (1) on the right and left sides of the belt. that are stuck at the backside of the belt conveyor. or in between the rollers and belt. (1): Direction of travel of belt k There is always the danger that you get caught in the revolving parts of the con- veyor. Check of each part in belt conveyor for any stuck foreign object Remove a stone. move discharge conveyor the belt in the direction indicated with an arrow. When the belt is deflected to the left. it tends to slip off and does not perform properly. When the belt is deflected to the right. If the belt is not deflected 1. move the belt in the direction indicated with an arrow. (1): Direction of travel of belt 46 BR380JG-1E0 . gravel. If the conveyor belt is slackened. etc.

earth stuck to the rollers will likely cause the rollers to wear prematurely. Keep a close watch on the head scraper con- stantly. replace the defec- tive belt with new one promptly. BR380JG-1E0 47 . Unless the scraper is in firm contact with the belt. 1. In that case.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.

SEN02305-01 30 Testing and adjusting List of companies which handles radio controllers Area Company name Address Yamada Bldg.Box 619 Unit 4/11 Durie Road Cardiff NSW 2285. Factory F15B MT-MST02 Mosta. Newcastle. Building A Oklahoma City. Germany Europe (all European countries) Hetronic Steuesysteme GmbH Tel: +49 9452-1890 Fax: +49 9452-189-20 P. Tel: +1 405-946-3574 Fax: +1 405-946-3574 Mosta Technopark. Honjo 2-3-12. Tel: +356-436214 Fax: +356-435057 48 BR380JG-1E0 . Matsumoto-shi.O. Malta Mediteranean and Middle East Hetronic Malta Ltd. OK 73108 USA USA (North & South America) Hetronic USA Inc. Australia Australia (Australia) Hetronic Australia Tel: +61 249-537931 Fax: +61 249-537932 4300 Highline Blvd. 2 D-84085 Langquaid. Nagano-ken Japan (Japan and Asia) Hetronic Japan Tel: 0263-38-7403 Fax: 0263-38-7404 Abalbert-Stifter-Sir..

If a T-adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting. BR380JG-1E0 49 .30 Testing and adjusting SEN02305-01 Handling voltage circuit of engine controller 1. Before disconnecting or connecting a connec- tor between the engine controller and engine. do not start the engine. 2. a You may turn the starting switch to the OFF or ON position but must not turn it to the START position. be sure to turn the starting switch OFF.

and maintain that state for 5 seconds. proceed to the next step. model num- ber and serial number Report the machine model. confirm the position of KOMTRAX terminal and the inspecting connector (the inspecting con- nector is provided at the bottom of KOMTRAX terminal).SEN02305-01 30 Testing and adjusting Procedure for turning on KOMTRAX terminal When the machine is delivered. a When installing KOMTRAX terminal after the machine is delivered (machine with the retro- spective equipment). 6) Connect the inspecting connector 1 again a Above completes the necessary opera. using the KOMTRAX client PC. Reporting of machine model. KOMTRAX ter- minal is installed: a When the machine is delivered. 2) Make sure visually that the inspecting con- nectors 1 and 2 are connected. 1. Station opening inspection a Referencing “Preparation work for trouble- shooting of electrical system”. 5) Disconnect the inspecting connector 2 a See “KOMTRAX administrator manual” for and maintain that state for 5 seconds. 1) Turn OFF the starting switch and then. 1. a Finish the operations of steps 4) to 7) within 30 seconds. model number and serial number to the person responsible to operation of KOMTRAX. When installing KOMTRAX terminal after the 8) Make sure that the KOMTRAX terminal 7- machine is delivered: segment indicator lamp is normally turned on. KOMTRAX terminal is installed (machine with the standard equipment). Registration of KOMTRAX terminal and maintain that state for 5 seconds. implement the following procedure. implement the following proce- dure. 3) Disconnect the inspecting connector 1 2. after making sure 5 seconds have elapsed. tions. Th e person responsible to ope ra tion of 4) Turn ON the starting switch and maintain KOMTRAX shall register the subject terminal that state for 5 seconds. the procedure. q Inspecting connector 1: G02 (female) and G03 (male) q Inspecting connector 2: G04 (female) and G05 (male) 50 BR380JG-1E0 . 7) Connect the inspecting connector 2 again and maintain that state for 5 seconds.

If any. 9) Set the starting switch to START position and maintain it in that state for 5 seconds. BR380JG-1E0 51 . 12) Make sure that the KOMTRAX terminal 7- segment indicator lamps are normally turned on. repair the trouble and repeat the pro- cedure from step 1). Make sure the engine is not started. repair the trouble and repeat the pro- cedure from step 1)). If any. check the GPS antenna and cable as well as the communication antenna and cable for external troubles. a If [Receiving error] were displayed. repair the trouble and repeat the pro- cedure from step 1). repeat the erencing “KOMTRAX terminal lamp procedure from step 1). check the GPS antenna and cable for external trou- bles. check KOMTRAX terminal CAN harness for troubles. check the communication antenna and cable for external troubles. Note: The third number on the display can be “2” or “3” though “3” is displayed in fig- ure below (both for the normal state and when trouble is present). the next step.30 Testing and adjusting SEN02305-01 a As [Normal] is indicated. a If [GPS position data sensing error and Receiving error] were displayed. a As [Normal] is confirmed. check the indication of [LED-C4] ref- a If [Abnormal] is indicated. indications”. a Don't return it to OFF position. 11) Set the starting switch to START position again and make sure the engine is started. (When CAN is not recog- nized. If any. a If the engine is started. 10) Return the starting switch to ON position and maintain that state for 5 seconds. proceed to the next step (it will take 90 seconds to 15 minutes until normal display is restored). If any. repair the trouble and repeat the procedure from step 1). proceed to a If [Network error] were displayed. repeat the procedure from step 1). a If [GPS position data sensing error] were display ed.

a Above completes the necessary oper- ations. 1) Concerning the machine body for which a If [Abnormal] is displayed. model number and serial number) (2) Part number and serial number of KOMTRAX terminal (3) The service meter reading when KOMTRAX terminal was installed (in 0. (1) Information of the machine body for which the station opening inspection has been completed (machine model. 52 BR380JG-1E0 .SEN02305-01 30 Testing and adjusting 13) Turn the starting switch OFF. the station inspection has been successfully ended. a See “KOMTRAX administrator man- ual” for the procedure. the inspec. tion to the person responsible to operation of KOMTRAX. only after the terminal station opening a As [Normal] is displayed. 2. Application for start of use 14) Make sure that the 7-segment indicator a The application for start of use is allowed lamp comes on normally in 10 seconds. report the following informa- repeated from step 1). the station opening inspection has been tion is incomplete and must be completed. opening inspection is complete.1 h unit) 2) The person responsible to operation of KOMTRAX shall register the machine body using the KOMTRAX client PC.

7-segment (Number of mails 2. Dot (GPS positioning state) 3. LED-A5 (Internal receiving state) lamp) 11. LED-A4 (Internal transmitting 9. LED-A2 (Within communica. LED-C4 (CAN state) lamp) 10. LED-A3 (Communication in 8. LED-C2 (Initial output state) 13. LED-C6 (Download writing state) BR380JG-1E0 53 . LED-C5 (Download writing 5. signal) not transmitted yet) tion range lamp) 7.30 Testing and adjusting SEN02305-01 KOMTRAX terminal lamp indications 1 LED for communication module LED for CPU 7-segment and dot for CPU 1. LED-C3 (S-NET and C signal progress lamp) state) 4. LED-A1 (Power lamp) 6. LED-C1 (R signal and ACC 12.

when a failure on the system is sus- pected. q The communication antenna shall not be disconnected or damaged. Thus. check the communication antenna and its vicinity as well as GPS antenna and its vicinity for any trouble. When above is not completed. ON LED comes on as the machine body moves inside the communication range 2 LED-A2 cation range lamp OFF of KOMTRAX system. Checking antennas a Before inspecting display of LED. q GPS antenna cable shall not be broken and shall be appropriately connected to KOMTRAX terminal.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. Display contents of LED for communication module a Turn ON the starting switch prior to inspection of LED display. q GPS antenna shall not be disconnected or damaged. Checking terminal LED indication 1. ON LED stays turned on as long as KOMTRAX terminal is connected to Communication in 3 LED-A3 KOMTRAX server. progress lamp OFF (Connection is made only needed) ON LED stays turned on as long as data transmission is continued from CPU to Internal transmit- 4 LED-A4 the communication module. LED Display Contents of display tion ON 1 LED-A1 Power lamp LED stays turned on as long as power is supplied normally OFF Within communi. Name and func- No. implement the following checkups. q Checking antennas q Checking terminal LED display Before using KOMTRAX. all LEDs for the communication module are turned off. It does not indicate the machine trouble. ting lamp OFF (Transmission is made only needed) ON LED stays turned on as long as the communication module is receiving data Internal receiving 5 LED-A5 from CPU. q The communication antenna cable shall not be broken and shall be appropriately connected to KOMTRAX terminal. lamp OFF (Receiving is made only needed) 54 BR380JG-1E0 . the application for start of use and the machine side station opening inspection must be completed.

LED Name and function Display Contents of display ON Starting switch ACC signal: ON. Alternator R signal: ON Quick State of starting switch Starting switch ACC signal: ON. BR380JG-1E0 55 . flashing 9 LED-C4 tion Slow CAN: Absent (Fuel sensor: Present) flashing OFF CAN: Absent (Fuel sensor: Absent) Single 10 LED-C5 Download writing mode (Special function for system administrator) side ON Download writing state Both 11 LED-C6 Normal working mode sides OFF a Types of flashing and flashing duration Quick flashing: Flashing of approximately 1 second cycle Slow flashing: Flashing of approximately 4 seconds cycle 3. START the starting switch or the engine prior to inspection of LED display.30 Testing and adjusting SEN02305-01 2. See * mark) 13 Dot ing with GPS Positioning with GPS incomplete (Position is not recognized OFF See * mark) * In a outdoor location within radio waves penetration range. Starting switch C signal: ON flashing 8 LED-C3 tion and starting switch C signal Slow (Not used) flashing OFF S-NET: Non-connection and starting switch C signal: OFF ON CAN: Present (Fuel sensor: Absent) Quick CAN: Present (Fuel sensor: Present) State of CAN connec. Alternator R signal: ON flashing OFF Starting switch ACC signal: OFF. alternator R signal Slow Starting switch ACC signal: OFF. Alternator R signal: OFF State of engine control ON Engine control signal: ON 7 LED-C2 signal OFF Engine control signal: OFF ON S-NET: Connection and starting switch C signal: OFF Quick State of S-NET connec. No. Display contents of LED for CPU a Turn ON. Positioning is not available in a location where radio waves are extremely weak or unreachable. No. Display contents of 7-segment and dots for CPU a Turn ON the starting switch prior to inspection of LED display. it sometimes takes more than a minute from turning on of the starting switch to completion of the positioning. Alternator R signal: OFF flashing 6 LED-C1 ACC signal. Display unit Name and function Display Contents of display Number of mails 12 7-segment 0–9 Number of mails not transmitted yet not transmitted yet Positioning with GPS complete (Position is recognized ON State of position.

remove the 7 main panel 3 Screw: 3 ± 1 Nm {0. procedure. a When returning connectors CE01 and a Since the machine monitor. expose the with screws. P02. CE02. tighten the screws to the specified torque. 2) Insert or connect troubleshooting T-adapt- a When carrying out troubleshooting for an elec. When disconnecting related connectors according to the following them. ers in or to connectors CE01. p u m p c o n t r o l l e r a n d a Connectors CE01 and CE02 are fixed KOMTRAX terminal controller. screws. engine and pump CE02. loosen the screws. and C03 of pump controller (3). C02. e n g i n e c o n t r o l l e r. Insert or connect test T-adapters to connectors a Since the connectors are fixed with P01.1 kgm} mounting screws and open the main panel first.3 ± 0. tighten the screws to the spec- controller and KOMTRAX terminal are installed ified torque.82 Nm {0. Pump controller Insert or connect test T-adapters to connectors 1. a When returning the connectors. 3.SEN02305-01 30 Testing and adjusting Preparation work for 2. a The engine controller is mounted on system the engine. 3 Screw: 2. Engine controller troubleshooting for electrical 1) Open the engine hood. loosen those screws before dis- connecting the connectors. Machine monitor C01. CE03 of engine controller (3).288 kgm} 56 BR380JG-1E0 . inside main panel (1). and tric circuit related to the machine monitor. and P03 of machine monitor (2).

Boost pressure and temperature sensor (BOOST PRESS & IMT) a Disconnection and connection of con- nector The connector of the boost pressure and temperature sensor has a special locking mechanism. Disconnection: (a) Slide lever – (b) Unlock – (c) Disconnect connector.30 Testing and adjusting SEN02305-01 4.288 kgm} a Cable (5) is used for the communication antenna (2 systems). a Disconnection and connection of con- nectors The connectors of the atmospheric pres- sure sensor. and troubleshooting”. a When returning the connectors to their original positions. Disconnect them according to steps (a) – (c) and connect them according to steps (d) – (f) as shown below. Atmospheric pressure sensor (AMBAIR steps (a) – (b) and connect it according to PRESSURE) steps (c) – (d) as shown below. a Removal and installation of sensor A torque wrench is necessary for removal and installation of the boost pressure and temperature sensor. Engine oil pressure switch (OIL PRESSURE Connection: (c) Connect connector – (d) SWITCH) Lock. 3 Screw: 2. a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch. engine Ne speed sensor. a The connectors are fixed with screws. Loosen the screws before disconnecting them. KOMTRAX terminal Insert or connect troubleshooting T-adapter in or to connector G01 of KOMTRAX terminal (4). fix them by tightening the screws with the specified torque. adjusting. See “Tools for test- ing. engine oil pressure switch have a special locking mechanism. 6. a Cable (6) is used for the GPS antenna. and troubleshooting”. Disconnect it according to 5. See “Tools for testing. Connection: (d) Connect connector – (e) Lock – (f) Slide lever. BR380JG-1E0 57 .82 Nm {0. adjusting. Engine Ne speed sensor (CRANK SENSOR) Disconnection: (a) Unlock – (b) Discon- Engine Bkup speed sensor (CAM SENSOR) nect connector. engine Bkup speed sensor.

available). 58 BR380JG-1E0 . connect the connector after a click is heard. Since the lock clicks when it is reset. 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. Disconnection: (a) Unlock – (b) Discon. Connection: (c) Connect connector – (d) Lock. Disconnection: (a) Unlock – (b) Discon- nect connector. Supply pump IMV solenoid (FUEL REGU. with triangular notch (f) on the sensor side nector (Do not engage lock (e) with square guide The connector of the common rail pres. Disconnect it according to steps (a) In this case. (f)). nism. and the lock is reset. Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. side or engine side). Connection: (c) Connect connector – (d) Lock. pinch the lock in direction (a) – (b) and connect it according to steps (c) with bent-nose nippers [1] (commercially – (d) as shown below. a Precautions for disconnecting connector LATOR) The direction of the lock of the connector a Disconnection and connection of con. nism. dis- nect connector. a Precautions for connecting connector Take care not to connect the connector 8.SEN02305-01 30 Testing and adjusting 7. PRESS) Engage lock (e) on the wiring harness side a Disconnection and connection of con. (g) on the opposite side of triangular notch sure sensor has a special locking mecha. Common rail pressure sensor (FUEL RAIL reversely.

Disconnect it according to steps (a) – (b) and connect it according to steps (c) – (d) as shown below. Connection: (c) Connect connector – (d) Lock.30 Testing and adjusting SEN02305-01 9. BR380JG-1E0 59 . a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch sensor. Disconnection: (a) Unlock – (b) Discon- nect connector. See “Tools for testing. adjusting. 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. and troubleshooting”.

q The indicated value changes: The diode has conductivity (Normal). 2) Apply the leads of the tester as explained below and check the movement of the a The conductive direction of the single diode is pointer. tery is indicated. 2. 60 BR380JG-1E0 . 3) Judge the condition of the diode by the indicated value. the voltage of the internal bat. check the indicated value. 1] Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cath- ode (N) side. 2) Apply the red (+) lead of the tester to the anode (P) side of the diode and apply the black (–) lead to the cathode (N) side and check the indicated value. When using digital circuit tester The diode is defective (Internal short 1) Set the tester in the diode range and circuit). q The indicated value does not change: The diode does not have conductivity (Defective). a The conductive directions of the assembled- type diode are as follows. however).SEN02305-01 30 Testing and adjusting Procedure for testing diodes 1 Note: In the case of a silicon diode. indicated on the surface of the diode. q The pointer moves in neither of 1] and a When an ordinary circuit tester is 2]: The diode is defective (Internal used. q The pointer moves in both 1] and 2]: 1. 3) Judge the condition of the diode by the movement of the pointer. 2] Apply the red (+) lead of the tester to the cathode (N) side of the diode and apply the black (–) lead to the anode (P) side. disconnection). When using analog circuit tester 1) Set the tester in the resistance range. 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. q The pointer does not move in 1] but moves in 2]: The diode is normal (The moving range (resistance) depends on the type and selected range of the tester.

30 Testing and adjusting SEN02305-01 BR380JG-1E0 61 .

SEN02305-01 © 2007 KOMATSU All Rights Reserved Printed in Japan 02-07 (01) 62 .SEN02305-01 BR380JG-1E0 Mobile crusher Form No.

........... SEN02088-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting 1 Failure code table and fuse locations Failure code table ................................................................ 6 BR380JG-1E0 1 ..................................................................................................................................................................... 2 Fuse locations ............................................

7RC1KB Short circuit conveyor ON switch W/E — Electrical system 7RC2KA Disconnection in conveyor OFF switch W/E — Electrical system 7RC5KB Short circuit in feeder ON switch W/E — Electrical system 7RD2KB Short circuit in conveyor reverse relay W/E — Electrical system 7RD2KZ Disconnection or short circuit in conveyor reverse relay W/E — Electrical system 7RE1KB Short circuit in crusher ON switch W/E — Electrical system 7RE2KA Disconnection in crusher OFF switch W/E — Electrical system 7RE6KB Short circuit in muck discharge conveyor ON switch W/E — Electrical system 7RE7KA Disconnection in muck discharge conveyor OFF switch W/E — Electrical system 7RE8KB Short circuit in magnetic separator ON switch W/E — Electrical system 7RE9KA Disconnection in magnetic separator OFF switch W/E — Electrical system 7REAKB Short circuit in accessory Input circuit W/E — Electrical system 7REDMA Abnormality in primary conveyor pressure sensor W/E — Electrical system Troubleshooting by failure code.SEN02088-00 40 Troubleshooting Failure code table 1 Failure Applicable User History Reference Failure contents code equipment code classification document No. 7RFLKA Disconnection in accessory EPC solenoid W/E — Electrical system Part 2 7RFLKB Short circuit in accessory EPC solenoid W/E — Electrical system SEN02091-00 7RFLKY Short circuit in accessory EPC solenoid W/E — Electrical system 7RFMKY Short circuit in abnormal pressure relay W/E — Electrical system 7RFMKZ Disconnection or short circuit in abnormal pressure relay W/E — Electrical system 7RFNKA Disconnection in lock cylinder unlock solenoid valve W/E — Electrical system 7RFNKB Short circuit in lock cylinder unlock solenoid valve W/E — Electrical system 7RFNKY Short circuit in lock cylinder unlock solenoid valve W/E — Electrical system 7RFPKB Short circuit in lock cylinder push relay W/E — Electrical system 7RFPKY Short circuit in lock cylinder push relay W/E — Electrical system 7RGAMA Abnormality in 2nd conveyor pressure sensor W/E — Electrical system 7RJAKA Disconnection in travel lock EPC solenoid valve W/E — Electrical system 2 BR380JG-1E0 . 7REEMA Abnormality in muck conveyor pressure sensor W/E — Electrical system Part 1 7RENKZ Abnormality in clearance potentiometer W/E — Electrical system SEN02090-00 7REPKA Disconnection in feeder OFF switch W/E — Electrical system 7RESKB Short circuit in one-touch start switch W/E — Electrical system 7RETKA Disconnection in one-touch stop switch W/E — Electrical system 7RF2KA Disconnection in crusher forward EPC valve W/E — Electrical system 7RF2KB Short circuit in crusher forward EPC valve W/E — Electrical system 7RF2KY Short circuit in crusher forward EPC valve W/E — Electrical system 7RF3KA Disconnection in crusher reverse EPC valve W/E — Electrical system 7RF3KB Short circuit in crusher reverse EPC valve W/E — Electrical system 7RF3KY Short circuit in crusher reverse EPC valve W/E — Electrical system 7RF4KA Disconnection in feeder forward EPC valve W/E — Electrical system 7RF4KB Short circuit in feeder forward EPC valve W/E — Electrical system 7RF4KY Short circuit in feeder forward EPC valve W/E — Electrical system 7RFAKY Short circuit in engine stop relay W/E — Electrical system 7RFAKZ Disconnection or short circuit in engine stop relay W/E — Electrical system 7RFBKB Short circuit in muck conveyor solenoid W/E — Electrical system 7RFBKZ Disconnection or short circuit in muck conveyor solenoid W/E — Electrical system 7RFCKA Disconnection in magnetic separator solenoid W/E — Electrical system 7RFCKB Short circuit in magnetic separator solenoid W/E — Electrical system 7RFCKY Short circuit in magnetic separator solenoid W/E — Electrical system 7RFHKB Short circuit in conveyor forward relay W/E — Electrical system 7RFHKY Short circuit in conveyor forward relay W/E — Electrical system 7RFKKB Short circuit in lock cylinder pull relay W/E — Electrical system 7RFKKY Short circuit in lock cylinder pull relay W/E — Electrical system Troubleshooting by failure code.

7RJAKB Short circuit in travel lock EPC solenoid valve W/E — Electrical system 7RJAKY Short circuit in travel lock EPC solenoid valve W/E — Electrical system 7RJMMW Lock cylinder slipping W/E — Mechanical system 7RJNMA Abnormality in vibratory screen pressure sensor W/E — Electrical system Troubleshooting 7RJPKB Short circuit in radio control work-mode switch W/E — Electrical system by failure code. CA435 Abnormality in engine oil pressure switch ENG E15 Electrical system Part 4 SEN02093-00 CA441 Power source voltage too low ENG E10 Electrical system CA442 Power source voltage too high ENG E10 Electrical system CA449 Common rail pressure sensor too high (2) ENG E11 Electrical system CA451 Common rail pressure sensor too high ENG E11 Electrical system CA452 Common rail pressure sensor too low ENG E11 Electrical system BR380JG-1E0 3 .2 ENG E11 Electrical system CA332 Disconnection or short circuit in injector No.6 ENG E11 Electrical system CA331 Disconnection or short circuit in injector No.5 ENG E11 Electrical system CA324 Disconnection or short circuit in injector No.40 Troubleshooting SEN02088-00 Failure Applicable User History Reference Failure contents code equipment code classification document No.4 ENG E11 Electrical system CA342 Abnormality in engine controller data consistency ENG E10 Electrical system CA351 Abnormality in injector drive circuit ENG E10 Electrical system CA352 Sensor power source 1 too low ENG E15 Electrical system CA386 Sensor power source 1 too high ENG E15 Electrical system CA428 Water detection sensor too high ENG E15 Electrical system Troubleshooting CA429 Water detection sensor too low ENG E15 Electrical system by failure code. 7RJQKB Short circuit in radio control travel-mode switch W/E — Electrical system Part 2 SEN02091-00 7RJRKB Short circuit on travel signal W/E — Electrical system 7RJSMA Abnormality in magnetic separator pressure sensor W/E — Electrical system AA10NX Air cleaner Clogging MON — Mechanical system AB00KE Charge voltage too low MON — Mechanical system B@BAZG Engine oil pressure too low ENG — Mechanical system B@BAZK Engine oil level reduction MON — Mechanical system B@BCNS Radiator coolant overheat ENG — Mechanical system B@BCZK Radiator coolant level reduction MON — Mechanical system B@HANS Hydraulic oil overheat MON — Mechanical system CA111 Abnormality in engine controller ENG E10 Electrical system CA115 Abnormality in engine NE and Bkup speed sensors ENG E10 Electrical system CA122 Charge pressure sensor too high ENG E11 Electrical system CA123 Charge pressure sensor too low ENG E11 Electrical system CA131 Throttle sensor too high ENG E14 Electrical system CA132 Throttle sensor too low ENG E14 Electrical system CA144 Coolant temperature sensor too high ENG E15 Electrical system CA145 Coolant temperature sensor too low ENG E15 Electrical system CA153 Charge temperature sensor too high ENG E15 Electrical system Troubleshooting CA154 Charge temperature sensor too low ENG E15 Electrical system by failure code.1 ENG E11 Electrical system CA323 Disconnection or short circuit in injector No.3 ENG E11 Electrical system CA325 Disconnection or short circuit in injector No. CA155 Charge temperature too high and engine speed derated ENG E11 Electrical system Part 3 SEN02092-00 CA187 Sensor power source 2 too low ENG E15 Electrical system CA221 Ambient pressure sensor too high ENG E11 Electrical system CA222 Ambient pressure sensor too low ENG E11 Electrical system CA227 Sensor power source 2 too high ENG E15 Electrical system CA234 Engine overspeed ENG — Mechanical system CA238 Abnormal power source for Ne speed sensor ENG E15 Electrical system CA271 Short circuit in fuel pump actuator ENG E10 Electrical system CA272 Disconnection in fuel pump actuator ENG E10 Electrical system CA322 Disconnection or short circuit in injector No.

a History classification: History classification indicates in which system. MON : Machine monitor system ENG : Engine controller system TM : Transmission controller system COM : Communication controller system W/E : Work equipment and pump controller (work equipment control) system PUMP: Work equipment and pump controller (pump control) system a User code: User code indicates what is displayed in the operator mode when a failure is detected. CA488 Charge temperature too high and torque derated ENG E11 Electrical system CA553 Common rail pressure sensor too high (1) ENG E15 Electrical system CA559 Supply pump no pressure ENG E15 Electrical system CA689 Abnormality in engine Ne speed sensor ENG E15 Electrical system CA731 Abnormal phase in engine Bkup speed sensor ENG E15 Electrical system CA757 Loss of all engine controller data ENG E10 Electrical system Troubleshooting CA778 Abnormality in engine Bkup speed sensor ENG E15 Electrical system by failure code. a Applicable equipment: Applicable equipment indicates in which controller system the failure has occurred. DHPAMA Abnormality in F pump pressure sensor PUMP — Electrical system Part 5 DHPBMA Abnormality in R pump pressure sensor PUMP — Electrical system SEN02094-00 DUB0KY Short circuit in beacon solid state relay W/E — Electrical system DUB0KZ Disconnection or short circuit in beacon solid state relay W/E — Electrical system DXA0KA Disconnection in PC-EPC Solenoid PUMP E02 Electrical system DXA0KB Short circuit in PC-EPC Solenoid PUMP E02 Electrical system DXA0KY Short circuit in PC-EPC Solenoid PUMP E02 Electrical system DXE0KA Disconnection in LS-EPC solenoid PUMP — Electrical system DXE0KB Short circuit in LS-EPC solenoid PUMP — Electrical system DXE0KY Short circuit in LS-EPC solenoid PUMP — Electrical system a Failure code: The failure code table is written in alphabetical order and also starting from small number. either electrical system or mechanical system in the fail- ure history displayed function. a failure has been recorded.SEN02088-00 40 Troubleshooting Failure Applicable User History Reference Failure contents code equipment code classification document No. The failure code in parentheses is not recorded in the failure history for both electrical and mechanical system. 4 BR380JG-1E0 . CA1633 CAN communication error (engine controller) ENG E0E Electrical system Part 4 SEN02093-00 CA2185 Throttle pedal sensor power source too high ENG E14 Electrical system CA2186 Throttle pedal sensor power source too low ENG E14 Electrical system CA2249 Supply pump no pressure (2) ENG E11 Electrical system CA2311 Abnormal resistance in pump regulator valve ENG E11 Electrical system CA2555 Disconnection in air intake heater relay ENG E15 Electrical system CA2556 Short circuit in air intake heater relay ENG E15 Electrical system D162KY Short circuit in horn relay W/E — Electrical system D162KZ Disconnection or short circuit in horn relay W/E — Electrical system DA22KK Solenoid power source too low PUMP E0E Electrical system DA25KP Abnormality in pressure sensor power source PUMP — Electrical system CAN communication error DA2RMC PUMP E0E Electrical system (work equipment and pump controller) DA2SKQ Abnormality in model code input PUMP — Electrical system DAFRMC CAN communication error (monitor controller) MON E0E Electrical system DDA6KA Disconnection in engine stop switch W/E — Electrical system Troubleshooting DGH2KB Short circuit in hydraulic oil temperature sensor MON — Electrical system by failure code.

a When carrying out troubleshooting related to the electrical system. 2 step relief relay 8 10A Travel straight. Destination of power of fuse Starting switch 1 20A KOMTRAX controller Constant power source 2 10A Machine monitor Fusible link E02 (30A) 3 30A Engine controller 4 10A Work equipment and pump controller Switched power source 5 5A Engine controller (ACC signal) Starting switch ACC Pump controller (solenoid power source) 6 15A Engine stop relay Preheater relay (when auto preheat relay is actuated) Front lamp Rear lamp 7 20A Machine monitor panel light Switched power source Box lamp Fusible link E07 (65A) Upper travel control box lamp Horn relay Travel straight.SEN02088-00 40 Troubleshooting Fuse locations 1 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. Locations and numbers of fuse boxes and fusible links Fuse box Fuse Capacity Type of power source Fuse No. 2 step relief solenoid valve Lock cylinder push solenoid valve Beacon lamp (red) relay 9 10A Beacon lamp (red) 6 BR380JG-1E0 . (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). you should check the fuse box and fusible links to see if the power is supplied normally.

right forward. left backward.40 Troubleshooting SEN02088-00 Capacity Type of power source Fuse No. sprinkler) Emergency stop relay 2 (spare) Pull-up power source for over feed sensor (spare) 11 15A Spare Switched power source 12 10A Horn Fusible link E07 (65A) Radio control select relay Beacon lamp for radio control (yellow) Radio control receiver Radio control travel relay (left forward. right forward. right backward) Sprinkler pump stop relay 14 20A Sprinkler pump 15 10A Radio control power charger BR380JG-1E0 7 . 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) 10 10A Conveyor/muck discharge conveyor select solenoid valve 2nd conveyor solenoid valve Vibrator screen solenoid valve Sprinkler relay Abnormal stop relay (2nd conveyor. left backward. vibrator screen. right backward) Radio control engine stop relay 13 10A Radio control horn relay Radio control beacon lamp relay Radio control one-touch stop relay Radio control feeder off relay Travel solenoid valve (left forward.

SEN02088-00 40 Troubleshooting Fusible link Fusible link Connector Capacity No.15 8 BR380JG-1E0 . of fusible link 1 Constant power source E02 30A Fuse No.5 2 Switched power source E07 65A Fuse No.1 – No.6 – No. Type of power source Destination of power No.

SEN02088-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01) 10 .SEN02088-00 BR380JG-1E0 Mobile crusher Form No.

............................................................................. 12 T-adapter box and T-adapter table............................................................................................................................................................................................................................................ 45 BR380JG-1E0 1 ................................................................................................................................ 4 Classification and procedures of troubleshooting ........... 3 Checks before troubleshooting ............. 2 Sequence of events in troubleshooting.................................... 10 Wiring table for connector pin numbers .................... 6 Contents of troubleshooting table ............................. SEN02089-01 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting 1 General information on troubleshooting Points to remember when troubleshooting ......................................................................................................................................................................................................

etc. When carrying out troubleshooting. externally. k When removing the plug or cap from a location which is under pressure from oil. of the failure. as a problem with the method of operation. will also Confirm the extent of the failure yourself. When installing testing equipment. or were troubleshooting flowchart to locate the position there problems with the machine condition of the failure exactly. be sure to connect it properly. 2.To prevent this. so wait for the engine to cool down before starting troubleshooting. then use the troubleshooting table or 3) Did the failure occur suddenly. a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symp- toms. k When disconnecting wiring. if the root cause of the failure is not repaired. to carry out repairs swiftly. k Be extremely careful not to touch any hot parts or to get caught in any rotating parts. the failure? When were these repairs car. The aim of troubleshooting is to pinpoint the basic cause of the failure. remove the root cause. or air. and check that the lock pin. carry out any investigation or measure- ment that may make the problem worse. However. Check before troubleshooting hurry to disassemble the components. Troubleshooting from the problem that has been reported? Use the results of the investigation and inspec- 2) Was there anything strange about the tion in Items 2 – 4 to narrow down the causes machine before the failure occurred? of failure. and lose the confidence of the user or operator. it is necessary to carry out thorough prior a When operating the machine to reenact investigation and to carry out troubleshooting the troubleshooting symptoms. blocks. and to pre- vent reoccurrence of the failure. 1. and at the same time. 6) Has the same kind of failure occurred 6. always disconnect the negative (–) terminal of the battery first. when carrying out troubleshooting. 4. water. do not 3. Then. occur? 1] Start from the simple points. ure or other unnecessary parts will be dis- 4) Other maintenance items can be checked assembled. parts. always release the internal pressure first. 5) Had any repairs been carried out before 2] Start from the most likely points.SEN02089-01 40 Troubleshooting Points to remember when troubleshooting 1 k Stop the machine in a level place. do not in accordance with the fixed procedure. and parking brake are securely fitted. 3) Make checks of other items. It will also cause a waste of manhours. before this? a The basic procedure for troubleshooting is 4) Under what conditions did the failure as follows. Measures to remove root cause of failure before? Even if the failure is repaired. and important point is of course to understand the structure and function. k If the radiator cap is removed when the engine is hot. For judge whether to handle it as a real failure or this reason. hot coolant may spurt out and cause burns. the same failure will occur again. Points to ask user or operator 1) Have any other problems occurred apart 5. and do not allow any unauthorized person to come near. 1) Is there any sign of irregularities of the If components are disassembled immediately machine? any failure occurs: 2) Make checks before starting day's work. k When carrying out the operation with 2 or more workers. 3] Investigate other related parts or ried out? information. always investi- gate why the problem occurred. so check any item that is con- q It will become impossible to find the cause sidered to be necessary. keep strictly to the agreed signals. When carrying out troubleshooting. Confirming failure or oil or grease. q Parts that have no connection with the fail. 2 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 Sequence of events in troubleshooting 1 BR380JG-1E0 3 .

Check battery electrolyte level Between H – L Add or replace 6. Check operating sound of battery relay (When starting switch — is turned ON. wiring — Tighten or replace 2. Check for missing wiring clamps. Check hydraulic filtering — Replace 1. exposed wiring — Charge or replace Electrical 7. — Tighten or replace wiring 4. Check for blown. Check hydraulic oil level Between H – L Add oil Lubricating 4. drain oil. Carry out air bleeding — Bleed air 1. Chassis Judgement Item Action Value 1. Check fuel level. Check coolant level (in sub tank) Between H – L Add coolant 7. smell — Repair Hydraulic. Check alternator voltage (Engine running at 1/2 throttle or several minutes: Replace above) 27. Check for looseness. corroded fuses — Replace After running for 10. burnt.SEN02089-01 40 Troubleshooting Checks before troubleshooting 1 1. corrosion of starting motor terminal. corrosion of battery terminal. Check for water leaking on wiring (Pay particular attention to Disconnect — water leaking on connectors or terminals) connector and dry 9. Check for impurities in fuel — Clean. mechanical 2. Check for abnormal noise. coolant 5. corrosion of alternator terminal. Check hydraulic oil strainer — Clean.5 – 29. Check for looseness. type of fuel — Add fuel 2. Check for oil leakage — Repair equipment 3.5 V 11. drain 3. Check engine oil level (oil pan oil level) Between H – L Add oil 6. OFF) 4 BR380JG-1E0 . Check for discolored. hanging wire — Repair equipment 8. Check dust indicator for clogging No red part Clean or replace 8. wiring — Tighten or replace 3. Check for looseness. Check battery voltage (Engine stopped) 20 – 30 V Charge or replace 5.

or foreign material caught in carrier Must not exist Clean roller or return roller Damage of head pulley and tail pulley Must not exist Replace Standard value Check of conveyor belt tension *See Testing Adjust and adjusting Check belt cleaner and scraper Must work Adjust or replace 4. Wear of swing jaw 3. Wear of cheek plate Wear limit 4. Wear of fixed jaw Spring Wear of consumable parts Reverse or replace 2. Belt conveyor Judgment Item Action value Must rotate Check carrier roller and return roller Adjust or replace easily Rollers Dirt or mud attached to. Check tooth plate wedge bolt spring case Standard value Retighten 2.40 Troubleshooting SEN02089-01 2. Wear of toggle seat 7. Crusher Judgment Item Action value 1. Check of crusher driving V-belt tension Adjust 3. 5. Wear of movable tooth wedge Replace 6. Check tension spring *See Testing and adjusting. Others Item Judgment value Machine installation condition (during work) Must be on a flat firm surface Machine exterior damage (by loading machine etc.) or modifica- Harmful damage must not exist tion (*1) *1: Frame deformation by hitting the hydraulic excavator bucket to the conveyor frame (that can cause the belt meandering or abnormal rotation of head pulley) Addition of liner plate to the feeder (that weakens the feeder feeding force) BR380JG-1E0 5 . Wear of protector *See Testing and adjusting. Wear of toggle plate 1.

2.”. or “S mode”. check the phenomenon looking like a trouble again and select the same phenomenon from the table of “Phenomena looking like troubles and troubleshooting Nos. a If an electrical system failure code is recorded. and then carry out trouble- shooting corresponding to that phenomenon in the “E mode”.SEN02089-01 40 Troubleshooting Classification and procedures of troubleshooting 1 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. In this case. and then go to the corresponding troubleshooting section. carry out the corresponding troubleshooting in “E mode”. carry out the troubleshooting for the corresponding “Display of code” according to the displayed failure code. check for a mechanical sys- tem failure code and an electrical system failure code with the fault history function of the machine mon- itor. according to the following procedure. 1. a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history function. 6 BR380JG-1E0 . Procedure for troubleshooting to be taken when user code and failure code are displayed on machine monitor: If a user code and a failure code are displayed on the machine monitor. delete all the codes and reproduce them. If a failure code is recorded. a A failure code of the mechanical system cannot be deleted. select a proper troubleshooting No. “H mode”. carry out troubleshooting for the corresponding “Display of code” accord- ing to that code. When electrical system failure code or mechanical system failure code is recorded in fault his- tory: If a user code and a failure code are not displayed on the machine monitor. 3. When user code or failure code is not displayed and no failure code is recorded in fault history: If a user code or a failure code is not displayed on the machine monitor and no failure code is recorded in the fault history. a trouble that the machine cannot find out by itself may have occurred in the electrical system or hydraulic and mechanical system. and then see if the trouble is still detected.

40 Troubleshooting SEN02089-01 Phenomena considered to be failures and troubleshooting Nos. or failure code 1 User code is displayed on machine monitor Accord- When failure history is checked. error code. error code is displayed in electri- 2 ing to cal system indicated When failure history is checked. Troubleshooting No. error code is displayed in code 3 mechanical system Phenomena related to engine 4 Engine does not start easily (It always takes time to start) S-1 5 Engine does not crank E-1 S-2 a) Engine cranks but exhaust smoke does not come 6 Engine does S-2 b) out not start Exhaust smoke comes out but engine does not 7 S-2 c) start 8 Engine speed does not rise sharply S-3 9 Engine stops during operation E-2 H-2 S-4 10 Engine does not rotate smoothly S-5 11 Engine lacks output (or lacks power) H-1 S-6 12 Exhaust gas color is bad (Incomplete combustion) S-7 13 Oil is consumed much or (exhaust gas color is blue) S-8 14 Oil becomes dirty quickly S-9 15 Fuel is consumed much S-10 Coolant contains oil (or coolant spurts back or coolant level goes 16 S-11 down) 17 Oil pressure drops S-12 18 Oil level rises (Water or fuel is mixed in oil) S-13 19 Coolant temperature becomes too high (overheating) S-14 20 Abnormal sound comes out S-15 21 Vibration is excessive S-16 22 Engine does not stop 23 Automatic warm-up function does not work E-3 24 The engine preheater does not operate E-4 Phenomena related to work equipment and travel 25 Speed or power of whole work equipment and travel is low H-1 S-6 26 Engine speed lowers extremely or engine stalls H-2 S-4 27 All work equipment stops suddenly E-5 28 Work equipment and travel systems do not work H-3 29 Abnormal sound comes out from around hydraulic pump H-4 30 Fine control performance or response is low H-5 BR380JG-1E0 7 . Phenomena considered to be failures Indication E-mode H-mode S-mode of code Phenomena related to user code.

SEN02089-01 40 Troubleshooting Troubleshooting(Rev. machine does 49 E-18 H-21 not travel Phenomena related to monitor panel (Operator menu: Ordinary screen) Red mark of emergency stop is indicated just after engine is 50 E-6 started 51 No items are displayed on machine monitor E-7 52 Some items are not displayed on machine monitor E-8 Contains of display by machine monitor are different from applica- 53 E-9 ble machine Radiator coolant level monitor lights red during check before start- 54 B@BCZK ing 55 Engine oil level monitor lights red during check before starting B@BAZK 56 Maintenance hour monitor lights red during check before starting Refer to Operation & Maintenance Manual 57 Battery charge level monitor lights red while engine is running AB00KE 58 Fuel level monitor lights red while engine is running E-10 59 Air cleaner clogging monitor lights red while engine is running AA10NX Engine coolant temperature monitor lights red while engine is run- 60 B@BCNS ning Hydraulic oil temperature monitor lights red while engine is run- 61 B@HANS ning 62 Engine coolant temperature gauge does not display normally E-11 63 Fuel level gauge does not display normally E-12 8 BR380JG-1E0 .11) No. Phenomena considered to be failures Indication E-mode H-mode S-mode of code Phenomena related to work equipment 31 Conveyor does not operate H-6 32 Speed or power of conveyor is low H-7 33 Crusher does not operate H-8 34 Speed or power of crusher is low H-9 35 Feeder does not operate H-10 36 Feeder does not feed smoothly (Vibration frequency is low) H-11 37 Magnetic separator does not operate H-12 38 Speed of magnetic separator belt is low H-13 39 Side conveyor does not operate H-14 40 Speed or power of side conveyor is low H-15 41 Primary conveyor and side conveyor do not move up and down H-16 42 Feeder cannot be turned ON and OFF by radio control E-19 43 One-touch start. 2006. stop switch cannot be operated by radio control E-20 44 Rotating direction cannot be changed by radio control E-16 Phenomena related to travel 45 Machine deviates during travel H-17 46 Travel speed is low H-18 47 Machine is not steered well or steering power is low H-19 48 Travel motor does not work E-17 H-20 When travel switch of radio controller is depressed.

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 Phenomena related to monitor panel (Service menu: Special function screen) Crusher cannot be operated with crusher manual forward/reverse 68 E-22 switch on monitor Conveyor cannot be operated with conveyor manual forward/ 69 E-23 reverse switch on monitor Crusher clearance cannot be adjusted with crusher clearance 70 H-22 increase/decrease switch on monitor Phenomena related to KOMTRAX system 71 KOMTRAX system does not operate normally E-24 BR380JG-1E0 9 . work.40 Troubleshooting SEN02089-01 Troubleshooting No. 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.

connect the plus (+) and minus (–) leads of the tester as described below unless especially specified. (2) Pin number description sequence and tester lead handling For troubleshooting.SEN02089-01 40 Troubleshooting Contents of troubleshooting table 1 a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. insert or connect the T-adapter as 3 described below unless especially specified.adapter in both the male and female. • Defective grounding A harness not connected to GND (ground) circuit comes into contact with the GND (ground) circuit. • When “male” or “female” is indicated for a connector num- ber. • Connect the minus (–) lead to a pin number or harness indi- cated in the rear. not a priority <Points to remember when troubleshooting> sequence. disconnect the connector. disconnect the connector. and insert the T. User code Failure code Machine Machine Names of the failure symptoms displayed in the failure history on the Trouble monitor monitor machine monitor display display Contents of State where the machine monitor or controller detects the trouble trouble Action of Action to be taken to protect the system and equipment when the machine monitor or control- controller ler detects a trouble Problem that Problem that appears as an abnormality in the machine by the action (above) taken by monitor appears on or controller machine Related Information related to troubles occurred or troubleshooting information Cause Standard value in normal state/Remarks on troubleshooting <Described contents> • Standard value when normal required to judge the possible cause 1 • Remarks required to judge whether any cause is right or not <Symptoms of defective harness> • Disconnection in wiring The connector connection is defective or the wiring harness is disconnected. • Hot short defect 2 A harness not connected to the electric power supply (24V) cir- cuit comes into contact with the electric power supply (24V) cir- cuit.) (1) Method of indicating connector numbers and handling T-adapter For troubleshooting. understand that information fully. in normal state indicates a serial num- ber. 10 BR380JG-1E0 . • When “male” or “female” is not indicated for a connector number. Before carrying out troubleshooting. 4 • Connect the plus (+) lead to a pin number or harness indi- cated in the front. Cause by which a trou- Possible ble is assumed to be • Short circuit causes and detected A harness abnormally comes into contact with a harness of sepa- standard value (The order number rate circuit. and insert the T-adapter in only either the male or female.

40 Troubleshooting SEN02089-01 Circuit diagram related This drawing is a part of the electric circuit diagram related to trouble- shooting. BR380JG-1E0 11 . and pin No. • Connector No. • “Connector No. • Arrow (io): Roughly shows the location on the machine.Number of pins) and (Color).“ from each branching/merging point: Shows the ends of branch or source of merging within the parts of the same wiring harness.: Indicates (Model .

2006.SEN02089-01 40 Troubleshooting Wiring table for connector pin numbers (Rev. while the terms of male housing and female housing refer to the mating portion of the housing.11) a The terms of male and female refer to the pins. 12 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 13 .

SEN02089-01 40 Troubleshooting 14 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 15 .

SEN02089-01 40 Troubleshooting 16 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 17 .

SEN02089-01 40 Troubleshooting 18 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 19 .

SEN02089-01 40 Troubleshooting 20 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 21 .

SEN02089-01 40 Troubleshooting 22 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 23 .

SEN02089-01 40 Troubleshooting 24 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 25 .

SEN02089-01 40 Troubleshooting 26 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 27 .

SEN02089-01 40 Troubleshooting 28 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 29 .

SEN02089-01 40 Troubleshooting 30 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 31 .

SEN02089-01 40 Troubleshooting 32 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 33 .

SEN02089-01 40 Troubleshooting 34 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 35 .

SEN02089-01 40 Troubleshooting 36 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 37 .

SEN02089-01 40 Troubleshooting 38 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 39 .

SEN02089-01 40 Troubleshooting 40 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 41 .

SEN02089-01 40 Troubleshooting 42 BR380JG-1E0 .

40 Troubleshooting SEN02089-01 BR380JG-1E0 43 .

SEN02089-01 40 Troubleshooting 44 BR380JG-1E0 .

2006. T-adapter kit Number of pins 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 799-601-4200 Out of kit Identification Part No.40 Troubleshooting SEN02089-01 T-adapter box and T-adapter table 1 (Rev.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. Part name symbol 799-601-2600 T-box (for ECONO) 21 q q q q q 799-601-3100 T-box (for MS) 37 799-601-3200 T-box (for MS) 37 799-601-3380 • Plate for MS (14-pin) q 799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3420 Adapter for BENDIX (MS) 24 MS-24P q 799-601-3430 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3440 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3450 Adapter for BENDIX (MS) 5 MS-5P q 799-601-3460 Adapter for BENDIX (MS) 10 MS-10P q 799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q 799-601-3520 Adapter for BENDIX (MS) 17 MS-17P q 799-601-3530 Adapter for BENDIX (MS) 19 MS-19P q 799-601-2910 Adapter for BENDIX (MS) 14 MS-14P q 799-601-3470 Case q 799-601-2710 Adapter for MIC 5 MIC-5P q q q 799-601-2720 Adapter for MIC 13 MIC-13P q q q 799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q 799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q 799-601-2950 Adapter for MIC 9 MIC-9P q q q q 799-601-2750 Adapter for ECONO 2 ECONO2P q q 799-601-2760 Adapter for ECONO 3 ECONO3P q q 799-601-2770 Adapter for ECONO 4 ECONO4P q q 799-601-2780 Adapter for ECONO 8 ECONO8P q q 799-601-2790 Adapter for ECONO 12 ECONO12P q q 799-601-2810 Adapter for DLI 8 DLI-8P q q 799-601-2820 Adapter for DLI 12 DLI-12P q q 799-601-2830 Adapter for DLI 16 DLI-16P q q 799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q 799-601-2850 Case q 799-601-4210 Adapter for DRC 50 DRC50 q 799-601-7010 Adapter for X (T-adapter) 1 q q 799-601-7020 Adapter for X 2 X2P q q q q 799-601-7030 Adapter for X 3 X3P q q q q 799-601-7040 Adapter for X 4 X4P q q q q 799-601-7050 Adapter for SWP 6 SW6P q q q 799-601-7060 Adapter for SWP 8 SW8P q q q 799-601-7310 Adapter for SWP 12 SW12P q 799-601-7070 Adapter for SWP 14 SW14P q q 799-601-7320 Adapter for SWP 16 SW16P q 799-601-7080 Adapter for M (T-adapter) 1 q q 799-601-7090 Adapter for M 2 M2P q q q q 799-601-7110 Adapter for M 3 M3P q q q q BR380JG-1E0 45 .

Part name symbol 799-601-7120 Adapter for M 4 M4P q q q q 799-601-7130 Adapter for M 6 M6P q q q q 799-601-7340 Adapter for M 8 M8P q 799-601-7140 Adapter for S 8 S8P q q q q 799-601-7150 Adapter for S (White) 10 S10P q q q q 799-601-7160 Adapter for S (Blue) 12 S12P q q q 799-601-7170 Adapter for S (Blue) 16 S16P q q q q 799-601-7330 Adapter for S (White) 16 S16PW q 799-601-7350 Adapter for S (White) 12 S12PW q 799-601-7180 Adapter for AMP040 8 A8P q 799-601-7190 Adapter for AMP040 12 A12P q q 799-601-7210 Adapter for AMP040 16 A16P q q q q 799-601-7220 Adapter for AMP040 20 A20P q q q q 799-601-7230 Short connector for X 2 q q q q 799-601-7240 Case q q 799-601-7270 Case q 799-601-7510 Adapter for 070 10 07-10 q 799-601-7520 Adapter for 070 12 07-12 q 799-601-7530 Adapter for 070 14 07-14 q 799-601-7540 Adapter for 070 18 07-18 q 799-601-7550 Adapter for 070 20 07-20 q 799-601-7360 Adapter for relay 5 REL-5P q 799-601-7370 Adapter for relay 6 REL-6P q 799-601-7380 Adapter for JFC 2 q 799-601-9010 Adapter for DTM 2 DTM2 q q 799-601-9020 Adapter for DT 2 DT2 q q q q 799-601-9030 Adapter for DT 3 DT3 q q 799-601-9040 Adapter for DT 4 DT4 q q q q 799-601-9050 Adapter for DT 6 DT6 q q 799-601-9060 Adapter for DT (Gray) 8 DT8GR q q 799-601-9070 Adapter for DT (Black) 8 DT8B q q 799-601-9080 Adapter for DT (Green) 8 DT8G q q 799-601-9090 Adapter for DT (Brown) 8 DT8BR q q 799-601-9110 Adapter for DT (Gray) 12 DT12GR q q 799-601-9120 Adapter for DT (Black) 12 DT12B q q 799-601-9130 Adapter for DT (Green) 12 DT12G q q 799-601-9140 Adapter for DT 12 DT12BR q q 799-601-9210 Adapter for HD30-18 8 D18-8 q q 799-601-9220 Adapter for HD30-18 14 D18-14 q q 799-601-9230 Adapter for HD30-18 20 D18-20 q q 799-601-9240 Adapter for HD30-18 21 D18-21 q q 799-601-9250 Adapter for HD30-24 9 D24-9 q q 799-601-9260 Adapter for HD30-24 16 D24-16 q q 799-601-9270 Adapter for HD30-24 21 D24-21 q q 799-601-9280 Adapter for HD30-24 23 D24-23 q q 799-601-9290 Adapter for HD30-24 31 D24-31 q q 799-601-9310 Plate for HD30 (24-pin) q q q 46 BR380JG-1E0 .SEN02089-01 40 Troubleshooting T-adapter kit Number of pins 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 799-601-4200 Out of kit Identification Part No.

2.2.4C q q Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 3 1.40 Troubleshooting SEN02089-01 T-adapter kit Number of pins 799-601-2500 799-601-2700 799-601-2800 799-601-7000 799-601-7100 799-601-7400 799-601-7500 799-601-8000 799-601-9000 799-601-9100 799-601-9200 799-601-9300 799-601-4100 799-601-4200 Out of kit Identification Part No.2.3L q q Commonrail pressure Socket for engine (CRI-T3) 799-601-4230* 4 1.2.PA q q Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* 4 1.3 q 795-799-5520* Socket for engine (HPI-T2) 2 S q Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) 2 C q q Temperature sensor Socket for engine (HPI-T2) 795-799-5540* 2 A q q Socket for engine (CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 3 q 795-799-5470 Cable for engine (HPI-T2) 3 q 795-799-5480 Cable for engine (HPI-T2) 3 q 799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q 799-601-4130 Adapter for engine (CRI-T3) NE.3A q q 799-601-4250* Socket for engine (CRI-T3) PIM 3 1.3.4T q Air intake pressure/temperature 799-601-4260 Adapter for controller (ENG) 4 DTP4 q q 799-601-4211 Adapter for controller (ENG) 50 DRC50 q 799-601-4220 Adapter for controller (ENG) 60 DRC60 q 799-601-4390* Socket for controller (95 ENG) 60 q 799-601-4280 Box for controller (PUMP) 121 q 799-601-9720 Adapter for controller (HST) 16 HST16A q 799-601-9710 Adapter for controller (HST) 16 HST16B q 799-601-9370 Adapter for controller (HST) 26 HST26A q “*” Shows not T-adapter but socket. CAM 3 FCIN q q Adapter for engine (CRI-T3) 799-601-4140 3 FCIG q q Atomosphere pressure 799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q Adapter for engine (CRI-T3) 799-601-4160 2 4160 q q Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q Socket for engine (CRI-T3) 799-601-4190* 3 1.G q q Socket for engine (CRI-T3) 799-601-4340* 2 2. Part name symbol 799-601-9320 T-box (for DT/HD) 12 q q q 799-601-9330 Case q 799-601-9340 Case q 799-601-9350 Adapter for DRC 40 DRC-40 q 799-601-9360 Adapter for DRC 24 DRC-24 q 799-601-9410* Socket for engine (CRI-T2) 2 G q Adapter for engine (CRI-T2) 799-601-9420 3 A3 q q Adapter for engine (CRI-T3) PFUEL Socket for engine (CRI-T2) 799-601-9430* 2 P q q Socket for engine (CRI-T3) PCV 799-601-9440* Socket for engine (CRI-T2) 3 1.2.3.3B q q 799-601-4330* Socket for engine (CRI-T3) G 3 1. BR380JG-1E0 47 .2.3.2.

SEN02089-01 © 2006 KOMATSU All Rights Reserved Printed in Japan 12-06 (01) 48 .SEN02089-01 BR380JG-1E0 Mobile crusher Form No.

................................................ 4 Failure code [7RC2KA] Disconnection in conveyor OFF switch .................................................................................... 14 Failure code [7RE2KA] Disconnection in crusher OFF switch........ 26 Failure code [7REDMA] Abnormality in primary conveyor pressure sensor .......................................... 8 Failure code [7RD2KB] Short circuit in conveyor reverse relay .................................................................................. 12 Failure code [7RE1KB] Short circuit in crusher ON switch .............................. 20 Failure code [7RE8KB] Short circuit in magnetic separator ON switch ................. 32 Failure code [7REPKA] Disconnection in feeder OFF switch .................................................... SEN02090-00 MOBILE CRUSHER 1SHOP MANUAL BR380JG-1E0 Machine model Serial number BR380JG-1E0 2001 and up 40 Troubleshooting 1 Troubleshooting by failure code............................................................................................................................. 16 Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch ....................................................................... 28 Failure code [7REEMA] Abnormality in muck conveyor pressure sensor........................................ 34 BR380JG-1E0 1 ...................... 22 Failure code [7RE9KA] Disconnection in magnetic separator OFF switch ............................................................................... 30 Failure code [7RENKZ] Abnormality in clearance potentiometer............................ Part 1 Failure code [7RC1KB] Short circuit conveyor ON switch .................................................................................................................. 6 Failure code [7RC5KB] Short circuit in feeder ON switch................................................ 24 Failure code [7REAKB] Short circuit in accessory input circuit.................................................. 18 Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch .................................... 10 Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay ........

........................... 40 Failure code [7RF2KB] Short circuit in crusher forward EPC valve .............SEN02090-00 40 Troubleshooting Failure code [7RESKB] Short circuit in one-touch start switch .................................................... 45 Failure code [7RF4KA] Disconnection in feeder forward EPC valve ............................... 42 Failure code [7RF3KA] Disconnection in crusher reverse EPC valve............................................................................................................................................................................................ 44 Failure code [7RF3KY] Short circuit in crusher reverse EPC valve ............................................. 36 Failure code [7RETKA] Disconnection in one-touch stop switch .................................... 38 Failure code [7RF2KA] Disconnection in crusher forward EPC valve.................................. 47 Failure code [7RF4KY] Short circuit in feeder forward EPC valve ...................................................... 43 Failure code [7RF3KB] Short circuit in crusher reverse EPC valve ........................................................................................ 41 Failure code [7RF2KY] Short circuit in crusher forward EPC valve ............................................. 46 Failure code [7RF4KB] Short circuit in feeder forward EPC valve ...... 48 2 BR380JG-1E0 .......................................................................

appears on • Horn sounds (three intermittent sounding) upon detecting a failure. Problem that • Primary conveyor does not work even if the conveyor ON switch is pressed. system does not reset itself until engine starting switch is turned OFF Action of • Turns all the output OFF for 1 second after turning the engine starting switch ON. 1 Mz Possible a Prepare with engine starting switch OFF. 1 Mz (female) (2) and chassis ground a Prepare with engine starting switch OFF. then carry out troubleshooting without turning engine starting switch ON. C02 (female) Conveyor ON switch Resistance troller Between (15) and chas. 1 z Between (1) and (2) OFF Min. then carry out troubleshooting Defective work equip.1 Mz 4 BR380JG-1E0 . without turning engine starting switch ON. information • The failure history is recorded.SEN02090-00 40 Troubleshooting Failure code [7RC1KB] Short circuit conveyor ON switch 1 User code Failure code Short circuit conveyor ON switch Trouble — 7RC1KB (Work equipment and pump controller (work equipment control) system) 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.1 z sis ground OFF min. standard value 2 ing harness (Contact in normal state Wiring harness between C02 (female) (15)