Komatsu BR380JG-1E0 Shop Manual Download Page 777

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SEN02307-00

40 Troubleshooting

BR380JG-1E0

S-7 Exhaust smoke is black (incomplete combustion)

*1: Displayed failure codes [CA559] and [CA2249]
*2: Displayed failure codes [CA144] and [CA145]

General causes why exhaust smoke is black

Insufficient intake of air

Defective condition of fuel injection

Improper selection of fuel

There is overheating

See “S-14 Coolant temperature becomes too high
(Overheating)”.

Controller is controlling in derate mode (limiting injection
rate (output) because of an error in electrical system)

Causes

logge

d air

cleaner

ele

ent

Seized turbochar

ger

, interfer

ence of turb

ochar

ger

efective co

act of va

lve and valve seat

Impr

oper

valve cleara

nce

akage

of air

betwee

n turbochar

ger and

cylinder

head

rushed, clogg

ed muf

fler

orn piston ring, cylinder liner

tuck, seized

supply pump plunger

logge

d, seized in

jector

Abno

rmally wor

n injector

Impr

oper

fuel injection timing

Impr

oper

fuel injection pr

essur

efective co

olant

temperatur

e senso

r, wirin

g harness

estions

Confirm recent repair history
Degree of use of machine Operated for long period

Color of exhaust gas

Suddenly became black

Q Q Q

Gradually became black

Blue under light load

Non-specified fuel is being used

Q Q

Oil must be added more frequently

Power was lost

Suddenly

Q Q

Gradually

Dust indicator is red

Muffler is crushed

Air leaks between turbocharger and cylinder head, clamp is loosened

heck items

Engine is operated in low-temperature mode at normal temperature

Q Q Q

When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low

Q w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

Pump relief speed is high (Fuel is injected excessively)

Exhaust noise is abnormal

Engine does not pick up smoothly and combustion is irregular

Q Q Q

Q w

Blow-by gas is excessive

There are a lot of return rates from injector

ubleshooting

Inspect air cleaner directly

When turbocharger is rotated by hand, it is found to be heavy

When compression pressure is measured, it is found to be low

Inspect valve clearance directly

When muffler is removed, exhaust sound improves

Carry out troubleshooting according to “Rail Press (Very) Low Error (*1)” indicated

by code

When a cylinder is cut out for reduced cylinder mode operation, engine speed does

not change

Carry out troubleshooting according to “Coolant Temp Sens High (Low) Error (*2)”

indicated by code

Check with monitoring function

q q

Remedy

Clean

place

Adjust

rrec

place

Adjust

place

Summary of Contents for BR380JG-1E0

Page 1: ...SEN01341 03 MOBILE CRUSHER BR380JG 1E0 SERIAL NUMBERS 2001 and up ...

Page 2: ......

Page 3: ...BR380JG 1E0 1 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 ...

Page 4: ...343 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 e...

Page 5: ...02306 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 ...

Page 6: ...ion 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 Underca...

Page 7: ...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 Measuri...

Page 8: ...ilure 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 swi...

Page 9: ...cuit 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 ...

Page 10: ...eed 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 ...

Page 11: ... 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 performan...

Page 12: ...rusher 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 conv...

Page 13: ...00 Index and foreword SEN01343 03 BR380JG 1E0 11 ...

Page 15: ...al 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 ...

Page 16: ...with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before starting any step of the operation Before starting work hang UNDER REPAIR warning signs in the operator s compartment 5 Only qualified workers must carry out work and operation which require license or qualification 6 Keep all...

Page 17: ...ver which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and alternately to release the pressure and then remove the cover 7 When removing components be careful not to break or damage the electrical wir ing Damaged wiring may cause electrical fires 8 When removing piping stop the fuel or oil from spilling out If an...

Page 18: ...de hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allow able load in kN kg when hoisting is made with 2 ropes each of which is allowed to sling up to 9 8 kN 1 000 kg vertically at various hanging angles When the 2 ropes sling a load vertically up to 19 6 kN 2 000 kg o...

Page 19: ...ile the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the ground and check safety and then lift it up 9 Consider the travel route in advance and lift up a load to a safe height 10 Place the control switch on a position where it will not be an obstacle to work an...

Page 20: ... Connection 1 When installing the air conditioner cir cuit hoses and tubes take care that dirt dust water etc will not enter them 2 When connecting the air conditioner hoses and tubes check that O rings 1 are fitted to their joints 3 Check that each O ring is not dam aged or deteriorated 4 When connecting the refrigerant pip ing apply compressor oil for refriger ant R134a DENSO ND OIL8 ZEXEL ZXL10...

Page 21: ...he standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them The troubleshooting is divided by failure modes The S mode of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume In this case see the Chassis volum...

Page 22: ...ated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are necessary when performing work a Caution Special technical precautions or other precautions for preserving stan dards are necessary when performing work 4 Weight Weight of parts of component or parts Caut...

Page 23: ...the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in the text and a table as standard size upper limit of tolerance lower limit of tolerance Example 120 0 022 0 126 q Usually the size of a hole and the size of the shaft to be fitted to that hole are indi...

Page 24: ...that the interference is in the standard range 4 Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the repair limit q If a part is worn to the repair limit must be replaced or repaired q The performance and function of a prod uct lowers while it is used A value below which the product can be used witho...

Page 25: ...more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely to suffer deformation or damage For this reason it is necessary to be extremely careful when handling wiring harnesses 2 Main failures occurring in wiring harness 1 Defective contact of connectors def...

Page 26: ...ter does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in 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 b...

Page 27: ... pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip pull the connector in a parallel direction to the clip for removing stop pers a If the connector is twisted up and down or to the left or right the housing may break 3 Action to take after removing co...

Page 28: ...his will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For connectors with the lock stopper push in the connector until the stop per clicks into position 3 Correct any protrusion of the boot and any misalignment of the wiring har ness For connectors fitted with ...

Page 29: ...re 1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are set normally Arrow 1 2 3 a Right of figure Lock a is pulled down not set completely and lock b is set completely 1 Male connector 2 Female connector a b Locks q Disconnection q Connection Example of in...

Page 30: ...n the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use a dryer to dry the connector a Hot air from the dryer can be used but regulate the time that the hot air is used in order not to make the connector or related parts too hot as this will cause deforma...

Page 31: ...connect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the power OFF before discon necting or connecting connectors 2 Before carrying out troubleshooting check that all the related connectors are properly inserted a Disconnect and connect the related connectors...

Page 32: ...isassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings After any piping or equipment is removed the openings should be sealed with caps tapes or vinyl bags to prevent any dirt or dust from entering If the opening is left open or is blocked with a rag the...

Page 33: ...ew oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and old oil from the hydraulic circuit Normally flushing is carried out twice primary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil 7 Cl...

Page 34: ...nnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1 toward you a Even if lock L2 is pressed connec tor 1 cannot be pulled out toward you if part A does not float In this case float part A with a small screw driver while press lock L2 and then pull out connector 1 toward you 2 Pull lock type PACKARD 2 q 107 170 12V140 e...

Page 35: ... the direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor with flat head screwdriver 1 pull out connector 3 in the direction of the arrow q 107 114 engine Example Intake air pressure temperature sensor in intake manifold SUMITOMO 04 3 While pressing lock D pul...

Page 36: ... Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn housing H1 in the direction of the arrow a When connector is unlocked housing H1 becomes heavy to turn 2 Pull out housing H1 in the direction of the arrow a Housing H1 is left on the wiring har ness side ...

Page 37: ...ndicates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV and AVS are classified by size nominal No they are not indi cated Table 1 Type Sym bol Material Using temperature range C Example of use Low voltage wire for aut...

Page 38: ... 23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diam eter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 109 1 d approx 3 7 4...

Page 39: ...lue 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 ...

Page 40: ...o use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal a Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembl...

Page 41: ...the cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for the first time after repair or long storage follow the same procedure 3 Precautions when completing the operation 1 Refilling with coolant oil and grease q If the coolant has been drained tighten the d...

Page 42: ... If any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler If any abnormal sound is heard repair the muffler referring to Troubleshooting and Disassembly and assembl...

Page 43: ...ter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig 2 3 Hold hose adapter 1 or hose 5 and pull it out Fig 3 a Since some hydraulic oil flows out prepare an oil receiving container 2 Connection 1 Hold hose adapter 1 or hose 5 and insert it in mating a...

Page 44: ...e hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to discon nect it Fig 8 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 Fig 9 ...

Page 45: ...d Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and 2 pull out whole body 9 to discon nect it Fig 12 2 Connection q Hold the tightening portion and push body 9 straight until the sliding prevention ring contacts contact surface b of the hexag onal po...

Page 46: ...eter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29 5 18 27 320 400 33 0 41 0 20 30 455 565 46 5 58 0 22 32 610 765 62 5 78 0 24 36 785 980 80 0 100 0 27 41 1 150 1 440 118 147 30 46 1 520 1 910 155 195 33 50 1 960 2 450 200 250 36 55 2 450 3 040 250 310 39 ...

Page 47: ...Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10 12 33 363 480 37 0 49 0 422 43 0 14 42 746 1 010 76 0 103 883 90 0 Nominal No Thread diameter Width across flats Tightening torque Nm kgm mm mm Range Target 08 8 14 5 88 8 82 0 6 0 9 7 35 0 75 10 10...

Page 48: ...2 107 and 114 engine series to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diame ter mm Ref erence 02 19 34 54 3 5 5 5 44 4 5 9 16 18UN 14 3 34 63 3 5 6 5 14 03 22 54 93 5 5 9 5 74 7 5 11 16 16UN 17 5 24 59 98 6 0 10 0 78 8 0 18 04 27 84 132 8 5 13 5 103 10 5 22 1...

Page 49: ...aper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque inch Nm kgm 1 16 3 1 0 31 0 10 1 8 8 2 0 81 0 20 1 4 12 2 1 22 0 20 3 8 15 2 1 53 0 20 1 2 24 4 2 45 0 41 3 4 36 5 3 67 0 51 1 60 9 6 12 0 92 ...

Page 50: ... so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divided by 10 so multiply 2 165 inches by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 inches Millimeters to inches B 1 mm 0 03937 in 0 1 2 3 4 5 6...

Page 51: ... 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12 70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17 80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 196 21 90 198 42 200 62...

Page 52: ...173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397 8 405 1 412 3 419 5 426 8 60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1 70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4 80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 ...

Page 53: ... 1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877 1 892 1 906 1 920 1 934 1 949 1 963 1 977 140 1 991 2 005 2 020 2 034 2 048 2 062 2 077 2 091 2 105 2 119 150 2 134 2 148 2 162 2 176 2 190 2 205 2 219 2 233 2 247 2 262 160 2 276 2 290 2 304 2 318 2 3...

Page 54: ... 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6 24 4 12 10 4 5 0 23 73 4 14 4 58 136 4 33 9 93 199 4 23 9 11 12 2 4 4 24 75 2 15 0 59 138 2 34 4 94 201 2 23 3 10 14 0 3 9 25 77 0 15 6 60 140 0 35 0 95 203 0 22 8 9 15 8 3 3 26 78 8 16 1 61 141 8 35 6 96 204 8 22 2...

Page 56: ...HER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 01 Specification 1 Specification and technical data Specification dimension drawings 2 Specifications 3 Weight table 5 Table of fuel coolant and lubricants 6 ...

Page 57: ...2 BR380JG 1E0 Specification dimension drawings 1 Dimensions 1 Unit mm A Overall length 12 500 B Overall height 3 200 C Overall width when transporting 2 870 2 810 D Width of track 500 E Tread 2 280 F Length of track on ground 3 275 ...

Page 58: ...displacement mm l cc SAA6D107E 1 4 stroke water cooled vertical direct injection type with turbocharger and aftercooler 6 107 124 6 69 6 690 Performance Rated output Max torque Max speed at no load Min speed at no load Min fuel consumption kW rpm HP rpm Nm rpm kgm rpm rpm rpm g kWh g HP 140 2 050 187 2 050 721 1 500 73 6 1 500 2 330 1 050 227 167 Starting motor Alternator Battery Type of radiator ...

Page 59: ... spool valve 10 spool valve if equipped Hydraulic Hydraulic motor Travel motor Crusher motor Feeder motor Conveyor motor Magnetic separator motor Side conveyor motor If equipped HMV110ADT 2 piston type x 2 With brake valve and shaft brake KMF125B 5 piston type With safety valve x 1 MSF 53 gear type x 1 MSE02 2 123 R02 1240 K000 piston type x 1 S 280AD2S K2875 x 1 2 200AS2S E3343 Hydraulic cylinder...

Page 60: ...lic 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 Track frame Idler Idler cushion Carrier roller Track roller Final drive Including travel motor 5 476 3 938 100 x 2 124 x 2 14 x 4 36 x 10 337 x 2 Track shoe assembly Standard triple sho...

Page 61: ...SEN01346 00 01 Specification 6 BR380JG 1E0 Table of fuel coolant and lubricants 1 a For details of the notes Note 1 Note 2 in the table see Operation and Maintenance Manual ...

Page 62: ...t l Reservoir BR380JG 1E0 Specified l Refill l Engine oil pan 25 4 24 Damper case 0 8 Jaw crusher motor bearing case 4 7 4 7 Final drive case each 3 5 3 3 Grizzly feeder vibrator case 15 15 Hydraulic system 209 112 Fuel tank 400 Cooling system 20 6 ...

Page 64: ... MOBILE CRUSHER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Engine and cooling system Engine mount damper 2 Radiator oil cooler and aftercooler 3 ...

Page 65: ...tenance standard 2 BR380JG 1E0 Engine mount damper 1 1 Drive plate 5 Muffler Outline The damper assembly is a wet type Oil capacity 0 8 l 2 Torsion spring 6 Rear engine mount 3 Stopper pin 7 Front engine mount 4 Friction plate 8 Damper assembly ...

Page 66: ...380JG 1E0 3 Radiator oil cooler and aftercooler 1 1 Fan 7 Radiator outlet hose Outline Radiator Aluminum wave type 4 rows Oil cooler CF40 1 2 Shroud 8 Radiator 3 Radiator cap 9 Oil cooler 4 Radiator inlet hose 10 Aftercooler 5 Net 11 Fuel cooler 6 Reservoir tank ...

Page 68: ...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 2 Drive system for components 3 Final drive 4 Sprocket 6 ...

Page 69: ...R02 1240 K000 2 Jaw crusher motor KFM125B 5 3 Final drive 10 Control valve 4 Travel motor HMV110ADT 2 11 Option connection port side conveyor 5 Option connection port magnetic separator 12 Primary belt conveyor lift cylinder 6 Hydraulic pump 13 Grizzly feeder motor MSF 53 7 Engine 14 Grizzly feeder 8 Primary belt conveyor 15 Jaw crusher ...

Page 70: ...10 Structure function and maintenance standard SEN01349 00 BR380JG 1E0 3 Drive system for components 1 ...

Page 71: ...SEN01349 00 10 Structure function and maintenance standard 4 BR380JG 1E0 Final drive 1 ...

Page 72: ...mm No Check Item Criteria Remedy 14 Backlash between No 2 sun gear and No 2 planetary gear Standard clearance Clearance limit Replace 0 13 0 47 1 00 15 Backlash between No 1 planetary gear and ring gear 0 17 0 57 1 10 16 Backlash between No 2 plane tary carrier and motor 0 06 0 25 17 Backlash between No 1 sun gear and No 1 planetary gear 0 14 0 46 1 00 18 Backlash between No 2 plane tary gear and ...

Page 73: ...it mm No Check Item Criteria Remedy 1 Wear of tooth tip Standard size Repair limit Build up welding for rebuilding or replace 294 5 282 5 2 Thickness of tooth root 17 11 3 Width of tooth 71 68 4 Wear of tooth shape Repair limit 6 measure with the full size drawing of sprocket tooth shape ...

Page 74: ...10 Structure function and maintenance standard SEN01349 00 BR380JG 1E0 7 Full size drawing of sprocket tooth shape ...

Page 76: ...HER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Undercarriage and frame Track frame and recoil spring 2 Idler 4 Carrier roller 6 Track roller 7 Track shoe 8 ...

Page 77: ...0 Track frame and recoil spring 1 1 Idler 2 Track frame 3 Carrier roller 4 Final drive 5 Track roller 6 Track shoe 7 Center guard 8 Front guard Specifications Number of track rollers 5 Each side Standard shoe Shoe width 500 mm Link pitch 190 mm Number of shoes Each side 45 ...

Page 78: ...olerance Repair limit Repair by build up welding or replace Track frame 107 Idler support 105 10 Lateral width of idler guide Track frame 250 Idler support 247 4 11 Recoil spring Standard size Repair limit Replace Free length x Outside diameter Installed length Installed load Free length Installed load 558 x 238 417 109 3 kN 11 150 kg 531 4 87 4 kN 8 920 kg ...

Page 79: ...SEN01350 00 10 Structure function and maintenance standard 4 BR380JG 1E0 Idler 1 ...

Page 80: ...ad 26 20 4 Step measurement of tread 19 25 5 Total width 159 6 Width of tread 37 5 7 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 65 0 250 0 350 0 164 0 074 0 176 0 514 8 Interference between idler and bushing Standard size Tolerance Standard Inter ference Interference limit Shaft Hole 72 0 108 0 008 0 032 0 062 0 040 0 1...

Page 81: ...th of tread 43 4 Thickness of tread 23 16 5 Width of flange 14 6 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Shaft Hole 40 0 170 0 190 0 301 0 168 0 338 0 491 7 Interference between roller and bushing Standard size Tolerance Standard interference Interference limit Shaft Hole 47 0 061 0 016 0 040 0 040 0 016 0 101 8 Axial clearance of roller Stand...

Page 82: ...4 3 Thickness of tread 44 5 38 5 4 Overall width 225 5 Inside width 85 6 Width of tread 44 5 7 Width of flange 25 5 8 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 60 0 215 0 315 0 195 0 195 0 215 0 510 1 5 9 Interference between roller and bushing Standard size Tolerance Standard inter ference Interference limit Shaft Hol...

Page 83: ...SEN01350 00 10 Structure function and maintenance standard 8 BR380JG 1E0 Track shoe 1 a P portion shows the link of bushing press fitting end ...

Page 84: ... press fitting portion 27 5 19 5 5 Shoe bolt pitch 160 4 Adjust or replace 6 62 7 18 8 Link Inside width 82 8 9 Overall width 42 7 10 Tread width 36 9 11 Protrusion of pin Regular 2 5 Master 2 5 12 Protrusion of bushing Regular 3 75 Master 0 0 13 Overall length of pin Regular 212 Master 212 14 Overall length of bushing Regular 137 5 Master 129 2 15 Thickness of bushing metal Standard 10 2 Reverse ...

Page 85: ...e Adjust or replace Shaft Hole 59 0 250 0 000 0 160 0 230 0 160 0 390 22 Interference between regular pin and link 38 0 100 0 000 0 230 0 280 0 230 0 380 23 Clearance between regular pin and bushing Standard size Tolerance Standard clearance Shaft Hole 38 0 100 0 000 0 200 0 300 0 200 0 400 24 Interference between master pin and bushing Standard size Tolerance Standard inter ference Shaft Hole 37 ...

Page 86: ... 00 BR380JG 1E0 11 Triple grouser shoe Unit mm No Check item Criteria Remedy 1 Height Standard size Repair limit Rebuild or replace 26 16 2 Thickness 8 5 3 Length of base 26 4 19 5 Length at tip 20 6 14 7 19 8 Thickness Standard size Repair limit 34 5 24 5 ...

Page 88: ...ER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Hydraulic sysmtem Part 1 Hydraulic piping drawing 2 Hydraulic tank and hydraulic oil filter 3 Hydraulic pump 4 ...

Page 89: ...ucture function and maintenance standard 2 BR380JG 1E0 Hydraulic piping drawing 1 1 Left travel motor 2 Crusher motor 3 Lock cylinder 4 Hydraulic tank 5 Control valve 6 Hydraulic pump 7 Right travel motor 8 Feeder motor ...

Page 90: ...Specifications Tank capacity 200 l Amount of oil inside tank 143 l Pressure valve Relief cracking pressure 16 7 6 9 kPa 0 17 0 07 kg cm2 Suction cracking pressure 0 0 49 kPa 0 0 005 kg cm2 Bypass valve set pressure 150 30 kPa 1 5 0 3 kg cm2 2 Oil filler cap 3 Filter element 4 Strainer 5 Bypass valve 6 Suction strainer 7 Sight gauge ...

Page 91: ...SEN01351 00 10 Structure function and maintenance standard 4 BR380JG 1E0 Hydraulic pump 1 HPV95 95 ...

Page 92: ... 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 L...

Page 93: ...tructure function and maintenance standard 6 BR380JG 1E0 1 Front shaft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12 Servo piston 13 PC valve ...

Page 94: ...5 constitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil to the cylinder surface B with cradle 2 which is secured to the case and forms a static pres sure bearing when it slides q Piston 6 carries out relative movement in the axial direction inside each cylin...

Page 95: ...s way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston 6 suctions and discharges the oil by the amount F E q As cylinder block 7 rotates and the volume of chamber E becomes smaller the pressurized oil is discharged q On the other hand the volume of chamber F grows larger and in this process the oil is su...

Page 96: ... surface rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side Main pump discharge pressure self pressure PP is always brought to the pres sure chamber of the small diameter piston side q Output pressure PEN of the LS valve is brought to the chamber receiving the pressure at...

Page 97: ...scharge pressure PP and control valve outlet port pressure PLS q Pump discharge pressure PP pressure PLS called the LS pressure coming from the control valve output and pressure PSIG called the LS selector pressure from the pro portional solenoid valve enter this valve q The relationship between the LS differential pressure between the pump discharge pres sure PP and LS pressure PLS dPLS PP PLS an...

Page 98: ...essure of the EPC valve for the LS valve entering port G also changes the position of spool 6 Setting force of the spring is changed q Before the engine is started servo piston 12 is pushed to the left See the figure q If the control lever is at the neutral position when the engine is started LS pressure PLS will be set to 0 MPa 0 kg cm2 It is intercon nected to the drain circuit via the control v...

Page 99: ...he PC valve is connected to the drain port so the pressure across circuits D and K becomes drain pressure PT The operation of the PC valve is explained later q The pressure at the large diameter end of servo piston 12 becomes drain pressure PT and pump pressure PP enters port J at the small diameter end so servo piston 12 is pushed to the left side Therefore the swash plate is moved in the directi...

Page 100: ... pressure PP pushes spool 6 to the right q When spool 6 moves pump pressure PP flows from port C to port D and from port K it enters the large diameter end of the pis ton q Pump pressure PP also enters port J of the small diameter end of the piston but because of the difference in area between the large diameter end and the small diameter end on servo piston 12 it is pushed to the right As the res...

Page 101: ...ld at the intermediate position 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 q At this point the relationship between the pres sure receiving areas across servo piston 12 is A0 A1 3 5 so the pressure applied across the piston when it is balanced becomes PP PEN C 5 3 q Force of spring 4 is ad...

Page 102: ... engine hose power q If the pump discharge pressure increases due to increased load during operation this valve decreases the pump delivery q And if the pump delivery pressure goes low it increases the pump delivery q In this case 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 repre...

Page 103: ...the com 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 q The pressure port C pressure output from PC valve is changed depending on the above position q The size of command current X is determined by the nature of the operation lever opera tion the selected working mode and the set value a...

Page 104: ...g piston 2 q Spring load of springs 4 and 6 is also affected by the command current X to PC EPC valve solenoid q Port C of the PC valve is connected to port E of the LS valve q Self pressure PP1 enters port B and the small diameter end of servo piston 9 and other pump pressure PP2 enters port A q When pump pressures PP1 and PP2 are small spool 3 will be positioned in the left side q Port C and D a...

Page 105: ... nected q As a result the pressure on port C rises and the pressure on the large diameter end of the piston also rises Thus the leftward move of servo piston 9 is stopped 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 pushing force of the solenoid in PC EPC valve gener ates and the pu...

Page 106: ...P2 Operation q When port E and port G of the LS valve are connected this pressure from port J enters the large diameter end of servo piston 9 stopping servo piston 9 q If pump pressure PP2 increases further and spool 3 moves further to the right pump pres sure PP1 flows to port C and acts to make the pump delivery the minimum q When servo piston 9 moves to the right springs 4 and 6 are compressed ...

Page 107: ...ump delivery Q becomes as shown below q If command voltage X sent to PC EPC valve solenoid 1 increases further the relationship between average pump pressure PP1 PP2 2 and pump delivery Q is proportional to the force of the PC EPC valve solenoid and moves in parallel q Namely 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...

Page 108: ...ucture function and maintenance standard SEN01351 00 BR380JG 1E0 21 3 LS PC EPC valve C To LS PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7 Plunger ...

Page 109: ...e in proportion to the size of the signal and outputs it to the LS PC valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller to coil 2 coil 2 is de energized q Spool 5 is pushed to the left by spring 4 q Port P closes and the pressurized oil from the self pressure reducing valve does not flow to the LS PC valve q The pressurize...

Page 110: ...d port T are connected q Spool 5 moves up and down so that the pro pulsion force of plunger 7 may be balanced with pressure of port C spring load of spring 4 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 3 When signal current is maximum coil is energized q As the signal current flows to coil 2 coil 2 is energized q W...

Page 112: ...0JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 2 Control valve 2 Self pressure reducing valve 10 CLSS 15 Functions and operation by valve 19 Functions and operation by valve 19 ...

Page 113: ...SEN01352 00 10 Structure function and maintenance standard 2 BR380JG 1E0 Control valve 1 8 spool valve ...

Page 114: ...o magnetic separator motor BP1 From 5 spool ON OFF valve P1 From 4 spool EPC valve P2 To hydraulic tank P3 From travel PPC valve P4 From travel PPC valve P5 From 4 spool EPC valve P6 To hydraulic tank P7 From 4 spool EPC valve P8 From 4 spool EPC valve P9 From travel PPC valve P10 From travel PPC valve P11 From 5 spool ON OFF valve P12 To hydraulic tank P 1 From 5 spool ON OFF valve P 2 To hydraul...

Page 115: ...ntenance standard 4 BR380JG 1E0 1 Unload valve 6 Left travel spool 2 Main relief valve 7 Grizzly feeder spool 3 Magnetic separator spool 8 Crusher spool 4 Side conveyor spool 9 Right travel spool 5 Accessory spool 10 Lock cylinder reset spool ...

Page 116: ...urn spring Standard size Repair limit If spring is damagedor deformed replace it Free length x Outside diameter Installed length Installed load Free length Installed load 54 5 x 34 8 53 5 120 6 N 12 3 kg 96 5 N 9 8 kg 10 Spool return spring 54 6 x 34 8 53 5 139 3 N 14 2 kg 111 4 N 11 4 kg 11 Spool return spring 54 2 x 34 8 53 5 94 1 N 9 6 kg 75 3 N 7 7 kg 12 Spool return spring 48 1 x 10 8 28 0 17...

Page 117: ...ad valve 2 Left travel spool 9 Main relief valve 3 Accessory spool 10 Pressure compensation valve 4 Safety suction valve 11 Pressure compensation valve 5 Safety suction valve 12 Merge divider valve Travel junction valve 6 Suction valve 13 Return spring 7 Safety suction valve 14 LS shuttle valve ...

Page 118: ... length x Outside diameter Installed length Installed load Free length Installed load 54 2 x 34 8 53 5 94 1 N 9 6 kg 75 3 N 7 7 kg 16 Spool return spring 54 6 x 34 8 53 5 139 3 N 14 2 kg 111 4 N 11 4 kg 17 Spool return spring 54 5 x 34 8 53 5 120 6 N 12 3 kg 96 5 N 9 8 kg 18 Spool return spring 48 1 x 10 8 28 0 17 5 N 1 78 kg 13 9 N 1 42 kg 19 Spool return spring 36 9 x 11 1 28 0 29 4 N 3 0 kg 23 ...

Page 119: ... compensation valve 7 Merge divider valve Main 4 Unload valve 8 LS bypass valve No Check item Criteria Remedy 9 Spool return spring Standard size Repair limit If spring is damaged or deformed replace it Free length x Outside diameter Installed length Installed load Free length Installed load 54 2 x 34 8 53 5 120 6 N 12 3 kg 96 5 N 9 8 kg 10 Spool return spring 48 1 x 10 8 28 0 17 5 N 1 78 kg 13 9 ...

Page 120: ...function and maintenance standard 10 BR380JG 1E0 Self pressure reducing valve 1 a Port P1 from front pump b Port PR supply to electromagnetic valve PPC valve EPC valve c Port T to hydraulic tank d Port PC to front pump LS valve ...

Page 121: ...Standard size Repair limit Replace spring if any damages or deforma tions are found Free length x Outside diameter Installed length Installed load Free length Installed load 19 2 x 7 2 16 1 19 6 N 2 kg 17 7 N 1 8 kg 6 Spring pressure reducing valve main 16 5 x 7 2 12 7 20 6 N 2 1 kg 18 6 N 1 9 kg 7 Spring 71 x 18 59 199 8 N 20 4 kg 186 2 N 19 kg 8 Spring safety valve 16 1 x 7 8 13 4 61 7 N 6 3 kg ...

Page 122: ... control pressure for the solenoid valve and PPC valve Operation 1 When engine is stopped q Poppet 5 is pushed against the seat by spring 6 and the passage from port PR o T is closed q Valve 8 is pushed to the left by spring 7 and the passage from port P1 o PR is open q Valve 2 is pushed to the left by spring 3 so the passage between port P1 o P2 is closed See Fig 1 ...

Page 123: ...spool 8 moves in the direction to close the opening from port P1 o PR Pressure P1 is reduced to a certain pressure set pressure by the amount of opening at this point and is sup plied as pressure PR See Fig 2 3 When load pressure P2 is high q If load pressure P2 increases and the pump discharge amount also increases because of operations pressure P1 also increases pressure P1 force of spring 7 are...

Page 124: ... reducing valve becomes abnormally high ball 10 pushes against the force of spring 9 separates from the seat and allows hydraulic oil to flow from output port PR o T so pres sure PR goes down This action protects the equipment at the destination for the hydraulic pressure supply PPC valve electromagnetic valve etc from abnormally high pressure See Fig 4 ...

Page 125: ...luenced by load q Controllability enabling operation even with 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 Configuration q CLSS is configured with variable capacity pis ton pumps control valves and respective actuators q The hydraulic pump is configured with pump bod...

Page 126: ...s constant q LS differential pressure dPLS Pump dis charge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure dPLS is lower than the set pressure of the LS valve when the actuator load pressure is high q If it becomes higher than the set pressure when the actuator load pressure is low the pump swash plate angle shifts toward the ...

Page 127: ...ide of the control valve to bal ance the load q When actuators are operated together 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 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 ...

Page 128: ... 1E0 this is always in the divide mode 1A Main pump 5A Control valve 9A Tank passage 1B Main pump 5B Control valve 9B Tank passage 2A Main relief valve 6A Actuator 10A Valve 2B Main relief valve 6B Actuator 10B Valve 3A Unload valve 7A Pump passage 11A Spring 3B Unload valve 7B Pump passage 11B Spring 4 Merge divider valve 8A LS circuit 12 LS bypass valve 8B LS circuit ...

Page 129: ...veyor spool 5 Accessory spool 6 Left travel spool 7 Grizzly feeder spool 8 Crusher spool 9 Right travel spool 10 Lock cylinder reset spool 11 Safety suction valve 13 7 0 5 MPa 140 5 kg cm2 12 Safety suction valve When normal 20 6 0 5 MPa 210 5 kg cm2 when pilot pressure is applied 10 8 0 5 MPa 110 5 kg cm2 13 Suction valve 14 Safety suction valve 17 2 0 5 MPa 175 5 kg cm2 15 Safety suction valve 3...

Page 130: ... pump circuit 3 is received by the end of valve 2 q Since the control valve is in neutral position pressure of LS circuit 1 is 0 MPa 0 kg cm2 q Pressurized oil of pump circuit 3 stops at valve 2 and the pressure rises as no relief is available q When this pressure becomes larger than the force of spring 5 valve 2 moves to the left q Ports b and c are interconnected and the pump pressure flows to t...

Page 131: ...e balance Operation q When the cylinder reaches the stroke end the main relief valve opens 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 the engine throttle and pump controller sends a signal to the sole noid of the PC valve q Carries out the cut off function to make pump delivery Q the minimum q The pump d...

Page 132: ...ool meter in of pres sure compensation valve 3 and leads to LS shuttle valve 7 as the LS pressure q Connected to actuator port B through valve 4 and makes LS pressure C actuator load pressure q Inlet pore a inside main spool 2 has a small diameter concurrently serving as a throttle Operation q When main spool 2 is operated the pump pressure enters port c through inlet pore a and is led to the LS c...

Page 133: ...es the residual pressure in LS pressure circuit 6 from orifices a and b q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres sure 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 q Effective LS differential pressure drops to improve a dynamic stabi...

Page 134: ...s spring chamber E and port C q The force of spring 5 operates piston 4 and valve 2 to the closing direction 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 q To prevent this a pressure c...

Page 135: ...ol meter in upstream pressure of port A is the pump pressure the spool meter in differential pressure upstream pressure port A pressure downstream pressure port B pressure becomes equivalent to all the spools in operation q Pump flow is divided according to the ratio of the meter in opening area Operation q Spring chamber E is interconnected to port D q Piston 4 and valve 2 operate in the closing ...

Page 136: ...ream pressure will be equal to the maximum load 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 and the pressure will be divided smaller than the opening area ratio q If area ratio 1 or under The spool meter in downstream pressure will be smaller than the ma...

Page 137: ...essure in the springing chamber B 1 Hydraulic pump 2 Valve 3 Pressure compensation valve inner shuttle valve 4 Piston Function q Shuttle valve 3 is pushed to the right by port A pressure and cuts off interconnection between ports A and C 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 ...

Page 138: ...ure function and maintenance standard 28 BR380JG 1E0 2 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 ...

Page 139: ...surized oil P1 and P2 dis charged from the two pumps or divides to respective control valve group q Merges and divides LS circuit pressure Operation q Pilot pressure PS is OFF 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 q Since pilot pr...

Page 140: ...d q Pressurized oil discharged from the two pumps are sent to respective control valves P1 pressure To crusher P2 pressure To grizzly feeder primary con veyor debris discharge conveyor and mag netic separator q When pilot pressure PS is turned ON LS spool 3 shifts to the right interconnects ports B and D and divides other ports q Forwards LS pressure led from each control valve spool to LS circuit...

Page 141: ...be supplied evenly to both travel motors to improve machine s straight travel performance q When the machine is steered outside pilot pressure PST closes the travel junction valve to improve steering performance Operation q Pilot pressure from the travel junction solenoid valve contracts spring 1 and travel junction spool 2 moves to the left to the stroke end q Junction circuit between port PTL L ...

Page 142: ... travel junction spool 2 is pressed by the force of spring 1 against the right side and the pass between ports PTL and PTR is open q If the oil flow rates to the L H and R H travel motors become different from each other the oil flows through the route between port PTL travel junction spool 2 and port PTR so that the oil flow rates to both motors will be equal ized again ...

Page 144: ...rial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 3 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 ...

Page 145: ...JG 1E0 Crusher motor 1 Type KMF125B 5 MA From control valve Specifications Model KMF125B 5 Theoretical delivery 125 0 cm3 rev Set pressure of safety valve 36 7 MPa 375 kg cm2 Rated speed 1 780 rpm MB From control valve S From back pressure compensation valve T To tank ...

Page 146: ...standard SEN01353 00 BR380JG 1E0 3 1 Drive shaft 6 Cylinder block 11 Check valve 2 Spacer 7 Valve plate 12 Check valve spring 3 Case 8 Center shaft 13 Shuttle valve 4 Housing 9 Center spring 14 Shuttle valve spring 5 Piston 10 Safety valve ...

Page 147: ...Criteria Remedy 1 Check valve spring Standard size Repair limit If damaged ordeformed replace spring Free length Outside diameter Installed length Installed load Free length Installed load 62 5 20 0 35 0 3 5 N 0 36 kg 2 8 N 0 29 kg 2 Shuttle valve spring 16 4 8 9 11 5 13 7 N 1 4 kg 10 8 N 1 1 kg ...

Page 148: ...tarting torque is generated in the motor and the motor starts to rotate The oil from the out let port of the motor passes from port MB thought the control valve and returns to the tank 2 When stopping crusher q When the crusher OFF switch is pressed the supply of pressure oil from the pump to port MA is stopped With the oil from the outlet port of the motor the return circuit to the tank is closed...

Page 149: ... maintenance standard 6 BR380JG 1E0 Grizzly feeder motor 1 P1 From control valve Specifications Model MSF 53 Theoretical delivery 53 4 cc rev Rated pressure 20 6 MPa 210 kg cm2 Max speed 3 000 rpm P2 From control valve T To hydraulic tank ...

Page 150: ...andard SEN01353 00 BR380JG 1E0 7 Conveyor motor 1 R From control valve Specifications Model MSE02 2 123 R02 1240 K000 Theoretical delivery 398 cc rev Max pressure 34 3 MPa 350 kg cm2 Max speed 165 rpm L From control valve 1 To hydraulic tank ...

Page 151: ...essure pickup port MB MB pressure pickup port P From travel speed solenoid valve PA From control valve PB From control valve T To tank Model Item BR380JG 1E0 Type HMV110ADT 2 Theoretical delivery Max 106 2 cm3 rev Set pressure 37 3 MPa 380 kg cm2 Rated speed Max capacity 1 842 rpm Brake releasing pressure 1 2 MPa 12 kg cm2 ...

Page 152: ...17 Valve plate 2 Spring 10 Output shaft 18 Counterbalance valve 3 Regulator valve 11 Rocker cam 19 Ring 4 Spring 12 Retainer guide 20 Spool return spring 5 Motor case 13 Pin 21 Brake piston 6 Suction safety valve spring 14 Piston 22 Plate 7 Suction safety valve 15 Retainer 23 Disc 8 Check valve 16 Cylinder 24 Ball ...

Page 153: ...If damaged ordeformed replace spring Free length x Outside diameter Installed length Installed load Free length Installed load 31 6 x 6 5 24 2 2 55 N 0 26 kg 1 96 N 0 2 kg 2 Check valve spring 13 0 x 6 5 9 5 1 96 N 0 2 kg 1 57 N 0 16 kg 3 Return spring 58 43 x 30 42 6 411 N 41 9 kg 329 N 33 5 kg 4 Regulator valve spring 21 5 x 11 1 17 1 55 N 5 6 kg 44 N 4 5 kg ...

Page 154: ...te 13 is separated from disc 14 and the brake is released 2 When stopping travel q As the travel lever is placed in neutral counter balance valve spool 19 returns to the neutral position and closing the parking brake circuit q The pressurized oil in chamber A of brake piston 12 passes through orifice of brake pis ton 12 and is drained to the motor case q Brake piston 12 is pushed to the right by s...

Page 155: ...ht q If the machine travels with the engine at low speed the motor may rotate without load causing the machine to run away resulting in a very dangerous situation q These valves are used to prevent above by controlling the machine to travel according to the engine speed pump delivery Operation when pressurized oil is supplied q Operating the travel lever conducts the pres surized oil from the cont...

Page 156: ...ling downhill the motor will be caused to rotate without load to decrease the inlet side oil pressure q Pressure in chamber S1 is released via ori fices E1 and E2 q As the pressure in chamber S1 goes below the spool selector pressure spool 19 is returned to the left by spring 20 and outlet port MB is throttled q The pressure at the outlet port side rises gen erating rotation resistance on the moto...

Page 157: ...it drops beyond the spool switching pressure spool 19 is returned to the left by spring 20 reducing the pressure at outlet passage B1 q The motor tries to continue rotation resorting to inertial force thus pressure on the outlet port MB is increased q When the pressure rises above the set pressure of the suction safety valve poppet 1 opens q The pressurized oil passes through notch A1 of spool 19 ...

Page 158: ...E0 Valve control 1 1 Hydraulic pump 6 Travel PPC valve Positions of lever 2 Control valve 7 Travel lock EPC valve A Neutral 3 Left travel lever 8 EPC valve B Travel Forward 4 Right travel lever 9 Solenoid selector valve C Travel Reverse 5 Solenoid valve 10 Hydraulic block ...

Page 159: ...ction and maintenance standard SEN01353 00 BR380JG 1E0 17 Travel PPC valve 1 P From self pressure reducing valve P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward P5 Travel signal P6 Steering signal T To tank ...

Page 160: ...SEN01353 00 10 Structure function and maintenance standard 18 BR380JG 1E0 ...

Page 161: ...ol spring Unit mm No Check item Criteria Remedy 11 Centering spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installation length Installation load Free length Installation load 47 6 x 15 5 32 5 108 N 11 0 kg 86 3 N 8 8 kg 12 Metering spring 26 5 x 8 15 24 9 16 7 N 1 7 kg 13 7 N 1 4 kg 13 Steering signal spring 12 8 x 7 3 8 5 8 8 N 0 9 kg 7 1 N...

Page 162: ...essure at port P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 q As a result spool 1 moves up and down until the force of metering spool 2 is balanced with the pressure at port P1 q The relationship of the position of spool 1 and body 10 fine con...

Page 163: ...il 4 At full stroke q Lever 5 pushes down piston 4 and retainer 9 pushes down spool 1 q Fine control hole f is shut off from drain chamber D and is interconnected to pump pressure chamber PP q Therefore the pilot pressure oil from the self pressure reducing valve passes through fine control hole f and flows to chamber A from port P1 to push the control valve spool q The oil returning from chamber ...

Page 164: ...00 10 Structure function and maintenance standard 22 BR380JG 1E0 Operation 1 When in neutral q No output is made from respective output ports from port P1 to P4 travel signal port P5 and steering signal port P6 ...

Page 165: ...on shows the circuit for travelling straight forward q When operating L H motor forward port P2 output and R H motor forward port P4 out put pressure of both L H spring chamber k and R H spring chamber l rises high q Steering signal spool j remains at neutral position and does not output a steering signal to port P6 ...

Page 166: ...the difference of the pilot pressure between both sides is higher than a certain level the pilot pressure is output as the steer ing signal q The pressure in left spring chamber k of steering signal spool j is P2 q The pressure in right spring chamber l is P4 q When the pressure state reaches P4 P2 x Spool section Spring set load the spool is switched to the direction of the arrow q Port P4 pressu...

Page 167: ...illustration shows the circuit for travelling left reverse and right forward q When operating L H motor reverse port P1 output and R H motor forward port P4 out put pressure of the R H spring chamber l only rises high q Steering signal spool j strokes to the left to output the steering signal to port P6 ...

Page 168: ...1 Straight travel and 2 stage relief T To tank 2 Magnetic separator A1 Control valve PST Straight travel 2 stage relief 3 Side conveyor A2 Control valve Port P 3 Magnetic separator 4 Bear lock reset A3 Control valve Port P 1 Side conveyor 5 Travel lock A4 Control valve Port P11 Bear lock reset A5 To travel PPC port P P1 From self pressure reducing valve ACC 2 spool ON OFF valve PPC To EPC valve ...

Page 169: ...the same time the pressurized oil from the actuator flows from port A to port T and is then drained to the tank When solenoid is energized q When the signal current flows from the control ler to solenoid 3 solenoid 3 is energized For this reason spool 5 is pushed to the right in the direction of the arrow As a result the pressurized oil from the control pump flows from port P through the inside of...

Page 170: ... Spool T To hydraulic tank 2 Feeder forward EPC valve 8 Spring C1 To control valve Port P1 3 Crusher forward EPC valve 9 Rod C2 To control valve Port P5 4 Crusher reverse EPC valve 10 Coil C3 To control valve Port P7 5 Block 11 Plunger C4 To control valve Port P8 6 Body 12 Connector P From 5 spool ON OFF valve ...

Page 171: ...alve 2 Spool 5 Plunger P From 5 spool ON OFF valve 3 Rod 6 Connector T To hydraulic tank No Check item Criteria Remedy 7 Return spring Standard size Repair limit Replace EPC valve assembly if there is damage or deformation Free length x Outside diameter Installed length Installed load Free length Installed load 9 0 8 4 3 14 N 0 32 kg ...

Page 172: ...roportion to the size of the signal and outputs it to the control valve Operation 1 When signal current is 0 coil is de energized q When there is no signal current flowing from the controller to coil 14 coil 14 is de ener gized q Spool 11 is pushed to the right by spring 12 q Port P closes and the pressurized oil from the self pressure reducing valve does not flow to the control valve q The pressu...

Page 173: ... are connected 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 q The circuit pressure between the EPC valve and the control valve is controlled in proportion to the size of the signal current 3 When signal current is maximum coil is energized q As the signal current flows to coil 5 coil 5 is energized q When this...

Page 174: ...ions Model DSG 01 3C4 D24 Rated pressure 30 9 MPa 315 kg cm2 Rated oil flow 40 l min Voltage DC 24 V 2 Spring 3 Coil assembly 4 Push pin 5 Spool 6 Cap nut 7 A To lock cylinder head To conveyor RAISE LOWER cylinder bottom B To lock cylinder bottom To conveyor RAISE LOWER cylinder head P Control valve from accessory port A1 T To hydraulic tank ...

Page 175: ...motor cylinder 1 Body Specifications Model DSG 01 3C2 D24 Rated pressure 30 9 MPa 315 kg cm2 Rated oil flow 20 l min Voltage DC 24 V 2 Spring 3 Coil assembly 4 Push pin 5 Spool 6 Cap nut A To conveyor motor R B To conveyor motor L P Control valve from accessory port B6 T To hydraulic tank ...

Page 176: ...SEN01353 00 10 Structure function and maintenance standard 34 BR380JG 1E0 Hydraulic cylinder 1 Conveyor elevation cylinder Side conveyor cylinder Lock cylinder ...

Page 177: ...25 0 020 0 072 0 115 0 003 0 017 0 187 0 487 Lock 90 2 Clearance between piston rod support shaft and bush ing Conveyor elevation 20 0 009 0 013 0 01 0 02 0 07 0 14 1 0 Side conveyor 25 0 009 0 013 0 122 0 071 0 161 0 252 1 0 Lock 75 0 015 0 015 1 0 3 Clearance between cylinder bottom support shaft and bushing Conveyor elevation 20 0 009 0 013 0 01 0 02 0 11 0 14 1 0 Side conveyor 25 0 009 0 013 0...

Page 179: ...model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Work equipment 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 ...

Page 180: ...ept above the set crusher load for 0 5 seconds 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 q While this function is operating the rotary lamp red 4 installed to the machine keeps lighting up If the front pump outlet pressure is kept below the set crusher load for 0 3 seconds the griz zly feeder is autom...

Page 181: ... opening direction the crusher stops immedi ately a For slip of the lock cylinder see Crusher tooth tip adjustment system Judgment of slip of lock cylinder q If this function operates the horn sounds for 5 seconds q After the work equipment is stopped by this function the lamp to show the abnormal sec tion lights up on the machine monitor a For the lamp see Display of working mode Condition for tu...

Page 182: ...SEN01354 00 10 Structure function and maintenance standard 4 BR380JG 1E0 Primary belt conveyor 1 ...

Page 183: ...10 Structure function and maintenance standard SEN01354 00 BR380JG 1E0 5 ...

Page 184: ...rubber 10 Rubber 11 Rubber 12 Slide plate 13 Rubber 14 Bearing 15 Frame 16 Head pulley 17 Primary conveyor motor 18 Tail pulley 19 Bearing stop screw No Check item Criteria Remedy 20 Wear of carrier roller Standard size Repair limit Replace 89 1 84 5 Minimum diameter pat of roller 21 Wear of return roller 89 1 84 5 Minimum diameter pat of roller 22 Wear of guide roller 76 3 71 7 Minimum diameter p...

Page 185: ...maintenance standard 8 BR380JG 1E0 Grizzly feeder 1 1 Hopper Fixed type 2 M type chute selector lever 3 Upper grizzly bar 4 Lower grizzly bar 5 Feeder fixing pin For transportation 6 M type chute 7 Vibrator 8 Grizzly feeder A Trough surface ...

Page 186: ...intenance standard SEN01354 00 BR380JG 1E0 9 Crusher 1 1 Supply opening guard 6 Oil filler plug 2 Scattering prevention guard 7 V sheave 3 Water sprinkler pipe 8 Drain plug 4 V belt 9 Turnbuckle 5 Crusher motor 10 Crusher assembly ...

Page 187: ...SEN01354 00 10 Structure function and maintenance standard 10 BR380JG 1E0 ...

Page 188: ...ock cylinder 5 Crusher motor 6 Swing tooth wedge bolt 7 Fixing link 8 Toggle seat 9 Toggle plate 10 Toggle seat 11 Swing jaw 12 Swing tooth 13 Crusher chamber 14 Fixed tooth 15 Front frame 16 V sheave 17 Bearing Frame 18 Bearing Swing jaw 19 Main shaft Crankshaft 20 Balance weight 21 Tension rod 22 Tension spring ...

Page 189: ...hed 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 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 so it is possible to change the particle size of the crushed material q When fixed jaw plate 4...

Page 190: ...0 Structure function and maintenance standard 14 BR380JG 1E0 Crusher tooth tip adjustment system 1 1 Fixed tooth 5 Rod 2 Swing tooth 6 Fixing link 3 Revolution angle sensor 7 Toggle plate 4 Lock cylinder 8 Swing jaw ...

Page 191: ...ng the tooth clearance by setting a target moving distance adjust it in the semi automatic mode a For the operation of the machine monitor see Machine monitor system Inspec tion mode Semiautomatic S 3 Automatic adjustment When adjusting the tooth clearance by setting a target tooth clearance adjust it in the auto matic mode a For the operation of the machine monitor see Machine monitor system Insp...

Page 192: ...6 BR380JG 1E0 Revolution angle sensor Specifications Type of sensor Resistance board type Total resistance 5 kz 20 Mechanical revolution angle 200 4 Electrical revolution angle 180 2 Rated voltage 0 5 W 25 C 1 Revolution angle sensor 2 Wiring harness 3 Connector ...

Page 193: ...1354 00 BR380JG 1E0 17 Vibrator 1 Gear matches and unites two marks B 1 Grizzly feeder motor 2 Shaft 3 Bearing 4 Gear 5 Housing 6 Unbalance weight 7 Drain plug 8 Oil level gauge 9 Filler plug 10 Breather 11 V checker installation position at maintenance ...

Page 194: ...18 BR380JG 1E0 No Check item Criteria Remedy 11 Frequency min con firmed by V checker Standard value Repair limit Replace 550 cpm 468 632 Frequency max con firmed by V checker 1 050 cpm 1 000 1 100 12 Vibrator case oil level Center of level window 5 mm Add oil ...

Page 196: ...AL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 10 Structure function and maintenance standard 1 Electrical system Engine control 2 Work equipment and pump controller 12 Electronic control system 15 Machine monitor system 28 Sensor 54 ...

Page 197: ...ply pump 3 Engine controller 4 Fuel control dial 5 Starting switch 6 Battery relay 7 Battery Outline q The engine can be started and stopped with starting switch 5 only q The control signal of fuel control dial 4 is input to engine controller 3 which controls the output to the injector to control the engine speed ...

Page 198: ...l 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 engine controller sends a driving signal to the supply pump depending on the signal volt age to control the fuel injection pump and eventually controls the engine speed Stopping engine q When...

Page 199: ...SEN01355 00 10 Structure function and maintenance standard 4 BR380JG 1E0 Component 1 Fuel control dial 1 Knob 2 Dial 3 Spring 4 Ball 5 Potentiometer 6 Connector ...

Page 200: ...f potentiom eter 5 q The rotation of the shaft changes the resis tance of the variable resistor in potentiometer 5 sending any throttle signal to the engine controller q The hatched area in the right graph is the abnormality detection area When the throttle voltage is within this area the engine is run ning at low idle ...

Page 201: ...3 Air pressure sensor B 4 NC 5 NC 6 CAN E 7 NC 8 CAN E 9 NC 10 NC Never connect to NC or malfunctions or failures will occur 11 NC 12 NC 13 NC B 14 WATER IN FUEL Input B 15 Coolant temperature input B 16 Sensor power 5 V A 17 Oil pressure switch B 18 NC 19 NC 20 NC 21 NC 22 NC D 23 Intake manifold temperature B 24 NC 25 Accumulator pressure signal B 26 Engine position sensor signal B 27 Engine spe...

Page 202: ... NC B 6 NC B 7 NC B 8 NC B 9 Fuel dial B 10 NC E 11 NC B 12 NC B 13 NC B Never connect to NC or malfunctions or failures will occur CN CE01 Pin No Signal name Input output Never connect to NC or malfunctions or failures will occur 14 NC B 15 NC B 16 NC B 17 NC B 18 NC B 19 NC B 20 NC E 21 NC A 22 Fuel dial 5 V A 23 Fuel dial C 24 NC B 25 NC B 26 NC B 27 NC B 28 NC B 29 NC C 30 NC B 31 NC B 32 NC C...

Page 203: ...SEN01355 00 10 Structure function and maintenance standard 8 BR380JG 1E0 Coolant temperature sensor 1 Connector 2 Sensor 3 O ring Oil pressure switch 1 Connector 2 Sensor 3 O ring ...

Page 204: ...10 Structure function and maintenance standard SEN01355 00 BR380JG 1E0 9 Rotation sensor 1 Connector 2 Sensor 3 O ring Boost pressure and temperature sensor 1 Connector 2 Sensor 3 O ring ...

Page 205: ...01355 00 10 Structure function and maintenance standard 10 BR380JG 1E0 WIF water in fuel detection sensor 1 Connector 2 Tube 3 Sensor 4 O ring Engine oil level sensor 1 Connector 2 Bracket 3 Float 4 Switch ...

Page 206: ...SEN01355 00 10 Structure function and maintenance standard 12 BR380JG 1E0 Work equipment and pump controller 1 ...

Page 207: ...setting mode select switch Auto Input 3 Magnetic separator ON switch Input 4 232C_RXD Input 5 Conveyor OFF switch Input 6 1 touch stop switch Input 7 Machine select 2 Input 8 Engine stop relay drive Output 9 Beacon lamp relay drive Output 10 NC Input 11 NC Output 12 CAN_SH 13 Conv Hi position sensor Input 14 232C_TXD Output 15 Conveyor ON switch Input 16 1 touch start switch Input 17 Machine selec...

Page 208: ...l 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 EPC Output 27 Lock cyl push relay Output 28 Accessory EPC Output 29 Radio Ctrl travel sig Input 30 Crusher ON switch Input 31 GND_PWR 32 GND_PWR 33 GND_PWR 34 ...

Page 209: ...ntrol system 1 Control function a For the self diagnosis function see Troubleshooting 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 ...

Page 210: ...SEN01355 00 10 Structure function and maintenance standard 16 BR380JG 1E0 Travel control function ...

Page 211: ...10 Structure function and maintenance standard SEN01355 00 BR380JG 1E0 17 ...

Page 212: ...SEN01355 00 10 Structure function and maintenance standard 18 BR380JG 1E0 Engine and pump compound control function ...

Page 213: ... q Matching point 107 0 kW 1 800 rpm 143 5 HP 1 800 rpm q Engine speed is always controlled so that it is kept around the matching point specified beforehand q If the pump load increases and the pressure rises engine speed N lowers If it happens the engine speed is increased to around the matching point allowing the pump controller to decrease pump delivery Q On the contrary the pump load decrease...

Page 214: ...SEN01355 00 10 Structure function and maintenance standard 20 BR380JG 1E0 Pump and valve control function ...

Page 215: ...ntial 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 q By this operation the start up time of the pump discharge is optimized and the composite operation and fine control performance is improved ...

Page 216: ...tion 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 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 ...

Page 217: ...dition Operation Remedy Resetting condition Coolant temperature Min 100 C or Hydraulic oil temperature Min 100 C Working mode each mode Engine speed Kept as is Reduce pump delivery Coolant temperature hydraulic oil temperature Below 100 C Under above condition controller is set to condi tion before operation of function Automatic reset Operating condition Operation Remedy Resetting condition Coola...

Page 218: ...ance standard 24 BR380JG 1E0 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 ...

Page 219: ...3 The position of the mode selector switch is judged 4 The drive signals for the travel lock EPC valve and LS EPC valve are output according to 1 3 and position of the travel speed switch to change the travel interlock and travel speed automatically Machine cannot travel Travel speed selector switch Lo Mi Hi Pump capacity 27 77 100 Travel motor capacity Max Max Max Travel speed km h 0 8 2 3 3 0 Mo...

Page 220: ...tacts Operating ON pressure 0 5 0 1 MPa 5 0 1 0 kg cm2 Resetting OFF pressure 0 3 0 05 MPa 3 0 0 5 kg cm2 Function q The travel PPC valve has 2 travel PPC oil pressure switches 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 ...

Page 221: ...r Operation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part the diaphragm is deformed q The deformation in the diaphragm causes the resistance of the gauge to change This causes a change in the output voltage which is trans mitted to the amplifier voltage amplifier q The relationship between the pressure applied to sensors P and output voltag...

Page 222: ... of the machine with sensors installed on various parts of the machine It processes and immedi ately displays the obtained information on the machine monitors notifying the operator of the condition of the machine The panel is roughly divided as follows 1 Monitor section to output alarms when the machine has troubles 2 Gauge section to display the condition constantly Coolant temperature hydrau li...

Page 223: ...monitor has the functions to display various items and the functions to select modes and electric parts The machine monitor has a CPU Central Process ing Unit in it to process display and output the information The monitor display unit consists of LCD Liquid Crystal Display The switches are flat sheet switches ...

Page 224: ...0 NC 11 NC 12 NC CN 2 Pin No Signal name Input 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 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 CN 3 Pin No Signal name Input output 1 NC 2 NC 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9...

Page 225: ... operation section Display section A Screen of check before starting B Main screen of working mode C Main screen of travel mode D Screen of maintenance overtime E1 Main screen of inspection mode manual E2 Main screen of inspection mode semi automatic E3 Main screen of inspection mode automatic ...

Page 226: ...itor 8 Service meter 9 Engine oil level caution 10 Air cleaner clogging 11 Fuel level gauge 12 Water separator 13 Fuel level monitor 14 Working mode monitor 15 Operating condition monitor 16 Engine coolant temperature gauge 17 Fuel level gauge 18 Hydraulic oil temperature gauge 19 Hydraulic oil temperature monitor 20 Maintenance time warning 21 Inspection mode monitor 22 Actual crusher clearance m...

Page 227: ... items and display Symbol Display item Display method Preheating Time to continue setting Condition of preheating monitor Up to 30 sec Lighting 30 sec 40 sec Flashing After 40 sec OFF Engine coolant temperature See gauge display on the next page Hydraulic oil temperature Fuel level ...

Page 228: ...ndicator Buzzer sound Engine coolant temperature C A1 105 Red Q A2 102 Red A3 100 Green A4 80 Green A5 60 Green A6 30 White Hydraulic oil temperature C B1 105 Red B2 102 Red B3 100 Green B4 80 Green B5 40 Green B6 20 White Fuel level l C1 289 Green C2 244 5 Green C3 200 Green C4 100 Green C5 60 Green C6 41 Red ...

Page 229: ...yed only the symbol is displayed Symbol Displayed item Item checked by check before starting While engine is stopped While engine is running Engine oil pressure Lamp lights up and buzzer sounds when abnormal Battery charge Lamp lights up when abnormal Radiator coolant level Lamp lights up when abnormal Lamp lights up and buzzer sounds when abnormal Engine oil level Lamp lights up when abnormal Air...

Page 230: ...m Display range Display method Monitor Working mode In working mode Set mode is displayed Travel speed In travel mode Lo Mi Hi Set mode is displayed Inspection mode In inspection mode A S M Set mode is displayed Actual crusher clearance monitor In inspection mode Actual crusher clearance is displayed 1 Set crusher clear ance monitor In inspection mode A S Set crusher clearance is displayed 2 Condi...

Page 231: ...e fol lowing are displayed Emergency stop switch ON warning If emergency stop switch 1 is depressed the whole work equipment stops the horn sounds and the items shown below are displayed Engine stop switch ON warning If engine stop switch 2 is depressed the whole work equipment stops the engine stops the horn sounds and the items shown below are displayed ...

Page 232: ...itch 2 Crusher manual rotation switch 3 Conveyor manual rotation switch 4 Crusher speed setting screen selector switch 5 Feeder speed setting screen selector switch 6 Crusher load setting screen selector switch 7 Operation switch 8 Buzzer cancel switch 9 Maintenance switch 10 Display brightness and contrast adjustment switch ...

Page 233: ...ed the speed setting screen appears and you can set the crusher speed q Operation switch This switch is used to use various setting func tions For details 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 The buzzer sounds when any of the following is detected q Abnormal coolant l...

Page 234: ...ed selector switch 2 on the upper control panel is changed Lo Low speed travel or Hi Hi speed travel is displayed Work mode If work mode B is selected with the mode selector switch 1 you can check the operating condition of each work equipment and find out the work equip ment receiving an overload or abnormal load 1 Mode selector switch 2 Side conveyor condition lamp 3 Feeder condition lamp 4 Crus...

Page 235: ...arance range 3 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 Conveyor Crusher Feeder Magnetic separator Side con veyor If equipped Secondary conveyor If equipped Vibratory screen If equipped Stop White lamp lights up White lamp lights up White lamp lights up Transparent Transparent Transparent Transpa...

Page 236: ...ttle monitor 11 2 Depress UP switch 5 or DOWN switch 6 of the monitor to bring the cursor to crusher clearance set value monitor 12 3 Depress settle switch 7 and clearance set value 12 lights up 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 5 Clearance set value 12 flashes and the clearance is increased...

Page 237: ...settle switch 7 5 Clearance set value 12 flashes and the clearance is increased or decreased as explained below i The crusher clearance is decreased until the swing tooth touches the fixed tooth ii The crusher clearance is increased to crusher clearance set value 12 iii When actual crusher clearance 10 becomes larger than crusher clear ance set value 12 the automatic clearance adjustment is finish...

Page 238: ...ed Feeder speed setting function q This function is used to set the feeder speed The material is sent to the crusher at a proper speed by selecting the feeder speed according to the contents of the work q This function is used while the ordinary screen travel mode work mode or inspection mode is displayed How to use 1 Depress feeder speed set switch 1 of the monitor to display the adjustment scree...

Page 239: ... crusher load set switch 1 of the monitor to display the adjustment screen 2 Depress the operation switch 2 to select the crusher load 3 After selecting the level depress input check switch 3 The selected crusher load level is settled and the ordinary screen appears At the same time the crusher load changes a The crusher load does not change until the input check switch is depressed If return swit...

Page 240: ...ls in a table 2 Select the No of the item to be maintained with operation switch 2 or input it through the numeral keys a The cursor moves and the selected part is inverted a Similarly to the relationship between the remaining time and display of caution on the previous page the items of remaining time shorter than 30 hours are indicated yellow and those of remaining time shorter than 0 hour are i...

Page 241: ...nce table screen 3 Check the contents of the check screen If there is no problem depress input check switch 3 to reset the maintenance time After resetting is completed the maintenance table screen appears again When returning to the maintenance table screen to check the remaining time or when you selected a wrong item depress return switch 4 a On the check screen the symbol and set time of the ma...

Page 242: ...2 Press control switch 2 or use the 10 key pad to input the number 00 02 to select either contrast or brightness After completing the selection press input con firmation switch 3 and return to the adjust ment screen 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 3 Press control switch 2 and adjust the bright ness a...

Page 243: ...ress 7 2 9 7 2 and 9 keys on the numeral key pad in order and the screen to input an 8 digit number appears While the screen is waiting for an input input the 8 digit number 19210513 with the numeral keys After the last digit 3 is input the screen to check valid invalid of the password appears 3 Depress operation switch 1 or 2 to set valid invalid of the password In the figure at right operation s...

Page 244: ...right top of the screen When inputting the number second time 2 is dis played After the input number is settled the ordinary screen appears a If the number input first time is different from that input second time the password is not settled but the screen to input the number first time appears again Function of checking service meter q When the starting switch is turned OFF if return switch 1 and...

Page 245: ... intervals of 3 sec onds q While the user code is displayed if the input check switch is depressed the service code and failure code are displayed q If there are multiple service codes failure codes which cause the service codes all of them are displayed at intervals of 3 seconds Even if there is a service code failure code which does not cause any user code it is not displayed by this function q ...

Page 246: ...Coolant level sensor 1 Sub tank 2 Float 3 Sensor 4 Connector 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 clogg...

Page 247: ... standard SEN01355 00 BR380JG 1E0 55 Engine oil level sensor Hydraulic oil level sensor 1 1 Connector 2 Bracket 3 Float 4 Switch Engine oil pressure sensor For low pressure 1 1 Plug 2 Contact ring 3 Contact 4 Diaphragm 5 Spring 6 Terminal ...

Page 248: ...nction and maintenance standard 56 BR380JG 1E0 Coolant temperature sensor Hydraulic oil temperature sensor 1 1 Thermistor 2 Body 3 Tube 4 Tube 5 Wire 6 Connector Fuel level sensor 1 1 Float 2 Connector 3 Cover 4 Variable resistor ...

Page 249: ...10 Structure function and maintenance standard SEN01355 00 BR380JG 1E0 57 Air cleaner clogging sensor 1 ...

Page 251: ...88 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 2 Standard value table for chassis 3 ...

Page 252: ...35 At high idle Valve clearance Normal temperature Intake valve mm 0 25 0 152 0 381 Exhaust valve mm 0 51 0 381 0 762 Compression pressure Oil temperature 40 60 C Compression pressure MPa kg cm2 Min 2 41 Min 24 6 1 69 17 2 Engine speed rpm 250 280 250 280 Blow by pressure Coolant temperature operating range At rated output kPa mmH2O Max 0 98 Max 100 1 96 200 Oil pressure SAE0W30E0S SAE5W40E0S SAE1...

Page 253: ...rack shoe rpm 2 050 100 2 050 100 Spool stroke All spools mm l a b l a b 9 5 0 5 9 5 0 5 9 5 0 5 9 5 0 5 Control lever Stroke Travel control lever Grip the lever at its knob center Read out the max value up to the stroke end Stop the engine Remove lever play at the neutral position mm 86 9 86 9 Play of control lever Max 15 Max 23 Operating effort Operating effort in travel Engine running at full t...

Page 254: ... 2 0 215 20 Release of lock cylinder 32 3 1 0 330 10 32 3 1 5 330 15 Operation of lock cylinder Extension retraction 11 8 1 0 120 10 11 8 1 5 120 15 Conveyor elevator cylinder 23 5 1 0 240 10 23 5 1 5 240 15 Side conveyor elevator cylinder 26 5 1 0 270 10 26 5 1 5 270 15 Side conveyor motor 14 7 1 0 150 10 14 7 1 5 150 15 Magnetic separator motor 19 6 1 0 200 10 19 6 1 5 200 15 Left travel 39 2 40...

Page 255: ...with lock pin 1 and relieve travel circuit l mm Max 13 6 Max 27 2 Travel speed Run engine at full throttle Hydraulic oil temperature 45 55 C Set primary conveyor in travel posture After approach run of at least 10 m on flat ground measure time required to travel 20 m Lo Sec 72 0 120 0 72 0 120 0 Mi 27 2 36 8 27 2 36 8 Hi 20 9 28 2 20 9 28 2 Travel deviation Run engine at full throttle Hydraulic oi...

Page 256: ... 297 363 MAX 280 380 MIN 153 187 MIN 136 204 Small torque up pulley MAX 261 319 MAX 246 334 MIN 135 165 MIN 120 180 2 Crusher speed Reverse Standard pulley MAX 238 322 MAX 224 336 MIN 144 196 MIN 136 204 Small torque up pulley MAX 209 283 MAX 196 295 MIN 127 173 MIN 120 180 3 Feeder vibration cpm MAX 1 000 1 100 MAX 950 1 150 MIN 468 632 MIN 440 660 4 Primary conveyor belt speed m min 102 138 96 1...

Page 257: ...is point a When measuring with the pump mounted on the machine if it is impossible to set the engine speed to the specified speed with the fuel control dial 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 Check point Test pump dis charge pressure MPa kg cm2 Discharge pres sure of...

Page 259: ...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 tra...

Page 260: ...d 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 ...

Page 261: ...1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 58 8 MPa 600 kg cm2 2 799 401 2320 Hydraulic gauge 1 Pressure gauge 0 98 MPa 10 kg cm2 Measuring fuel pressure G 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure...

Page 262: ...e gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 58 8 MPa 600 kg cm2 2 799 401 3100 Adapter 1 Size 02 Measuring PPC valve out put pressure P 1 799 101 5002 Hydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 58 8 MPa 600 kg cm2 2 799 101 5230 Nipple 1 Size 14 1 5...

Page 263: ...controllers sensors actuators electrical equipment and wiring harnesses see Trou bleshooting General information on troubleshooting List of T boxes and T adapters Removal and installation of engine coolant temper ature sensor Commercially available Socket 1 21 mm deep socket MITOLOY 4ML 21 or equivalent Testing Adjusting item Sym bol Part No Part name Q ty Remarks ...

Page 264: ...gine 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 3 Measuring high idle speed 1 Start the engine and set the fuel control dial in the high idle MAX position 2 Set the machine in the operation mode and turn the all work equipment switches OFF 4 Measu...

Page 265: ...igher speed and bleed oil from the hose a Insert the connecting parts of the gauge and hose about a half and open the self seal on the hose side repeatedly and the oil will be drained a If Pm kit A is available you use the air bleeding coupling 790 261 1130 in that kit a If oil is left in the hose the gauge does not work Accordingly be sure to drain the oil 4 Set the machine in the travel mode sel...

Page 266: ...the mea suring tools and return the removed parts 2 Checking with smoke meter B2 1 Insert probe 1 of smoke meter B2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip 2 Connect the probe hose receptacle of the accelerator switch and air hose to smoke meter B2 a Limit the supplied air pressure to 1 5 MPa 15 kg cm2 3 Connect the power cable to an AC recep tacle a Before con...

Page 267: ...sensor ring to projection top a of front cover a Projection top a must be within the range of wide slit b when it is seen from the fan side a If you can see the yellow marks of projec tion top a and wide slit b you may set them to each other k When the crankshaft is set as above the piston in the No 1 or No 6 cylinder is not set to the compression top dead center TDC Take care 5 Check the movement...

Page 268: ...Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance again 7 Rotate the crankshaft forward by 1 turn and set wide slit b to projection top a according to step 4 8 Adjust the other valve clearances according to steps 5 and 6 a If the valves marked with q in the valve arrangement drawing were adjusted in steps 5 and 6 adjust the valves marked with Q a If the valves ...

Page 269: ...ot need to remove the rocker arm assembly on the intake side 3 Remove fuel tube 3 and then remove inlet connector 7 in the cylinder head a The inlet connector is connecting the fuel tube to the injector 4 Disconnect injector wiring harness Using tool D2 remove injector 4 5 Install adapter D3 to the injector mounting part with the injector clamp and connect compres sion gauge D1 a Install the gaske...

Page 270: ...cedure 1 Apply new engine oil SAE15W 40 to the O ring of injector 4 and cylinder head 2 Install injector 4 with the fuel inlet hole directed to the air intake manifold 3 Install injector clamp 6 and tighten the mounting bolt by 3 4 threads 4 Install inlet connector 7 and tighten inlet connector retainer temporarily 5 Tighten the mounting bolt of injector clamp 6 securely 3 Injector clamp mounting ...

Page 271: ... 1 and connect gauge 2 Start the engine and lock the travel k Insert pin 2 between the sprocket and the track frame to lock the travel securely 3 Start the engine set the conveyor height to Hi Travel operation position set the machine in the travel mode and select travel speed Hi 4 While running the engine at high idle relieve the travels Right and left and measure the blow by pressure a Read the ...

Page 272: ...hin oper ating range 1 Remove oil pressure pickup plug 1 from the top of the engine oil filter 2 Install nipple 1 of hydraulic tester F1 and con nect hydraulic gauge F2 3 Run the engine and measure the engine oil pressure at high idle and low idle 4 After finishing measurement remove the mea suring tools and return the removed parts Symbol Part No Part name F 1 799 101 5002 Hydraulic tester 790 26...

Page 273: ...entering it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure from fuel system 1 a Pressure is generated in the low pressure cir cuit and high pressure circuit of the fuel sys tem while the engine is running Low pressure circuit Feed pump Fuel main filter Supply pump High pressure circuit Supply pump Co...

Page 274: ...er G1 and connect them to oil pressure gauge 2 a Use the oil pressure gauge of 2 5 MPa 25 kg cm2 3 Run the engine at low idle and measure the pressure in the fuel low pressure cir cuit a If the pressure in the fuel low pres sure circuit is in the following range it is normal k If the engine cannot be started you may measure the fuel pressure while rotating the engine with the starting motor Do not...

Page 275: ...e and measure the pressure in the fuel return circuit a If the pressure in the fuel return circuit is in the following range it is normal k If the engine cannot be started you may measure the fuel pressure while rotating the engine with the starting motor Do not rotate for more than 20 seconds continu ously however for protection of the starting motor 4 After finishing measurement remove the measu...

Page 276: ... 1 minute with measuring cylinder H4 a If the return rate from the supply pump is in the following range it is normal k If the engine cannot be started you may measure the fuel return rate while rotating the engine with the starting motor Do not rotate for more than 20 seconds continu ously however for protection of the starting motor 5 After finishing measurement remove the measuring tools and re...

Page 277: ...ge from the pressure limiter is in the following range it is normal 5 After finishing measurement remove the mea suring tools and return the removed parts 3 Joint bolt 24 4 Nm 2 4 0 4 kgm 3 Measuring return rate from injector a The leakage from the injector is measured while the return hose of the pressure lim iter is connected Accordingly before measuring the leakage from the injector check that ...

Page 278: ...tection of the starting motor 5 After finishing measurement remove the measuring tools and return the removed parts 3 Joint bolt 24 4 Nm 2 4 0 4 kgm Bleeding air from fuel circuit 1 a If fuel is used up or if a fuel circuit part is removed and installed bleed air from the fuel circuit according to the following procedure k Stop the machine on a level ground 1 Fill the fuel tank with fuel a Add fue...

Page 279: ...30 Testing and adjusting SEN02303 00 BR380JG 1E0 21 a Air bleeding route of fuel circuit Fuel tank o Pre filter o Feed pump o Main filter o Metering unit o Fuel tank ...

Page 280: ...high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check again from step 2 4 Run the engine at low idle 5 Check the fuel piping and devices for fuel leak age a Check mainly around the high pressure circuit parts coated with the color checker for fuel leakage a If any fuel leakage is detected repair it and check again from step...

Page 281: ... maximum clearance a 10 30 mm Adjusting a If the track shoe tension is abnormal adjust it according to the following procedure 1 Increasing tension 1 Add grease through grease fitting 1 with a grease gun 2 To check that the tension is normal run the engine at low idle and move the machine forward by the length of track on ground then stop slowly 3 After adjusting check the track shoe ten sion agai...

Page 282: ...sen the valve more than 1 turn If it is loosened more it may jump out because of the high pres sure grease in it 2 To check that the tension is normal run the engine at low idle and move the machine forward by the length of track on ground then stop slowly 3 After adjusting check the track shoe ten sion again according to the above proce dure ...

Page 283: ... code 01101 R pump pressure a Measure the oil pressure in the work equip ment and travel circuits under the following condition q Hydraulic oil temperature Within operat ing range 1 Preparation work k Stop the engine and gradually loosen the oil filler cap of the hydraulic tank to release the air from the tank 1 Remove oil pressure pickup plugs 1 and 2 q 1 Front pump discharge pressure pickup plug...

Page 284: ...feeder primary conveyor side conveyor and magnetic separator block the piping of the motor inlet cir cuit or the valve outlet circuit 5 Measuring travel relief pressure 1 Run the engine and lock the travel mecha nism k Put pin 2 between the sprocket and track frame to lock the travel mechanism securely 2 Set the conveyor height to Hi Travel oper ation position set the machine in the travel mode an...

Page 285: ...ustment screw 5 tighten locknut 6 3 Locknut 29 4 39 2 Nm 3 4 kgm 4 After finishing adjustment check again that the oil pressure is normal according to the above described measurement procedure 2 Adjusting work equipment safety valves a If the work equipment safety valves are abnormal adjust safety valves 7 8 10 and 11 of the work equipment according to the following procedure q 7 Motor for magneti...

Page 286: ... Locknut 93 123 Nm 9 5 12 5 kgm 3 Connect pilot hose 14 4 After finishing adjustment check again that the oil pressure is normal according to the above described measurement procedure a If the high pressure setting side is adjusted the low pressure setting side changes Accordingly adjust the low pressure setting side too a Adjusting relief pressure Low pressure setting side q Lock cylinder Extensi...

Page 287: ... temperature Within operating range 1 Disconnect inlet hose 1 of the 5 spool sole noid valve 2 Connect adapter K2 to hose 1 and install the hose again 3 Install nipple 2 and oil pressure gauge 1 of hydraulic tester K1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 4 Start the engine 5 While running the engine at high idle turn all the operation switches OFF and measure the oil pressure 6 After ...

Page 288: ... the oil pressure in the pump PC con trol circuit under the following condition q Hydraulic oil temperature Within operating range 1 Measuring PC valve output pressure servo piston inlet pressure a Measure the PC valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Remove oil pressure pickup plugs 1 2 3 and 4 q 1 Front pump discharge press...

Page 289: ... inlet pressure is the same as the pump discharge pressure or almost 0 5 After finishing measurement remove the measuring tools and return the removed parts 2 Measuring PC EPC valve output pressure 1 Remove oil pressure pickup plug 5 2 Install nipples L2 and connect them to oil pressure gauges 1 of hydraulic tester L1 a Use the oil pressure gauges of 5 9 MPa 60 kg cm2 3 Start the engine 4 Turn OFF...

Page 290: ...8 a Before loosening the locknut make counter mark at the adjustment screw end so that you can see the position of the locknut before the adjustment and you can return the locknut to its original posi tion after turning it in reverse 2 Turn adjustment screw 9 clockwise or coun terclockwise to adjust a Turn the adjustment screw q Clockwise when the work equipment speed is low to increase pump absor...

Page 291: ...re normal a Measure the oil pressure in the pump LS con trol circuit under the following condition q Hydraulic oil temperature Within operating range 1 Measuring LS valve output pressure servo piston inlet pressure a Measure the LS valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Remove oil pressure pickup plugs 1 2 3 and 4 q 1 Front p...

Page 292: ...es are in the following ratio the LS valve is normal 5 After finishing measurement remove the measuring tools and return the removed parts 2 Measuring LS differential pressure a Measure the pump discharge pressure and LS pressure actuator load pressure simultaneously and calculate the differ ence between them 1 Remove oil pressure pickup plugs 1 2 3 and 4 q 1 Front pump discharge pressure pickup p...

Page 293: ...58 8 MPa 600 kg cm2 having the unit of 0 98 MPa 10 kg cm2 Since the dif ferential pressure is about 3 9 MPa 40 kg cm2 at maximum measure it by installing the same gauge to the pickup plugs alternately q The figure shows the pump discharge pressure side q The figure shows the LS pressure side 3 Run the engine 4 While running the engine at high idle under the condition shown in the table measure the...

Page 294: ...f the LS differential pressure is abnormal adjust the LS valve according to the following procedure q 6 Front pump LS valve q 7 Rear pump LS valve 1 While fixing adjustment screw 9 loosen lock nut 8 2 Turn adjustment screw 9 to adjust the differ ential pressure a If the adjustment screw is q Turned to the right the differential pressure is increased q Turned to the left the differential pressure i...

Page 295: ... nipple 1 of hydraulic tester N1 and con nect it to oil pressure gauge 2 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 4 Start the engine Symbol Part No Part name N 1 799 101 5002 Hydraulic tester 790 261 1204 Digital hydraulic tester 2 799 401 3100 Adapter Size 02 No Solenoid valve to be measured 1 Travel junction 2 stage relief solenoid valve 2 Magnetic separator solenoid valve 3 Side convey...

Page 296: ...Exclude EPC solenoid valve Operating condition Operation In travel mode When travel steering signal is ON ON When travel steering signal is OFF OFF Intesting mode When crusher clearance reducing switch is ON ON When crusher clearance reducing switch is OFF OFF Operating condition Operation Side conveyor signal Side conveyor ON switch is pressed and side conveyor operating signal is ON ON ON OFF OF...

Page 297: ... Operating condition Output Left MPa kg cm2 Crusher reverse signal Crusher speed MAX ON Approx 2 9 30 OFF 0 0 Operating condition Operation Vibratory sieve signal Vibratory sieve ON switch is pressed and vibratory sieve operating signal is ON ON ON OFF OFF Operating condition Operation Secondary belt conveyor signal Secondary belt conveyor ON switch is pressed and second ary belt conveyor operatin...

Page 298: ...ch 2 Travel signal Black q Switch 3 Steering signal Red 3 Install nipple P2 and connect it to oil pressure gauge 1 of hydraulic tester P1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 4 Start the engine 5 Run the engine at high idle and measure the oil pressure with the control lever in neutral and moved to the stroke end a If the output pressure is as follows the PPC valve is normal 6 After f...

Page 299: ... Use the following part to block the hose side 07376 70422 Plug 04 4 Run the engine at high idle relieve the travel circuit and measure the oil leakage k Before operating the travel lever check the position and locking direction of the locked sprocket again k Wrong operation of the lever can cause an accident Accordingly make signs and checks securely a Start measuring the oil leakage 30 sec onds ...

Page 300: ...her motor Bleeding air from travel motor Bleeding air from belt con veyor motor Checking oil level and start ing opera tion Replacing hydraulic oil Cleaning strainer q q q q q See note o q Replacing return filter element q o o o o q Replacing and repairing hydrau lic pump Removing suction piping q q q q q o q Replacing and repairing control valve Removing control valve piping q q q q o q Replacing...

Page 301: ...nd the automatic warm up opera tion is reset 3 Bleeding air from grizzly feeder motor 1 Run the engine at low idle loosen drain hose 1 and check that oil flows out of the drain port 2 If the oil does not flow out stop the engine disconnect the drain hose and fill the motor case with oil 3 After bleeding air tighten the drain hose 4 Run the engine at low idle to rotate the motor slowly 4 Bleeding a...

Page 302: ...r 1 Run the engine at low idle loosen drain hose 1 and check that oil flows out of the drain hose 2 If the oil does not flow out stop the engine and fill the motor case with hydraulic oil 3 After bleeding air tighten the drain hose 4 Run the engine at low idle to rotate the motor slowly ...

Page 303: ... machine in the travel posture raise the primary belt conveyor and hitch mount hook 1 in fixing position for travel a securely 2 Make run up for 10 m and then measure the travel deviation in 20 m a Run the engine at full throttle for measure ment a Install an oil pressure gauge and measure the pump discharge pressure during the measurement of the travel deviation ...

Page 304: ...SEN02303 00 30 Testing and adjusting 46 BR380JG 1E0 Adjusting mirrors 1 ...

Page 305: ...the machine both sides of the conveyor or objects of a height of 1 m and diameter of 30 cm 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 Adjusting view Adjust each mirror so that the operat...

Page 307: ...JG 1E0 1 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 ...

Page 308: ...witch 1 2 Figure input switch 2 3 Figure input switch 3 4 Figure input switch 4 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 Return switch E Upward move switch R Downward move switch Input confirmation switch ...

Page 309: ...r mality record 02 Electrical systems 3 Check before starting function 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 25 Function of default 06 Language 8 Function of testing mode Unit 9 Function...

Page 310: ...bove display is available only when the password function is selected 2 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 3 Check before starting function Check before starting screen is displayed for 2 seconds succeeding to display of KOMATSU logo 4 Maintenance display function Succeeding to...

Page 311: ...d with the mode selector switch of the main control box the operator can check the operating condition of each work equipment unit and specify the work equipment that is overloaded or loaded abnor mally q If the hydraulic oil temperature is abnor mally high the travel mode is selected forcibly 8 Function of testing mode If the testing mode is selected with the mode selector switch of the main cont...

Page 312: ...speed The operator can adjust the crusher speed with the crusher speed setting switch of the machine monitor A Speed is minimum B Speed is maximum 11 Function of setting crusher load The operator can adjust the crusher load with the crusher load setting switch of the machine monitor A Load is set to minimum B Load is set to maximum 12 Display s brightness and contrast adjusting function The screen...

Page 313: ...lable by operating the following switches after the starting switch is turned OFF q Switch operation E Simultaneous operation 15 Caution generation display function If a caution is warned for a caution item appli cable symbol mark is displayed large for 2 sec onds and then it remains on the screen in a smaller size until the trouble is eliminated 16 User code display function If a trouble occurs o...

Page 314: ...mmediately E11 Engine controller system error Output reduced to protect engine Operate machine to a safe posture and have inspection car ried out immediately E14 Throttle system error Operate machine to a safe posture and have inspection car ried out immediately E15 Engine sensor coolant temperature fuel temperature and oil pressure system error Operations are possible but have inspection carried ...

Page 315: ...red q Switching operation a The screen display sequentially changes as shown below 1 Failure code 2 Telephone symbol mark 3 Telephone number a The telephone mark and telephone num ber are displayed only when the telephone number is registered to the machine moni tor Registration correction or deletion of a telephone number is done from the ser vice menu a For detailed information of failure codes ...

Page 316: ...3KY 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 e...

Page 317: ... 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 sys...

Page 318: ...onnection 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...

Page 319: ...r is notified to the operator the buzzer sounds The operator can stop the buzzer with the alarm buzzer cancel switch e Since the caution monitor is also turned ON its function sounds the buzzer a Component in charge MON The machine monitor is in charge of detection of abnormality W E The work equipment and pump controller is in charge of detection of abnormality PUMP The pump controller is in char...

Page 320: ...elected with the mode selector switch of the main control box the color of mode monitor a changes according to the conveyor posi tion q When conveyor position is Upper Mode monitor a becomes red At this time the whole work equipment stops q When conveyor position is Middle or Lower Mode monitor a becomes yellow At this time the work equipment can operate 2 Conveyor position display in travel mode ...

Page 321: ...he display is changed to the initial display of Service Menu program Select an appropriate item from among the menu 4 Ending the menu and function When ending the operation from the service menu screen or respective menu screens select either of the following operations q Press switch enables every screen q When RETURN switch is displayed press the applicable switch q When Return menu is displayed...

Page 322: ...ollowing switch operations after the registra tion work has been completed q Hold down switch for about 3 seconds q Select menu 99999 and press switch a When you have registered all the items that can be registered the screen will be automatically switched to the monitoring information screen a Monitored information are transmitted via communication circuits Thus the number of selected items can i...

Page 323: ...Crusher FWD EPC Curr mA mA mA PUMP 26000 Crusher REV EPC Curr mA mA mA PUMP 25705 Acc EPC Curr mA mA mA PUMP 28801 Travel Lock EPC 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 36400 Rail Pressure MPa kg cm2 psi ENG 37400 Ambient Pressure kPa kg cm2 psi ENG 18500 Charge Temperature C C F ENG 36500 Boost Pressure kPa kg c...

Page 324: ...MON R Ctrl Trv Sw MON R Ctrl On Trv MON 25002 Switch Input 2 Mode Sel Work ON OFF PUMP Mode Sel Travel PUMP Crush FWD REV PUMP Machine Select1 PUMP Machine Select2 PUMP 25003 Switch Input 3 Emergency Sw ON OFF PUMP Engine Stop Sw PUMP 1 touch start Sw PUMP 1 touch stop Sw PUMP 25004 Switch Input 4 Conv Hi Sensor ON OFF PUMP Conv Mi Sensor PUMP MuckConv Sen PUMP Overfeed Sensor PUMP 25005 Switch In...

Page 325: ...2202 Switch Input 7 Key Switch ACC ON OFF PUMP 25500 Solenoid Valve Mag Sep Sol ON OFF PUMP Lock Cyl Unlock PUMP Muck Conv Sol PUMP 25601 Relay Drive 0 Horn Relay ON OFF PUMP Becon Relay PUMP Abno Press Relay PUMP LockCyl Push Re PUMP LockCyl Pull Re PUMP Eng Stop Relay PUMP 25602 Relay Drive 1 Conv FWD Relay ON OFF PUMP Conv REV Relay PUMP 26100 Clearance Potentio Vol V V V PUMP 26200 Clearance A...

Page 326: ...ay of electrical system abnormality record information screen 1 Occurrence order of abnormalities from latest one Total number of records 2 Failure code Equipment 4 digits Phenomena 2 digits 3 Elapsed time on service meter from the first occurrence 4 Contents of trouble a See the operator menu Failure codes table 4 Contents of display of mechanical system abnormality record information screen 1 Re...

Page 327: ...lement the following procedure 1 Following switch operation from the electrical system abnormality record screen opens the reset screen q Switch operation E 1 o 2 o 3 a Above is the same as that done when switching to the service menu 2 From the reset screen do the switch operation according to the screen instructions a When a specific individual infor mation alone is to be reset be sure to displa...

Page 328: ...played q Oil and filter names q Replacement time elapsed up to present q Time elapsed on service meter up to the last replacement 23 Function of maintenance mode change 04 Following procedure allows changing the cur rently set operating conditions of the mainte nance display function q Set function effective or ineffective q Change set replacement interval 1 Menu selection Select 04 Maintenance Mo...

Page 329: ... be freely set The main tenance mode operates based on this time the time can be increased or decreased in multiple of 50 hours by use of E and R switches 3 Use On Maintenance display func tion for this item is enabled 4 Not use Off Maintenance display function for this item is disabled a The lower limit of this setting is 50 hours 5 Description of Initialize all items Select this menu and then pr...

Page 330: ...Phone number is already inputted it is deleted if you switch the Phone Number Entry screen 3 Entry and setting phone number Following the method explained below entry a phone number in the Phone Num ber Entry display Entry automatically begins with a cursor at the left end 1 Using the numerical keypad enter the number starting with the cursor position situated at the left end a Numbers can be ente...

Page 331: ...he target sub menu of setting change and then press switch 3 Language setting function Service Menu allows switching the lan guage between Japanese and English a The default language of the machine monitor is English a When using the machine monitor which is a spare part in the Japa nese speaking sphere switch this function from English to Japanese 4 Unit selection function You can select 1 from t...

Page 332: ...n be adjusted within the range shown in the table below 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 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 initia...

Page 333: ... switch and switch and depress switch 2 The adjusted current flashes and the value input window is displayed 3 Input a value with the numeral keys and depress switch a If a value out of the proper range is input the value before inputting is dis played again a If the LS EPC solenoid current is adjusted the minimum crusher speed and maximum and minimum feeder speeds as well as the maximum crusher s...

Page 334: ...service menu to display the clearance potentiometer initialization screen 7 Depress 1 SET on the clearance potentiometer initialization screen 7 Function for option registration Use Disuse of the options of the machine can be set 1 On the option setting menu screen move the cursor with the E switch and R switch to an option to be adjusted and press the switch 2 The screen changes to the use on dis...

Page 335: ...rvice Menu initial screen and press switch 2 Selecting cylinder to be cut out Press a switch corresponding to the cylin der No to be cut out from switches 1 to 6 of the machine monitor a If pressing the switch changes the cylinder number on the screen to a white letter enclosed in the white frame the cylinder is cut out when a wrong number is selected press the correct switch again a Number of cyl...

Page 336: ...nction remains on it until the holding is cancelled In other words enabling or disabling of the cylinder cut out mode does not affect the display Thus when identifying a failed cylinder quicker fol lowing operation is effective 1 Run the engine from the normal operation mode no cylinder cut out and then hold the speed of that time 2 Specify the cylinder to be diagnosed as the cut out 3 Run the eng...

Page 337: ...or instance for measurement of com pressive pressure a This setting must be done after stopping the engine 1 Selecting menu Select 09 No Injection Cranking from the Service Menu initial screen and press switch 2 The initial screen for the no injection cranking will appear a Check Communication will be dis played in red 3 As the checkup is over following screen appears 4 Select No Injection and pre...

Page 338: ...the starting motor 7 After the no injection cranking is over press switch from the previous screen and the letters End will be displayed for 3 seconds a The letters End are displayed in green 8 Press Return when ending the no injec tion cranking a If the no injection cranking function is inadvertently selected while the engine is running Engine Running will appear as No Injection in step 4 is sele...

Page 339: ...usher clearance 1 Selection of menu Select 10 Crusher Clearance Record in the initial display of Service Menu and depress switch 2 Information shown in display 1 Crusher clearance 2 Service meter reading at which crusher clearance was saved 30 Function for lock cylinder slip record 11 The machine monitor records the information about the past slip of the crusher lock cylinder service meter reading...

Page 340: ...SEN02304 00 30 Testing and adjusting 34 BR380JG 1E0 2 Deletion of data 1 o 2 o 3 While pressing input numbers ...

Page 342: ...ing 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 troublesh...

Page 343: ... operation If the work equipment is actuated by mis take there is danger that this may lead to serious personal injury 1 Always carry out operations with 2 or more workers One worker should stand in front of the control box to prevent any other person from turning the starting switch ON by mistake 2 One worker should turn the key in the starting switch to the OFF position A then remove the key and...

Page 344: ...1 BR380JG 1E0 3 4 Press work equipment lock switch 1 5 When moving from the deck on the right side of the machine to the top of the feeder put stand 2 of a height of approx 300 mm on top of the deck then go up to the feeder from stand 2 ...

Page 345: ...ully open Measure at three places both ends and the center and take the value for the smallest clearance as the representative value a When measuring outlet clearance A it is con venient to use a jig as shown in the example below Example Length approx 1500 mm diame ter of rod φ6 to 10 mm at both ends Weld a rod of the commonly used outlet clearance dimension for example 50 mm to an H shape A Crush...

Page 346: ...nually by using the panel switch k Start the engine For adjusting the outlet clearance set the travel lever lock to the LOCK position without fail k Be sure to attach a warning tag to the start ing switch in the control box k For starting the engine see the sections of Check before starting engine and Start ing engine in Operation of OPERATION in Operation and maintenance manual When adjusting the...

Page 347: ...c mode then input the OSS clearance A to be adjusted to the machine monitor in the follow ing order 1 Use UP switch 4 or DOWN switch 5 to move the cursor on the screen display to position A 2 Press input confirmation switch 6 A starts flashing and numeral input window B is displayed at the top left of the screen 3 Use UP switch 4 or DOWN switch 5 to increase or decrease the value on the dis play a...

Page 348: ...itch 5 to move the cursor on the screen display to position C 2 Press input confirmation switch 6 to complete the preparations lamp C flashes 3 Press input confirmation switch 6 again to carry out the adjustment lamp C lights up and the automatic adjustment is carried out 7 lamp C goes out to show that the clear ance adjustment is completed q Automatic adjustment is carried out with the following ...

Page 349: ...e displayed on 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 In such cases measure the clearance and adjust with S semi automatic mode or M manual mode Adjusting clearance in S semi automatic mode 1 Measure the present crusher outlet clearance to understand how much ...

Page 350: ...ove the cursor on the screen display to position A 2 Press input confirmation switch 6 A starts flashing and numeral input window B is displayed at the top left of the screen 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 The numerical value can be set in units of 1 mm in a range of 50 to 150 mm display Adjustment to op...

Page 351: ... lamp C flashes 3 Press input confirmation switch 6 again to carry out the adjustment lamp C lights up 8 lamp C goes out to show that the clear ance adjustment is completed Adjusting clearance in M manual mode 1 Measure the present crusher outlet clearance to understand how much to increase or decrease the value to reach the target value for the clearance 2 Start the engine 3 Set fuel control dial...

Page 352: ...tch 4 pressed to bring the teeth into contact with the fixed jaw plate 1 Keep crusher clearance decrease switch 4 pressed to bring the movable teeth and fixed jaw plate into contact When the value A shows no more change the movable teeth and fixed jaw plate are in contact 2 After bringing the movable teeth and fixed jaw plate into contact keep crusher clearance decrease switch 4 pressed for approx...

Page 353: ...ts and bolts may change so carry out inspection and control thoroughly If tension spring set length is greater than dimension shown below q Knocking occurs between the toggle plate and toggle seat and this will reduce the life of the toggle plate and toggle seat q The toggle plate may fall out If tension spring set length is less than dimension shown below q The tension rod or tension spring may b...

Page 354: ...on spring measure at 4 places 90 apart around the circumference Check that there is no deformation of the spring If the difference in the spring set length of the ten sion spring is more than 3 mm rotate the spring to change the seating position of the spring then tighten again k This machine uses cover assembly 1 with springs built into the fixed jaw plate wedge portion and swing jaw plate wedge ...

Page 355: ...ates on account of the worsened partial wear Replace the partially worn jaw plates with new ones k If jaw plates are used beyond their wear limit a serious damage will be inflicted on the jaw crusher main body itself 1 Hypothetical wear range hatched portion 2 Tooth plate 3 Frame a Even if dimension A and B have not reached the wear limit if position C 100 300 mm from the bottom end is the same as...

Page 356: ... at the same time Protector Replace when the remaining dimension is approx 10 mm wear amount 10 mm Replace also if part of the protector is worn unevenly A Wear amount 10 mm B Protector thickness 19 mm Swing jaw plate wedge Replace when remaining dimension A at the bot tom of the wedge is approx 79 mm wear amount B 10 mm Replace also if part of the wedge is worn unevenly Toggle seat If the wear di...

Page 357: ...m 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 a When replacing toggle plate 1 replace the toggle plate dust cover also at the same time a If noise is generated between toggle seat 2 and toggle plate 1 the noise made when tog gle plate 1 rolls on the surface of the toggle seat has no effect on the machine ...

Page 358: ...e side of toggle plate 1 and as a result the side comes in contact with the tip of rod pin 2 replace the toggle plate with a new one Liner plate Crusher feeder portion Liner plate 1 needs to be replaced with a new one when its remaining dimension reaches 10 mm wear amount of 9 mm ...

Page 359: ...xtension Accessory tool No 4 Socket Accessory tool No 5 Wrench Accessory tool No 7 Pipe Accessory tool No 8 k For details of the accessory tool see Crusher accessory tool in Mainte nance volume of the operation and maintenance manual 3 Fit the tool supplied with the machine to the lift ing hole then lift up vertically If the load is at an angle it may be difficult to remove Tools to use Hook Acces...

Page 360: ...fter removing all the cheek plates completely remove the soil and sand from the cheek plate fitting surfaces front rear right and left In particular remove the soil and sand clog ging both sides of the fixed jaw 8 Insert new cheek plates in order from the underside along the fixed jaw and a guide of the side frame 9 Tighten the cheek plate lock bolts Top cheek plate 1 M24 x 2 each side Bottom chee...

Page 361: ...ly they may cause a backlash on the fixed jaw plate If the clearance is not even on the right and left sides there will be a slippage from the swing jaw plate tip which likely leads to premature wear or partial wear on the jaw plates 1 Remove the cheek plate For details see Replacement of cheek plate 2 Remove the fixed jaw wedge bolt spring cover assembly fixed jaw wedge bolt and fixed jaw wedge b...

Page 362: ...nut 8 and washer 9 3 Remove spring cover assembly 10 and raise it with wire 3 Lift up the fixed jaw plate with a wire rope q When reversing the fixed jaw plate lower it on to a block once Then hook a wire rope on the other side to lift it up and insert it into the crusher frame q When replacing the worn fixed jaw plate lower it on to a block once Then lift up a new fixed jaw plate with a wire rope...

Page 363: ...n the fixed jaw plate and the crusher frame so that both centers are aligned 5 If fixed jaw 13 is not in tight contact with the frame insert wooden block 11 or equivalent object between fixed jaw 13 and swing jaw 12 6 Push out swing jaw 12 and push fixed jaw 13 against the front frame For details see Outlet clearance adjusting method ...

Page 364: ... plate due to burrs remaining on the contact face of either parts In that case remove the burrs before install ing the wedge If it is left unstable with burrs remaining the wedge securing bolt may loosen during the initial running in period of crushing operation and the machine may be damaged q Condition of wedge sitting 1 Unstable q Condition of wedge sitting After initial running in period of cr...

Page 365: ...ing torque to nut 8 3 Check that spring holder 6 is being pushed into the correct position The width of A should be 0 2 mm If it is not being pushed in to the correct position turn 2 bolts 5 to adjust the holder 4 Tighten wedge bolt locknut 7 At this time secure nut 8 so that it will not rotate together with wedge bolt locknut 7 In addition secure spring cover assembly 10 too so that it will not r...

Page 366: ... spring holder push bolt 5 so that dimension B becomes 15 mm then tighten locknut 4 6 Repeat the procedure in Step 3 to check that spring holder 6 is being pushed in to the correct position If it is not the specified value adjust again 8 Install the cheek plates ...

Page 367: ...rom falling always leave one of the swing jaw plate wedge bolts inserted 2 Remove the swing jaw wedge bolt spring cover assembly 2 places then remove 1 swing jaw wedge bolt on one side After removing the swing jaw wedge spring cover assembly fit the nut and leave the bolt inserted Tools to use Wrench Accessory tool No 1 Hook Accessory tool No 6 Wrench Accessory tool No 7 Pipe Accessory tool No 8 A...

Page 368: ...7 nut 8 and washer 9 4 Remove spring cover assembly 10 and raise it with wire a To make it easier to fit lifting wire A to the swing jaw plate wedge push the swing jaw plate wedge out approximately 30 mm 3 Check that the swing jaw wedge is completely loose fit lifting wire A to the center portion then remove the temporarily installed bolts and nuts and raise the wedge ...

Page 369: ...jaw each upper surface of swing jaw plate mount stopper and transverse stopper piece If not removed completely they may cause a backlash on the swing jaw plate q When turning over lower the swing jaw plate on top of a stand then fit the wire to the hook on the opposite side and insert again in the crusher frame q When replacing the swing jaw plate lower the worn plate on to a block once Lift up a ...

Page 370: ...aining on the contact face of either parts In that case remove the burrs before install ing the wedge If it is left unstable with burrs remaining the wedge securing bolt may loosen during the initial running in period of crushing operation and the machine may be damaged q Condition of wedge sitting 1 Unstable q Condition of wedge sitting 2 After initial running in period of crushing operation Spri...

Page 371: ...ng torque to nut 8 3 Check that spring holder 6 is being pushed into the correct position The width of A should be 0 2 mm If it is not being pushed in to the correct position turn 2 bolts 5 to adjust the holder 4 Tighten wedge bolt locknut 7 At this time secure nut 8 so that it will not rotate together with wedge bolt locknut 7 In addition secure spring cover assembly 10 too so that it will not ro...

Page 372: ...r inspection hatch in the open position 2 Remove the dust prevention rubber plate at the side of the crusher left and right 3 Wrap a nylon sling around toggle plate 1 and sling it 4 Check that there is no one inside the machine then start the engine 5 Set mode selector switch 3 to the inspection position 6 Attach a warning tag to announce to those concerned that the machine is now worked on 7 Pres...

Page 373: ...he accessory tool see Crusher accessory tool in Mainte nance volume of the operation and maintenance manual 10 Pass the wire through the hole in the bottom of the swing jaw then use a chain block to pull the crusher case and the track frame and fix them in position 11 Check that there is no one inside the machine then start the engine 12 Set mode selector switch 3 to the inspection position 13 Att...

Page 374: ...over 6 on top of the toggle plate get caught 20 Remove the nylon sling fitted to the toggle plate 21 Install the tension spring and tighten it to the specified tightening length Set tightening length C of the tension spring so that it is 258 260 mm when the lock cylin der length Min maximum clearance at crusher addendum 22 Loosen the chain block installed to the bottom of the swing jaw and remove ...

Page 375: ...the toggle plate before hand referring to the section dealing with replacement of the toggle plate in this manual 2 Remove toggle seat holder plates 1 of the swing jaw at both ends Bolts to use M20 x 8 3 Screw in eyebolts M12 into tap hole 2 at both ends of the toggle seat and fit the wire 4 Raise the toggle seat 4 Toggle seat at swing jaw end 44 5 kg 5 Remove only one toggle seat holder plate 3 a...

Page 376: ... the same time remove motor cover 2 3 Loosen locknuts 4 and 5 of crusher V belt adjustment turnbuckle 3 Locknut 5 turns in the opposite direction to normal Tools to use Wrench Accessory tool No 1 Wrench Accessory tool No 11 k For details of the accessory tool see Crusher accessory tool in Mainte nance volume of the operation and maintenance manual 4 Turn the crusher V belt adjustment turnbuckle 3 ...

Page 377: ...p of the crusher motor 6 Fit new belts to the flywheel in the opposite order from removal then turn crusher V belt adjustment turnbuckle 3 to extend distance L between the yokes and adjust the V belt tension For details of the method of adjusting the V belt tension see Adjusting tension of crusher drive V belt 7 After completing adjustment of the V belt ten sion tighten locknuts 4 and 5 8 Return t...

Page 378: ...method The V belt tension may be changed by adjusting the turnbuckle located behind the crusher motor After the adjustment be sure to tighten the locknut 1 Open the V belt inspection window 2 Loosen locknuts 4 and 5 of crusher V belt adjustment turnbuckle 3 Locknut 5 turns in the opposite direction to normal Tools to use Wrench Accessory tool No 1 Wrench Accessory tool No 11 k For details of the a...

Page 379: ...ween the top and bottom then check the tension accord ing to Step 5 above Check and adjustment of primary conveyor k When inspecting and cleaning the primary conveyor and its surrounding there is always the danger that you are caught in a revolving parts Be sure to start the work only after stopping the belt conveyor Check and adjustment of snaky movement of conveyor belt k If it becomes necessary...

Page 380: ...achine 2 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 3 Measure the maximum deflection of the con veyor belt top surface from the bottom surface of the wooden block Standard value for deflection Deflection a should be 170 to 175 mm ...

Page 381: ...rubber and belt loosen the adjustment bolt Standard clearance 0 mm i e close contact Adjustment of scraper Driving pulley side 1 The default condition is as shown in the dia gram 2 Loosen nuts 1 and bolts 2 then set cleaner plate 4 so that it is at right angles to belt 3 3 Loosen nuts 5 and 6 then move the cleaner up so that the tip 7 of the cleaner contacts the belt ...

Page 382: ... 5 Raise the cleaner 5 mm 6 Tighten nuts 5 and 6 7 Rotate cleaner shaft 8 so that cleaner plate 4 is at right angles 8 Check that cleaner tip 7 and the belt are at the 60 position then tighten bolt 2 and nut 1 If the angle of the tip of the cleaner and the belt is less than 60 move the cleaner up 3 Bolt M12 34 3 Nm 3 5 kgm ...

Page 383: ...N02305 01 30 Testing and adjusting 42 BR380JG 1E0 Driven pulley side If the scraper rubber has been worn out replace it by loosening the securing bolts It is in even contact with the belt across the width ...

Page 384: ... carry out the following inspection and make adjustments or replace a parts if nec essary 1 Operate the belt conveyor without load 2 Check the frame at portion A visually and if the frame is found to sway sideways it means the frame needs to be replaced with a new one If the frame does not show such sway there is no need for the replacement a This sideways sway can be visually confirmed when an am...

Page 385: ...when approach ing the magnetic separator k When conduction a trial run of the machine be sure to run the motor at low speed and check that the conveyor belt does not make a snaky movement k If metal pieces are drawn by the magnetic separator they will be ejected accelerated by the metal piece discharging belt As that poses a big danger provide a safety cover at the discharging outlet to prevent th...

Page 386: ...nce from conveyor The clearance between the surface of the conveyor belt and the magnet when the machine is shipped from the factory is approx 350 mm at both A and B when the primary conveyor height is at the fixed position for crushing reinforced concrete Change as necessary according to the crusher dis charge clearance and condition For details of the fixed position for crushing reinforced concr...

Page 387: ...oes not perform properly Adjust the belt ten sion by turning the adjusting bolts 1 on the right and left sides of the belt If the belt is not deflected 1 When the belt is deflected to the left move the belt in the direction indicated with an arrow 1 Direction of travel of belt 2 When the belt is deflected to the right move the belt in the direction indicated with an arrow 1 Direction of travel of ...

Page 388: ...belt that is about to break The conveyor belt may be damaged or broken while in operation In that case replace the defec tive belt with new one promptly 1 Keep a close watch on the head scraper con stantly Unless the scraper is in firm contact with the belt earth stuck to the rollers will likely cause the rollers to wear prematurely ...

Page 389: ... GmbH Abalbert Stifter Sir 2 D 84085 Langquaid Germany Tel 49 9452 1890 Fax 49 9452 189 20 Australia Australia Hetronic Australia P O Box 619 Unit 4 11 Durie Road Cardiff NSW 2285 Newcastle Australia Tel 61 249 537931 Fax 61 249 537932 USA North South America Hetronic USA Inc 4300 Highline Blvd Building A Oklahoma City OK 73108 USA Tel 1 405 946 3574 Fax 1 405 946 3574 Mediteranean and Middle East...

Page 390: ...onnec tor between the engine controller and engine be sure to turn the starting switch OFF 2 If a T adapter is inserted in or connected to a connector between the engine controller and engine for troubleshooting do not start the engine a You may turn the starting switch to the OFF or ON position but must not turn it to the START position ...

Page 391: ...nt the following procedure 1 Station opening inspection a Referencing Preparation work for trouble shooting of electrical system confirm the position of KOMTRAX terminal and the inspecting connector the inspecting con nector is provided at the bottom of KOMTRAX terminal a Finish the operations of steps 4 to 7 within 30 seconds 1 Turn OFF the starting switch and then after making sure 5 seconds hav...

Page 392: ... trouble is present a As Normal is confirmed proceed to the next step it will take 90 seconds to 15 minutes until normal display is restored a If GPS position data sensing error were displayed check the GPS antenna and cable for external trou bles If any repair the trouble and repeat the procedure from step 1 a If Receiving error were displayed check the communication antenna and cable for externa...

Page 393: ...essfully ended 1 Concerning the machine body for which the station opening inspection has been completed report the following informa tion to the person responsible to operation of KOMTRAX 1 Information of the machine body for which the station opening inspection has been completed machine model model number and serial number 2 Part number and serial number of KOMTRAX terminal 3 The service meter ...

Page 394: ...unication in progress lamp 4 LED A4 Internal transmitting lamp 5 LED A5 Internal receiving lamp LED for CPU 6 LED C1 R signal and ACC signal 7 LED C2 Initial output state 8 LED C3 S NET and C signal state 9 LED C4 CAN state 10 LED C5 Download writing state 11 LED C6 Download writing state 7 segment and dot for CPU 12 7 segment Number of mails not transmitted yet 13 Dot GPS positioning state ...

Page 395: ...ately connected to KOMTRAX terminal q GPS antenna shall not be disconnected or damaged q GPS antenna cable shall not be broken and shall be appropriately connected to KOMTRAX terminal Checking terminal LED indication 1 Display contents of LED for communication module a Turn ON the starting switch prior to inspection of LED display No LED Name and func tion Display Contents of display 1 LED A1 Powe...

Page 396: ...F Slow flashing Starting switch ACC signal OFF Alternator R signal ON OFF Starting switch ACC signal OFF Alternator R signal OFF 7 LED C2 State of engine control signal ON Engine control signal ON OFF Engine control signal OFF 8 LED C3 State of S NET connec tion and starting switch C signal ON S NET Connection and starting switch C signal OFF Quick flashing Starting switch C signal ON Slow flashin...

Page 397: ...ers to connectors P01 P02 and P03 of machine monitor 2 2 Engine controller 1 Open the engine hood a The engine controller is mounted on the engine 2 Insert or connect troubleshooting T adapt ers in or to connectors CE01 CE02 and CE03 of engine controller 3 a Connectors CE01 and CE02 are fixed with screws When disconnecting them loosen the screws a When returning connectors CE01 and CE02 tighten th...

Page 398: ...ne oil pressure switch have a special locking mechanism Disconnect them according to steps a c and connect them according to steps d f as shown below Disconnection a Slide lever b Unlock c Disconnect connector Connection d Connect connector e Lock f Slide lever a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch See Tools f...

Page 399: ...it according to steps c d as shown below Disconnection a Unlock b Discon nect connector Connection c Connect connector d Lock a Precautions for disconnecting connector The direction of the lock of the connector varies with the tightened position of the sensor and the lock may be in a direction in which it is difficult to reset on the under side or engine side In this case pinch the lock in directi...

Page 400: ...ensor has a special locking mechanism Disconnect it according to steps a b and connect it according to steps c d as shown below Disconnection a Unlock b Discon nect connector Connection c Connect connector d Lock a Removal and installation of sensor A deep socket is necessary for removal and installation of the engine oil pressure switch sensor See Tools for testing adjusting and troubleshooting ...

Page 401: ... diode does not have conductivity Defective q The indicated value changes The diode has conductivity Normal Note In the case of a silicon diode a value in the range from 460 to 600 is indi cated 2 When using analog circuit tester 1 Set the tester in the resistance range 2 Apply the leads of the tester as explained below and check the movement of the pointer 1 Apply the red lead of the tester to th...

Page 402: ...30 Testing and adjusting SEN02305 01 BR380JG 1E0 61 ...

Page 404: ...G 1E0 1 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 2 Fuse locations 6 ...

Page 405: ...cal 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 Troubleshooting by failure code Part 2 S...

Page 406: ...engine speed derated ENG E11 Electrical system 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 E1...

Page 407: ...dal 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 T...

Page 408: ...ations and numbers of fuse boxes and fusible links Fuse box Fuse Type of power source Fuse No Capacity of fuse Destination of power Constant power source Fusible link E02 30A 1 20A Starting switch KOMTRAX controller 2 10A Machine monitor 3 30A Engine controller 4 10A Work equipment and pump controller Switched power source Starting switch ACC 5 5A Engine controller ACC signal Switched power source...

Page 409: ...ncy stop relay 2 spare Pull up power source for over feed sensor spare 11 15A Spare 12 10A Horn 13 10A Radio control select relay Beacon lamp for radio control yellow Radio control receiver Radio control travel relay left forward left backward right forward right backward Radio control engine stop relay Radio control horn relay Radio control beacon lamp relay Radio control one touch stop relay Rad...

Page 410: ...hooting 8 BR380JG 1E0 Fusible link Fusible link No Type of power source Connector No Capacity of fusible link Destination of power 1 Constant power source E02 30A Fuse No 1 No 5 2 Switched power source E07 65A Fuse No 6 No 15 ...

Page 412: ...shooting 1 General information on troubleshooting Points to remember when troubleshooting 2 Sequence of events in troubleshooting 3 Checks before troubleshooting 4 Classification and procedures of troubleshooting 6 Contents of troubleshooting table 10 Wiring table for connector pin numbers 12 T adapter box and T adapter table 45 ...

Page 413: ...lso lose the confidence of the user or operator For this reason when carrying out troubleshooting it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure 2 Points to ask user or operator 1 Have any other problems occurred apart from the problem that has been reported 2 Was there anything strange about the machine before the ...

Page 414: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 3 Sequence of events in troubleshooting 1 ...

Page 415: ...trical equipment 1 Check for looseness corrosion of battery terminal wiring Tighten or replace 2 Check for looseness corrosion of alternator terminal wiring Tighten or replace 3 Check for looseness corrosion of starting motor terminal wiring Tighten or replace 4 Check battery voltage Engine stopped 20 30 V Charge or replace 5 Check battery electrolyte level Between H L Add or replace 6 Check for d...

Page 416: ...ate Spring 1 Check tooth plate wedge bolt spring case Standard value See Testing and adjusting Retighten 2 Check tension spring Check of crusher driving V belt tension Adjust Item Judgment value Action Rollers Check carrier roller and return roller Must rotate easily Adjust or replace Dirt or mud attached to or foreign material caught in carrier roller or return roller Must not exist Clean Damage ...

Page 417: ...Display of code accord ing to that code a If an electrical system failure code is recorded delete all the codes and reproduce them and then see if the trouble is still detected a A failure code of the mechanical system cannot be deleted a If a trouble is displayed in the air conditioner fault history or heater fault history by the fault history function carry out the corresponding troubleshooting ...

Page 418: ...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 16 Coolant contains oil or coolant spurts back or coolant level goes down S 11 17 Oil pressure drops S 12 18 Oil level rises Water or fue...

Page 419: ...epressed machine does not travel E 18 H 21 Phenomena related to monitor panel Operator menu Ordinary screen 50 Red mark of emergency stop is indicated just after engine is started E 6 51 No items are displayed on machine monitor E 7 52 Some items are not displayed on machine monitor E 8 53 Contains of display by machine monitor are different from applica ble machine E 9 54 Radiator coolant level m...

Page 420: ...monitor panel Service menu Special function screen 68 Crusher cannot be operated with crusher manual forward reverse switch on monitor E 22 69 Conveyor cannot be operated with conveyor manual forward reverse switch on monitor E 23 70 Crusher clearance cannot be adjusted with crusher clearance increase decrease switch on monitor H 22 Phenomena related to KOMTRAX system 71 KOMTRAX system does not op...

Page 421: ...ge the possible cause 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 Defective grounding A harness not connected to GND ground circuit comes into contact with the GND ground circuit Hot short defect A harness not connected to the electric power supply 24V c...

Page 422: ...ectric circuit diagram related to trouble shooting Connector No Indicates Model Number of pins and Color Connector No and pin No from each branching merging point Shows the ends of branch or source of merging within the parts of the same wiring harness Arrow io Roughly shows the location on the machine ...

Page 423: ...bleshooting 12 BR380JG 1E0 Rev 2006 11 Wiring table for connector pin numbers a The terms of male and female refer to the pins while the terms of male housing and female housing refer to the mating portion of the housing ...

Page 424: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 13 ...

Page 425: ...SEN02089 01 40 Troubleshooting 14 BR380JG 1E0 ...

Page 426: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 15 ...

Page 427: ...SEN02089 01 40 Troubleshooting 16 BR380JG 1E0 ...

Page 428: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 17 ...

Page 429: ...SEN02089 01 40 Troubleshooting 18 BR380JG 1E0 ...

Page 430: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 19 ...

Page 431: ...SEN02089 01 40 Troubleshooting 20 BR380JG 1E0 ...

Page 432: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 21 ...

Page 433: ...SEN02089 01 40 Troubleshooting 22 BR380JG 1E0 ...

Page 434: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 23 ...

Page 435: ...SEN02089 01 40 Troubleshooting 24 BR380JG 1E0 ...

Page 436: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 25 ...

Page 437: ...SEN02089 01 40 Troubleshooting 26 BR380JG 1E0 ...

Page 438: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 27 ...

Page 439: ...SEN02089 01 40 Troubleshooting 28 BR380JG 1E0 ...

Page 440: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 29 ...

Page 441: ...SEN02089 01 40 Troubleshooting 30 BR380JG 1E0 ...

Page 442: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 31 ...

Page 443: ...SEN02089 01 40 Troubleshooting 32 BR380JG 1E0 ...

Page 444: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 33 ...

Page 445: ...SEN02089 01 40 Troubleshooting 34 BR380JG 1E0 ...

Page 446: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 35 ...

Page 447: ...SEN02089 01 40 Troubleshooting 36 BR380JG 1E0 ...

Page 448: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 37 ...

Page 449: ...SEN02089 01 40 Troubleshooting 38 BR380JG 1E0 ...

Page 450: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 39 ...

Page 451: ...SEN02089 01 40 Troubleshooting 40 BR380JG 1E0 ...

Page 452: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 41 ...

Page 453: ...SEN02089 01 40 Troubleshooting 42 BR380JG 1E0 ...

Page 454: ...40 Troubleshooting SEN02089 01 BR380JG 1E0 43 ...

Page 455: ...SEN02089 01 40 Troubleshooting 44 BR380JG 1E0 ...

Page 456: ...9 601 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 6...

Page 457: ...TM2 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 ...

Page 458: ...99 601 4160 Adapter for engine CRI T3 Oil pressure switch 2 4160 q q 799 601 4180 Adapter for engine CRI T3 PEVA 3 4180 q q 799 601 4190 Socket for engine CRI T3 Commonrail pressure 3 1 2 3L q q 799 601 4230 Socket for engine CRI T3 Air intake pressure temperature 4 1 2 3 4C q q 799 601 4240 Socket for engine CRI T3 PAMB 3 1 2 3A q q 799 601 4250 Socket for engine CRI T3 PIM 3 1 2 3B q q 799 601 4...

Page 460: ...KB 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...

Page 461: ...r 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 forw...

Page 462: ...g upon detecting a failure Related information Input state ON OFF from the conveyor ON switch can be checked with the monitoring function Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective conveyor ON switch aPrepare with engine starting switch OFF then carry out tr...

Page 463: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 5 Related electrical circuit diagram ...

Page 464: ...ut state ON OFF from the conveyor stop switch can be checked with the monitoring function Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective conveyor OFF switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting s...

Page 465: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 7 Related electrical circuit diagram ...

Page 466: ...rom the conveyor feeder ON switch can be checked with the monitoring fusion Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective feeder ON switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON B71C mal...

Page 467: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 9 Related electrical circuit diagram ...

Page 468: ...ure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective discharge conveyor reverse rota tion relay Internal short circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON R17 male Resistance Between 1 and 2 100 500 z Between 3 and 5 Min 1 M...

Page 469: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 11 Related electrical circuit diagram ...

Page 470: ... has a grounding fault etc See cause 4 2 Defective discharge conveyor reverse rota tion relay aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON R17 male Resistance Between 1 and 2 100 500 z Between 3 and 6 Max 1 z 3 Disconnection in wiring harness Disconnec tion or defective con tact in connector aPrepare with engine starting switch O...

Page 471: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 13 Related electrical circuit diagram ...

Page 472: ... Related information Input state ON OFF from the crusher ON switch can be checked with the monitoring function Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher ON switch aPrepare with engine starting switch OFF then carry out troubleshooting without turnin...

Page 473: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 15 Related electrical circuit diagram ...

Page 474: ...state ON OFF from the jaw crusher stop switch can be checked with the monitoring function Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher OFF switch aPrepare with nine starting switch OFF then carry out troubleshooting without turning engine starting swit...

Page 475: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 17 Related electrical circuit diagram ...

Page 476: ...e Related information Input state ON OFF from the muck discharge conveyor starting switch can be checked with the monitoring function Code 25006 Switch Input 6 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective muck dis charge conveyor ON switch aPrepare with engine starting switch OFF then ...

Page 477: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 19 Related electrical circuit diagram ...

Page 478: ...ted information Input state ON OFF from the much discharge conveyor OFF switch can be checked with the mon itoring function Code 25006 Switch Input 6 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective muck dis charge conveyor OFF switch aPrepare with engine starting switch OFF then carry out...

Page 479: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 21 Related electrical circuit diagram ...

Page 480: ...ntly Related information Input state ON OFF from the magnetic separator ON switch can be checked with the monitoring function Code 25006 Switch Input 6 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective magnetic separator ON switch aPrepare with engine starting switch OFF then carry out trou...

Page 481: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 23 Circuit diagram related to magnetic separator ON switch ...

Page 482: ... information Input state ON OFF from the magnetic separator OFF switch can be checked with the monitoring function Code 25006 Switch Input 6 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective magnetic separator OFF switch aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 483: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 25 Circuit diagram related to magnetic separator OFF switch ...

Page 484: ...ut state ON OFF from the accessory input circuit can be checked with the monitoring func tion Code 25006 Switch Input 6 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective conveyor up switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine startin...

Page 485: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 27 Related electrical circuit diagram ...

Page 486: ...ssure sensor Internal defect aPrepare with engine starting switch OFF then start engine and carry out troubleshooting aIf Items 3 5 are normal S01 Voltage Between 1 and 3 0 3 4 5 V Between 1 and 2 4 5 5 5 V If the voltage is abnormal replace with another pressure sensor pressure sensor of magnetic separator etc and check if failure codes are displayed If the E mark of the failure code disappears t...

Page 487: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 29 Related electrical circuit diagram ...

Page 488: ...Internal defect aPrepare with engine starting switch OFF then turn engine starting switch ON or start engine and carry out troubleshooting in each case aIf Items 3 5 are normal S02 Voltage Between 1 and 3 4 5 5 5 V Between 1 and 2 0 3 4 5 V If the voltage is normal replace with another pressure sensor pressure sensor of primary conveyor etc and check if failure codes are displayed If the E mark of...

Page 489: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 31 Related electrical circuit diagram ...

Page 490: ...tarting switch OFF then turn engine starting switch ON or start engine and carry out troubleshooting in each case S12 male Resistance Between A C 4 0 6 0 kz Between B A 0 25 5 0 kz Between B C 0 25 5 0 kz 3 Disconnection in wiring harness Disconnection in wiring or defective contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting...

Page 491: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 33 Related electrical circuit diagram ...

Page 492: ...put state ON OFF of the feeder OFF switch can be checked with the monitoring function Code 25000 Switch Input 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective feeder OFF switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ...

Page 493: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 35 Related electrical circuit diagram ...

Page 494: ... state ON OFF of the one touch start switch can be checked with monitoring function Code 25003 Switch Input 3 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective one touch start switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting swit...

Page 495: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 37 Related electrical circuit diagram ...

Page 496: ...rmation Input state ON OFF of the one touch stop switch can be checked with monitoring function Code 25003 Switch Input 3 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective one touch stop switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine st...

Page 497: ...40 Troubleshooting SEN02090 00 BR380JG 1E0 39 Related electrical circuit diagram ...

Page 498: ... the controller detects disconnection while the solenoid output is turned ON be sure to turn the solenoid output ON when checking for reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher forward EPC valve solenoid Internal dis connection aPrepar...

Page 499: ...r FWD EPC Curr Since the controller detects short circuit while the solenoid output is turned ON be sure to turn the solenoid output ON when checking for reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher forward EPC valve solenoid Grounding f...

Page 500: ...oblem that appears on machine The crusher does not stop operating forward When this trouble is detected the horn sounds 3 times intermittently Related information The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short with wiring harness Contact with 24 V circuit aPrepare with engine starting sw...

Page 501: ...urr Since the controller detects disconnection while the solenoid output is turned ON be sure to turn the solenoid output ON when checking for reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher reverse EPC valve solenoid Internal dis connectio...

Page 502: ...or reproduction of the failure after repair The drive current of the EPC valve solenoid for crusher reverse rotation can be checked with the monitoring function Code 26000 Crusher REV EPC Curr The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective crusher reverse EPC valve solenoid Internal grou...

Page 503: ...ppears on machine The crusher does not stop operating in reverse When this trouble is detected the horn sounds 3 times intermittently Related information The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short with wiring harness Contact with 24 V circuit aPrepare with engine starting switch OFF ...

Page 504: ...oller detects disconnection while the solenoid output is turned ON be sure to turn the solenoid output ON when checking for reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective feeder for ward EPC valve sole noid Internal disconnec tion aPrepare with en...

Page 505: ... for reproduction of the failure after repair Feeder forward EPC valve solenoid drive current can be checked with the monitoring function Code 24700 Feeder FWD EPC Curr The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective feeder for ward EPC valve sole noid Internal grounding fault aPrepare wi...

Page 506: ...pears on machine The feeder does not stop operating forward When this trouble is detected the horn sounds 3 times intermittently Related information The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short with wiring harness Contact with 24 V circuit aPrepare with engine starting switch OFF then ...

Page 508: ...lure 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 cod...

Page 509: ...ode 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 ...

Page 510: ...ned ON be sure to turn the solenoid output ON when checking for reproduction of the failure after repair This failure code is generated when the primary coil side of engine stop relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on ...

Page 511: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 5 Related electrical circuit diagram ...

Page 512: ...rmal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective fuse No 7 If the fuse No 7 is blown the circuit probably has a grounding fault etc See cause 4 2 Defective engine stop relay Internal discon nection or grounding aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON R19 male Resistance Between 1 and 2 1...

Page 513: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 7 Related electrical circuit diagram ...

Page 514: ...detects ground short circuit while the muck conveyor solenoid is driven be sure to turn the solenoid output ON when checking reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective muck dis charge conveyor sole noid Internal short circuit or grounding aPre...

Page 515: ...lve The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective muck dis charge conveyor sole noid Internal disconnection aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON AV3 male Resistance Between 1 and 2 20 60 z 2 Disconnection in wi...

Page 516: ...id Valve Since the controller detects the disconnection while the magnetic separator solenoid is driven be sure to turn the solenoid output ON when checking reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective magnetic separator solenoid Internal discon...

Page 517: ...lve Since the controller detects the ground short circuit while the magnetic separator solenoid is driven be sure to turn the solenoid output ON when checking reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective magnetic separator solenoid Internal shor...

Page 518: ... the magnetic separator solenoid can be checked with the monitoring function Code 25500 Solenoid Valve The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective magnetic separator solenoid Internal defect aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine...

Page 519: ...driven be sure to turn the solenoid output ON when checking reproduction of the failure after repair This failure code is generated when the primary coil side of conveyor forward relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on...

Page 520: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 15 Related electrical circuit diagram ...

Page 521: ... 1 This failure code is generated when the primary coil side of magnetic separator relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective conveyor for ward rotation relay Internal defect aPrepare with engi...

Page 522: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 17 Related electrical circuit diagram ...

Page 523: ...de 25601 Relay Drive 0 This failure code is generated when the primary coil side of lock cylinder pull relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder pull relay Internal disconnec tio...

Page 524: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 19 Related electrical circuit diagram ...

Page 525: ...th the monitoring function Code 25601 Relay Drive 0 This failure code is generated when the primary coil side of lock cylinder pull relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder retr...

Page 526: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 21 Related electrical circuit diagram ...

Page 527: ...checked with the monitoring function Code 25705 Acc EPC Curr Since the controller detects a disconnection when the solenoid output is ON turn the output ON for reproduction check after recovery The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective accessory drive EPC valve sole noid Internal di...

Page 528: ... checked with the monitoring function Code 25705 Acc EPC Curr Since the controller detects a short circuit when the solenoid output is ON turn the output ON for reproduction check after recovery The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective accessory drive EPC valve sole noid Internal g...

Page 529: ...lock cyl inder push pull switch have failed these operations do not stop If they do not stop press the engine stop switch or turn OFF the engine starting switch Horn sounds three intermittent sounding upon detecting a failure Related information The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot s...

Page 530: ... hot short contact with 24 V circuit turn the output ON for reproduc tion check after recovery This failure code is generated when the primary coil side of abnormal pressure recovery relay has failed A failure of the secondary contact side cannot be detected with this code The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remark...

Page 531: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 27 Related electrical circuit diagram ...

Page 532: ...andard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective fuse No 10 If fuse No 10 is blown circuit probably has ground fault See cause 4 2 Defective abnormal pressure recovery relay Internal discon nection or contact with ground aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON R05 male ...

Page 533: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 29 Related electrical circuit diagram ...

Page 534: ...toring function Code 25500 Solenoid Valve Since the controller detects a disconnection when the solenoid output is ON turn the output ON for reproduction check after recovery The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder unlock solenoid Inter nal disconnection aPrepare wit...

Page 535: ... be checked with the monitoring function Code 25500 Solenoid Valve Since the controller detects a ground short circuit when the lock cylinder unlock solenoid is driven turn the output ON for reproduction check after recovery The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder un...

Page 536: ... state ON OFF of the lock cylinder unlock solenoid can be checked with the monitoring function Code 25500 Solenoid Valve The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder unlock solenoid Inter nal defect aPrepare with engine starting switch OFF then carry out troubleshooting w...

Page 537: ...relay can be checked with the monitoring func tion Code 25601 Relay Drive 0 Since the controller detects a disconnection when the relay output is ON turn the output ON for reproduction check after recovery The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylin der push relay Internal ...

Page 538: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 35 Related electrical circuit diagram ...

Page 539: ...mation The drive state ON OFF of the lock cylinder push relay can be checked with the monitoring func tion Code 25601 Relay Drive 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective lock cylinder push relay Internal short circuit aPrepare with engine starting switch OFF then carry out troub...

Page 540: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 37 Related electrical circuit diagram ...

Page 541: ...ART and carry out troubleshooting S06 male Voltage Between 1 and 3 4 5 5 5 V Between 1 and 2 0 3 4 5 V If the voltage is abnormal replace with another pressure sensor pressure sensor of magnetic separator etc and check if failure codes are dis played If the E mark of the failure code disappears the secondary con veyor pressure sensor is defective 3 Disconnection in wir ing harness Discon nection o...

Page 542: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 39 Related electrical circuit diagram ...

Page 543: ... in normal state Remarks on troubleshooting 1 Defective travel lock EPC valve solenoid Internal disconnec tion aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON V11 male Resistance Between 1 and 2 7 14 z 2 Defective travel diffuse switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine sta...

Page 544: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 41 Related electrical circuit diagram ...

Page 545: ...ecorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel lock EPC valve solenoid Internal short circuit or grounding fault aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON V11 male Resistance Between 1 and 2 7 14 z Between 1 and chassis ground Min 1 ...

Page 546: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 43 Related electrical circuit diagram ...

Page 547: ...machine The travel speed increases equivalent to the Mi gear position in the Lo position Horn sounds three intermittent sounding upon detecting a failure Related information The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short in wiring har ness Contact with 24V circuit aPrepare with engine st...

Page 548: ...ted information If a foreign material such as mass of iron enters the crusher is overloaded and lock cylinder slips for crusher protection in the crusher while the machine is operating properly The lock cylinder slip history can be checked with the SERVICE MENU on the machine monitor Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting ...

Page 549: ...nal failure aPrepare with engine starting switch OFF then turn engine starting switch ON or START and carry out troubleshooting S07 male Voltage Between 1 and 3 4 5 5 5 V Between 1 and 2 0 3 4 5 V If the voltage is normal replace with another pressure sensor pressure sensor of conveyor etc and check if failure codes are displayed If the E mark of the failure code disappears the vibratory screen pr...

Page 550: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 47 Related electrical circuit diagram ...

Page 551: ...nding upon detecting a failure Related information The input state ON OFF of the radio control work mode switch can be checked with the monitoring function Code 25001 Switch Input 1 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective radio control ler receiver Contact with ground circuit aPre...

Page 552: ...cting a failure Related information The input state ON OFF of the radio control travel mode switch can be checked with the monitor ing function Code 25001 Switch Input 1 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective radio control ler receiver aPrepare with engine starting switch OFF the...

Page 553: ...adio control work mode switch on panel side then carry out troubleshooting after starting the engine S23 male Mode selector switch Resistance Between 1 and 2 Working mode Min 1 Mz Travel mode aSet the conveyor to the travel operation position upper posi tion Max 1 z 2 Defective travel signal pressure switch aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out ...

Page 554: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 51 Related electrical circuit diagram ...

Page 555: ...nternal failure aPrepare with engine starting switch OFF then turn engine starting switch and carry out troubleshooting S03 male Voltage Between 1 and 3 4 5 5 5 V Between 1 and 2 0 3 4 5 V If the voltage is normal replace with another pressure sensor pressure sensor of conveyor etc and check if failure codes are displayed If the E mark of the failure code disappears the magnetic separator pressure...

Page 556: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 53 Related electrical circuit diagram ...

Page 557: ...tate Cause Standard value in normal state Remarks on troubleshooting 1 Clogged air cleaner When system is nor mal Check the air cleaner If it is clogged clean or replace it 2 Defective air cleaner clogging switch Internal disconnec tion aPrepare with engine starting switch OFF then start engine and carry out troubleshooting S15 male Air cleaner Resistance Between 1 and 2 Normal Max 1 z Clogged Min...

Page 558: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 55 Circuit diagram related to air cleaner clogging ...

Page 559: ...rnator Insufficient genera tion aPrepare with engine starting switch OFF then start engine and carry out troubleshooting E12 male Engine speed Voltage Between 1 and chassis ground Medium or higher 27 5 29 5 V 2 Disconnection in wir ing harness Disconnection in wir ing harness or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning ...

Page 560: ...40 Troubleshooting SEN02091 00 BR380JG 1E0 57 Circuit diagram related to charge voltage ...

Page 562: ...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 CA14...

Page 563: ...eed sensor 38 Failure code CA271 Short circuit in fuel pump actuator 39 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 injecto...

Page 564: ...put lowers If machine is operated as it is engine may be damaged Related information Engine oil pressure switch signal is input to engine controller and then transmitted to machine mon itor Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil pressure when system i...

Page 565: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 5 Circuit diagram related to engine oil pressure of machine monitor ...

Page 566: ...le causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of engine oil level When system is nor mal Check the oil level in the engine oil pan If it is low add oil If this trouble occurs frequently find the cause 2 Defective engine oil level switch Internal disconnec tion aPrepare with engine starting switch OFF then carry out troublesh...

Page 567: ...s engine may be seized Related information Engine coolant temperature sensor signal is input to engine controller and then transmitted to machine monitor Engine coolant temperature can be checked with monitoring function Code 04107 Coolant Temperature Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on t...

Page 568: ...1 Lowering of radiator coolant level When system is nor mal Check the coolant level in the radiator sub tank If it is low add coolant If this trouble occurs frequently find the cause 2 Defective radiator coolant level switch Internal disconnec tion aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON S16 male Radiator coolant level Resis...

Page 569: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 9 Circuit diagram related to radiator coolant level ...

Page 570: ...dard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Overheating of hydrau lic oil when system is normal Hydraulic oil may be overheating Check it and remove cause if it is over heating 2 Defective hydraulic oil temperature gauge system If cause 1 is not detected hydraulic oil temperature gauge system may be defective Carry out troubleshooting for E 13 Hydra...

Page 571: ...ine Bkup speed sensor are abnormal Action of controller None in particular Problem that appears on machine Engine stops Engine does not start Related information Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective connection of sensor connector Connectors of Ne speed sensor an...

Page 572: ...n 2 4 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5 V 24 V circuit in wiring harness aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Wiring harness between CE01...

Page 573: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 13 Circuit diagram related to boost pressure temperature sensor Combination sensor ...

Page 574: ...ower supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 f...

Page 575: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 15 Circuit diagram related to boost pressure temperature sensor Combination sensor ...

Page 576: ...ting switch OFF then turn engine starting switch ON and carry out troubleshooting P10 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5 V 24 V circuit in wiring harness aPrepare with engine starting swit...

Page 577: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 17 Circuit diagram related to fuel control dial ...

Page 578: ...itch OFF then turn engine starting switch ON and carry out troubleshooting P10 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF th...

Page 579: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 19 Circuit diagram related to fuel control dial ...

Page 580: ...ection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 15 COOLANT TEMP female B Resistance Max 10 z Wiring harness between CE01 female 38 JC03 COOLANT TEMP female A Resistance Max 10 z 3 Short circuit in wiring harness wi...

Page 581: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 21 Circuit diagram related to coolant temperature sensor ...

Page 582: ... Between B chassis ground Min 100 kz 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 15 COOLANT TEMP female B and chassis ground Resistance Min 100 kz 3 Short circuit in wiring harness with another wiring harness aPrepare with engine s...

Page 583: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 23 Circuit diagram related to coolant temperature sensor ...

Page 584: ... male Resistance Between 3 4 0 18 160 kz 2 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 23 BOOST PRESS IMT female 3 Resistance Max 10 z Wiring harness between CE01 female 47 JC02 BOOST PRESS IMT female 4 ...

Page 585: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 25 Circuit diagram related to boost pressure temperature sensor Combination sensor ...

Page 586: ...h ON BOOST PRESS IMT male Resistance Between 3 4 0 18 160 kz Between 3 chassis ground Min 100 kz 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 23 BOOST PRESS IMT female 3 Resistance Min 100 kz 3 Short circuit in wiring harness with a...

Page 587: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 27 Circuit diagram related to boost pressure temperature sensor Combination sensor ...

Page 588: ...th monitoring function Code 18500 Charge Temperature Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Lowering of cooling performance of after cooler Cooling performance of aftercooler may be low Check following points directly Looseness and breakage of fan belt Insufficiency of cool...

Page 589: ...ith engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Disconnect sensors and wiring harness at right in order and carry out operation to repro duce trouble If E of failure code goes off when a sensor or wiring harness is discon nected that sensor or wiring harness is defec tive Boost pressure temper ature sensor BOOST PRESS IMT Common rail pressure sensor...

Page 590: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 31 Circuit diagram related to sensor power supply 2 ...

Page 591: ...y 4 75 5 25V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5V 24V circuit in wiring harness aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Wiring harness between CE01 female 3 AMBIENT AI...

Page 592: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 33 Circuit diagram related to ambient pressure sensor ...

Page 593: ...5V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 3 AMBIENT AIR P...

Page 594: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 35 Circuit diagram related to ambient pressure sensor ...

Page 595: ...ears on machine Engine output lowers Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiring har ness connector Connecting parts between each sensor engine wiring harness engine controller may be defective Check them directly Looseness of conn...

Page 596: ...ted information Engine speed can be checked with monitoring function Code 01002 Engine Speed Method of reproducing failure code Run engine at high idle Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Use of improper fuel Fuel used may be improper Check it directly 2 Improper use Machine may be used improperly Teach operator prope...

Page 597: ... in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness aDisconnect connector with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Disconnect sensor and wiring harness at right in order and carry out operation to reproduce trouble If E of failure code goes off when sensor or wiring har ness i...

Page 598: ... chassis ground Min 100 kz 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGULATOR female 1 Resistance Min 100 kz 3 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then ...

Page 599: ...hout turning engine starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGULATOR female 1 Resistance Max 10 z Wiring harness between CE01 female 32 CP3 PUMP REGULATOR female 2 Resistance Max 10 z 3 Hot short Short circuit with 24V circuit in wir ing harness aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Wiring harness betwee...

Page 600: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 45 INJ CYL 1 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 601: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 43 Circuit diagram related to No 1 injector ...

Page 602: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 46 INJ CYL 5 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 603: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 45 Circuit diagram related to No 5 injector ...

Page 604: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 55 INJ CYL 3 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 605: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 47 Circuit diagram related to No 3 injector ...

Page 606: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 57 INJ CYL 6 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 607: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 49 Circuit diagram related to No 6 injector ...

Page 608: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 54 INJ CYL 2 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 609: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 51 Circuit diagram related to No 2 injector ...

Page 610: ...tance Max 2 z 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 56 INJ CYL 4 female 1 Resistance Max 2 z 4 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshootin...

Page 611: ...40 Troubleshooting SEN02092 00 BR380JG 1E0 53 Circuit diagram related to No 4 injector ...

Page 613: ...nsor 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 sen...

Page 614: ...re 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 c...

Page 615: ...f controller None in particular Problem that appears on machine Continues normal operation Engine stops or does not start Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defect in related sys tem If another failure code is displayed carry out troublesh...

Page 616: ...9 If fuse is broken circuit probably has ground fault 3 Defective relay for engine controller power supply aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Replace relay R21 R22 for engine controller with another relay and per form reproducing operation If E of failure code goes off at this time replaced relay is defective 4 Disconnection i...

Page 617: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 5 Circuit diagram related to engine controller ...

Page 618: ...with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Disconnect sensor and wiring harness at right in order and carry out operation to reproduce trouble If E of failure code goes off when sensor or wiring har ness is disconnected that sensor or wiring harness is defective Ambient pressure sensor AMBIENT AIR PRESSURE Engine wiring harness CE01 2 Defectiv...

Page 619: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 7 Circuit diagram related to sensor power supply 1 ...

Page 620: ...Related information Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiring harness connector Connecting parts between ambient pressure sensor engine wiring har ness engine controller may be defective Check them directly Looseness of connector breakage of lock or...

Page 621: ...nnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 14 P47 male 1 Resistance Max 10 z Wiring harness between CE01 female 47 JC02 P47 male 2 Resistance Max 10 z 3 Short circuit in wiring harness with another wiring harness aPrepare with engine start...

Page 622: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 11 Circuit diagram related to water in fuel sensor ...

Page 623: ...in 100 kz 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 14 P47 male 1 Resistance Min 100 kz 3 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshooting without...

Page 624: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 13 Circuit diagram related to water in fuel sensor ...

Page 625: ...chassis ground Max 10 z 2 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 17 OIL PRESSURE SWITCH female 1 Resistance Max 10 z 3 Short circuit in wiring harness with another wiring harness aPrepare with engin...

Page 626: ...ontroller with another relay and per form reproducing operation If E of failure code goes off at this time replaced relay is defective 5 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between B28 No 3 R21 R22 female 3 Resistan...

Page 627: ... machine wiring harness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage push in or expansion of pin Moisture or dirt in connector or defective insulation 9 Defective engine controller aPrepare with engine starting switch OFF then turn engine starting switch ON and start engine and carry out troubleshooting i...

Page 628: ...causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective battery voltage aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Battery Voltage Between terminals Max 32 V 2 Defective alternator aPrepare with engine starting switch OFF then start engine and carry out troubleshooti...

Page 629: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 19 Circuit diagram related to engine controller power supply ...

Page 630: ...t There may be air in low pressure circuit Check it directly according to the following procedure 1 Remove pressure pickup plug outlet side of fuel main filter 2 Operate feed pump of fuel pre filter 3 Check pressure pickup plug for leakage of fuel and air 3 Defect in fuel return circuit parts aFor check of fuel return circuit pressure see Testing and adjusting Checking fuel pressure Fuel return ci...

Page 631: ...y 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Hot short Short circuit with 5V 24V circuit in wiring harness aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Wiring harness between CE01 female 25 FUEL RAI...

Page 632: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 23 Circuit diagram related to common rail pressure sensor ...

Page 633: ...5 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Wiring harness between CE01 female 25 FUEL RAIL PRE...

Page 634: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 25 Circuit diagram related to common rail pressure sensor ...

Page 635: ...ger may be abnormally high Check related parts directly 3 Defective engine controller If causes 1 2 are not detected engine controller may be defective Since trouble is in system troubleshooting cannot be carried out User code Failure code Trouble Common rail pressure sensor too high 1 Engine controller system E15 CA553 Contents of trouble There is high pressure error in common rail circuit Action...

Page 636: ...check of pressure in fuel low pressure circuit see Testing and adjusting Checking fuel pressure Pressure in fuel low pressure circuit During cranking if engine cannot be started 0 3 1 1 MPa 3 1 11 3 kg cm2 During low idle if engine can be started 0 5 1 3 MPa 5 1 13 3 kg cm2 3 Defective pressure limiter aFor check of leakage through pressure limiter see Testing and adjust ing Checking fuel return r...

Page 637: ...ne Ne speed sensor may be broken or may have improper clearance Check it directly 4 Breakage of rotation sensor wheel Rotation sensor wheel may be broken Check it directly 5 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness betwe...

Page 638: ... between engine Ne speed sensor engine wiring har ness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage push in or expansion of pin Moisture or dirt in connector or defective insulation 10 Defective engine controller aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out tr...

Page 639: ...n sensor wheel on crank shaft side Rotation sensor wheel on crankshaft side may be installed defectively or broken Check it according to the following procedure 1 Set No 1 cylinder at compression top dead center Match stamped mark 2 If center of oblong hole of rotation sensor wheel is at tip of Ne speed sensor rotation sensor wheel is installed normally 4 Defective installation or breakage of rota...

Page 640: ...ircuit probably has ground fault 5 Defective relay for engine controller power supply aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out troubleshooting Replace relay R21 R22 for engine controller with another relay and per form reproducing operation If E of failure code goes off at this time replaced relay is defective 6 Disconnection in wiring harness Disc...

Page 641: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 33 Circuit diagram related to engine controller power supply ...

Page 642: ...p speed sensor may be broken or may have improper clear ance Check it directly 4 Breakage of rotation sensor ring Rotation sensor ring may be broken Check it directly 5 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE...

Page 643: ... between engine Bkup speed sensor engine wiring har ness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage push in or expansion of pin Moisture or dirt in connector or defective insulation 10 Defective engine controller aPrepare with engine starting switch OFF then turn engine starting switch ON and carry out ...

Page 644: ... harness between P03 female 16 P04 female B P03 female 16 C02 female 22 P03 female 16 G01 female 7 P03 female 16 CE02 female 47 P03 female 16 K02 female B and P03 female 16 C05 male 10 Resistance Max 1 z 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness bet...

Page 645: ...ng 4 Defective CAN termi nal resistance Inter nal short circuit or disconnection aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON K02 male P03 male Resistance Between A B 120 12 z 5 Defective engine controller If causes 1 4 are not detected engine controller may be defective Since trouble is in system troubleshooting cannot be carrie...

Page 646: ... code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Short circuit in wiring harness with another wiring harness aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE02 female 22 each of CE02 female pins With P10 discon ...

Page 647: ...Standard value in normal state Remarks on troubleshooting 1 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE02 female 22 P10 female 1 Resistance Min 100 kz 2 Short circuit in wiring harness with another wiring harness aPrepare with engine starting...

Page 648: ...ler Limits output and continues operation Problem that appears on machine Engine does not start easily Exhaust gas becomes black Engine output lowers Related information Common rail pressure can be checked with monitoring function Code 36400 Common rail pressure Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state R...

Page 649: ...s Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGULATOR female 1 Resistance Max 5 z Wiring harness between CE01 female 32 CP3 PUMP REGULATOR female 2 Resistance Max 5 z 4 Ground fault in wiring harness Short circuit with GND...

Page 650: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 43 Circuit diagram related to supply pump actuator metering unit ...

Page 651: ...Replace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 2 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between CE02 fe...

Page 652: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 45 Related electrical circuit diagram ...

Page 653: ... troubleshooting Troubleshooting by replace ment Replace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 2 Ground fault in wiring harness Short circuit with GND circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harn...

Page 654: ...40 Troubleshooting SEN02093 00 BR380JG 1E0 47 Related electrical circuit diagram ...

Page 656: ... 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 S...

Page 657: ...094 00 40 Troubleshooting 2 BR380JG 1E0 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 ...

Page 658: ... output is turned ON be sure to turn the horn output ON when checking for reproduction of the failure after repair The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective horn relay Internal short circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engi...

Page 659: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 5 Circuit diagram related to horn relay ...

Page 660: ...burn the circuit probably has a grounding fault etc 2 Defective horn relay Ground fault aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON aDisconnect R04 Horn relay R04 male Resistance Between 1 and 2 100 500 z 3 Disconnection in wiring harness Disconnection or defective contact with connector aPrepare with engine starting switch OFF ...

Page 661: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 7 Related electrical circuit diagrams ...

Page 662: ...efective fusible link E07 or fuse No 6 If fusible link or fuse is broken circuit probably has ground fault See Cause 3 2 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between C03 female 2 12 22 B28 No 6 Resistance Max 1 z Wir...

Page 663: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 9 Circuit diagram related to pump controller power supply ...

Page 664: ...conveyor pressure sensor S02 Magnetic separator pressure sensor S03 F pump pressure sensor S10 R pump pressure sensor S11 Clearance detection potentiometer S12 Secondary conveyor pressure sensor S06 Vibrating sieve pressure sensor S07 2 Ground fault in wiring harness Contact with ground circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting ...

Page 665: ...parator pressure sensor system Voltage Max 5 3V Wiring harness between C01 female 22 J03 S10 female 3 and chassis ground F pump pressure sensor system Voltage Max 5 3V Wiring harness between C01 female 22 J03 S11 female 3 and chassis ground R pump pressure sensor system Voltage Max 5 3V Wiring harness between C01 female 22 J03 S12 female C and chassis ground Clearance detection potentiometer syste...

Page 666: ...SEN02094 00 40 Troubleshooting 12 BR380JG 1E0 Related electrical circuit diagram ...

Page 667: ... female 32 P03 female 15 P04 female A G01 female 8 CE02 female 46 K02 female A C05 male 3 Resistance Max 1 z Wiring harness between C02 female 22 P03 female 16 P04 female B G01 female 7 CE02 female 47 K02 female B C05 male 10 Resistance Max 1 z 2 Grounding fault in wir ing harness Contact with ground circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning en...

Page 668: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 15 Related electrical circuit diagram ...

Page 669: ...e 1 and 2 Resistance Max 1 z Wiring harness between A24 male 1 and 3 4 Resistance Min 1 Mz 2 Disconnection in wiring harness Disconnection or defective contact in connector aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between C02 female 7 and A24 female 3 Resistance Max 1 z Wiring harness between C02 female 17 and ...

Page 670: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 17 Related electrical circuit diagram ...

Page 671: ... B G01 female 7 CE02 female 47 K02 female B C05 male 10 Resistance Max 1 z 2 Grounding fault in wir ing harness Contact with ground circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch Between wiring harness P03 female 15 C02 female 32 P04 female A G01 female 8 CE02 female 46 K02 female A C05 male 3 and chassis ground Resistance Min...

Page 672: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 19 Related electrical circuit diagram ...

Page 673: ...ring function Code 25003 Switch Input 3 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective engine stop switch aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Between B76B female 1 and B76A male 1 Engine stop switch Resistance ...

Page 674: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 21 Circuit diagram related to engine stop switch ...

Page 675: ...checked with monitoring function Code 04402 Hydr Temp Sensor Vol Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective hydraulic oil temperature sensor Internal disconnec tion or short circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turnin...

Page 676: ...nsor Internal defect aPrepare with engine starting switch OFF then turn engine starting switch ON or start engine and carry out troubleshooting in each case S10 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace F pump pressure sensor with R pump pres sure sensor and check failure code If E of failure code goes off at this time F pump pressure se...

Page 677: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 25 Circuit diagram related to F pump pressure sensor ...

Page 678: ... engine starting switch OFF then turn engine starting switch ON or start engine and carry out troubleshooting in each case S11 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage is abnormal replace R pump pressure sensor with F pump pres sure sensor and check failure code If E of failure code goes off at this time R pump pressure sensor is defective 3 Disconnection ...

Page 679: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 27 Circuit diagram related to R pump pressure sensor ...

Page 680: ...mality of the primary side input side of rotary lamp SSR solid state relay the secondary side load side cannot be detected The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective resistance Internal short circuit aPrepare with engine starting switch OFF then carry out troubleshooting without turn...

Page 681: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 29 Related electrical circuit diagram ...

Page 682: ...monitoring function Code 25601 Relay Drive 0 The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Disconnection in wiring harness aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON Wiring harness between C02 female 9 R11 7 Resistance Max 1 z...

Page 683: ...40 Troubleshooting SEN02094 00 BR380JG 1E0 31 Related electrical circuit diagram ...

Page 684: ...1300 PC EPC Sol Curr The failure history is recorded Method of reproducing failure code turn engine starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PC EPC solenoid Internal dis connection aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON ...

Page 685: ...ction Code 01300 PC EPC Sol Curr The failure history is recorded Method of reproducing failure code turn engine starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PC EPC solenoid Internal short circuit or ground fault aPrepare with engine starting switch OFF then carry out troubleshooting without turning...

Page 686: ...ue can be checked with monitoring function Code 01300 PC EPC Sol Curr The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PC EPC solenoid Internal dis connection aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON V06 male Resistan...

Page 687: ...corded LS EPC electric current value can be checked with the monitoring function Code 01500 LS EPC Sol Curr Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EPC solenoid Internal dis connection aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON V05 male Re...

Page 688: ...ded LS EPC electric current value can be checked with the monitoring function Code 01500 LS EPC Sol Curr Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EPC solenoid Internal short circuit or ground fault aPrepare with engine starting switch OFF then carry out troubleshooting without turning engine starting switch ON...

Page 689: ...elated information LS EPC electric current value can be checked with the monitoring function Code 01500 LS EPC Sol Curr The failure history is recorded Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EPC solenoid Internal dis connection aPrepare with engine starting switch OFF then carry out troubleshooting without t...

Page 691: ...rate 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 2...

Page 692: ...nnot 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 switc...

Page 693: ...e 24 V cir cuit is in contact with power source 24 V circuit Short circuit Independent wiring harnesses are in contact with each other abnormally 2 3 Precautions for troubleshooting 1 Method of indicating connector No and handling of T adapter Insert or connect T adapter as explained below for troubleshoot ing unless otherwise specified If connector No has no marks of male and female discon nect c...

Page 694: ... starting switch OFF then carry out troubleshooting without turning starting switch ON R01 male Resistance Between 1 2 250 350 z Between 3 5 Min 1 Mz Between 3 6 Max 1 z 5 Defective starting motor safety relay Internal defect aPrepare with starting switch OFF with only terminal C disconnected then turn starting switch to START and carry out troubleshooting Safety relay terminal Voltage Between B E...

Page 695: ...female 2 A09 4 5 B28 1 power supply side Resistance Max 1 z Wiring harness between B28 1 starting switch B Resistance Max 1 z Wiring harness between starting switch BR A07 5 battery relay BR Resistance Max 1 z Wiring harness between battery relay M start ing motor B SB Resistance Max 1 z 10 Ground fault in wiring harness Short circuit with GND circuit aPrepare with starting switch OFF then carry o...

Page 696: ...SEN02095 00 40 Troubleshooting 6 BR380JG 1E0 Electrical circuit diagram related to engine preheating starting stopping and charging ...

Page 697: ...ctive engine stop switch Internal discon nection aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Connector Switch Resistance Between B76A male 1 B76B female 1 Released Max 1 z Pressed Min 1 Mz 5 Disconnection in wiring harness Disconnec tion in wiring or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshoot...

Page 698: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 9 Electrical circuit diagram related to engine preheating starting stopping and charging ...

Page 699: ...oolant temperature is below 10 C turbocharge protection function operates to keep the engine speed at low idle Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective engine cool ant temperature signal If the monitor does not display normally go to troubleshooting No E 11 Monitoring code Monitoring item Normal display 04107 Eng...

Page 700: ...ch case P02 Starting switch Voltage Between 18 chassis ground OFF Max 1 V HEAT 20 30 V Trouble 2 When starting switch is turned to HEAT position intake air heater mounting part does not become warm Related information Check that engine can be turned with starting motor If engine cannot be turned carry out trouble shooting for E 1 Engine does not start Engine does not turn Possible causes and stand...

Page 701: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 13 Electrical circuit diagram related to engine preheating starting stopping and charging ...

Page 702: ...yor position sensor and detection plate 2 Defective fuse No 10 If fuse is broken circuit probably has ground fault See cause 6 3 Defective conveyor position sensor When the state of the conveyor up position sensor and conveyor middle position sensor on the monitor is different from the actual state and when grounding fault is not found in the below conveyor position sensors the conveyor position s...

Page 703: ...ess Contact with ground circuit aPrepare with starting switch OFF Keep the conveyor lower then carry out troubleshooting without turning starting switch ON Wiring harness between B28 10 B13 female 4 circuit branch end Resistance Min 1 Mz Wiring harness between B13 female 3 C01 female 11 and chassis ground Resistance Min 1 Mz Wiring harness between S21 female B A04 C02 female 13 and chassis ground ...

Page 704: ...4A male 1 B75A female 1 OFF Max 1 z Wiring harness between B74B male 1 B75B female 1 OFF Max 1 z AWiring harness between B93F male 1 B94F female 1 OFF Max 1 z Wiring harness between B91A male 1 B92A female 1 OFF Max 1 z Wiring harness between B91B male 1 B92B female 1 OFF Max 1 z Wiring harness between B91C male 1 B92C female 1 OFF Max 1 z Wiring harness between B91D male 1 B92D female 1 OFF Max 1...

Page 705: ...emale 3 Resistance Max 1 z Wiring harness between A34 female 4 A10B A04 3 B75A 1 B74A 1 R23 female 3 Resistance Max 1 z AWiring harness between A34 female 4 A10B 4 A37 1 B94G 1 B93G 1 B94H 1 B93H 1 A38 male 1 Resistance Max 1 z AWiring harness between A38 male 2 A37 2 A10B male 6 Resistance Max 1 z Wiring harness between R23 female 5 C01 female 24 Resistance Max 1 z Wiring harness between R28 10 A...

Page 706: ...SEN02095 00 40 Troubleshooting 18 BR380JG 1E0 Electrical circuit diagram related to engine emergency stop ...

Page 707: ...ing switch ON Wiring harness between P01 female 1 2 starting switch ACC Resistance Max 1 z Wiring harness between starting switch B fuse box B28 1 Resistance Max 1 z Wiring harness between P01 female 6 7 A09 chassis ground Resistance Max 1 z Wiring harness between P01 female 8 B28 2 Resistance Max 1 z 4 Short circuit with chas sis ground in wiring harness Contact with ground circuit aPrepare with ...

Page 708: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 21 Electrical circuit diagram related to machine monitor power supply system ...

Page 709: ...n the machine monitor If the above cause is not the cause of the failure the machine monitor must be defective Trouble Contents of display by machine monitor are different from applicable machine Related information Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective model code signal Internal defect In the case monitoring ...

Page 710: ... When system is nor mal aAdd fuel 2 Defective fuel level sensor Internal disconnec tion aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON S14 male Fuel level Resistance Between 1 chassis ground FULL Upper limit Approx 12 z EMPTY Lower limit 85 110 z 3 Disconnection in wiring harness Disconnection in wir ing or defective contact in connector aPrepar...

Page 711: ...C 0 18 160 kz Between B chassis ground Min 1 Mz 2 Disconnection in wiring harness Disconnection in wir ing or defective contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between CE01 female 15 coolant temperature sensor female B Resistance Max 1 z Wiring harness between coolant temperature sensor female A chassis...

Page 712: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 25 Electrical circuit diagram related to engine coolant temperature sensor ...

Page 713: ...er limit 85 110 z 2 Disconnection in wiring harness Disconnection in wir ing harness or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between P02 female 2 A03 7 S14 female 1 Resistance Max 1 z 3 Short circuit with chas sis ground in wiring harness Contact with ground circuit aPrepare with starting ...

Page 714: ...tance Between 1 2 25 100 C 3 5 90 kz Between 1 chassis ground Min 1 Mz 2 Disconnection in wir ing harness Disconnection in wir ing harness or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Between P02 female 12 A06 11 S17 female 1 Resis tance Max 1 z Between P02 female 13 A06 12 S17 female 2 Resis tance Max 1 z 3...

Page 715: ...e 10 If the fuse or block fuse is broken the circuit probably has a grounding fault etc 3 Disconnection in wiring harness Disconnection in wir ing harness or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between fuse box B28 12 B13 female 4 Resistance Max 1 z C01 female 5 B13 female 2 Resistance Ma...

Page 716: ...n troubleshooting 6 Defective controller aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting C01 female Position of selector switch Voltage Between 5 chassis ground Inspection Max 1 V Between 11 chassis ground Max 1 V Between 5 chassis ground Work Max 1 V Between 11 chassis ground 20 30 V Between 5 chassis ground Travel 20 30 V Between 11 chassis ground 20 ...

Page 717: ...ng harness or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between C02 female 2 B52 female 2 Resis tance Max 1 z Wiring harness between C02 female 38 B52 female 3 Resis tance Max 1 z Between B52 female 4 chassis ground Resis tance Max 1 z 3 Grounding fault in wir ing harness Contact with ground i...

Page 718: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 31 Electrical circuit diagram related to crusher clearance adjustment mode selector switch ...

Page 719: ...ing starting switch ON Selector switch B15 male Position of selector switch Resistance Between 2 4 FORWARD Min 1 Mz REVERSE Max 1 z 2 Disconnection in wir ing harness Disconnection in wir ing harness or defec tive contact in connector aPrepare with starting switch OFF then carry out troubleshooting with out turning starting switch ON Wiring harness between C02 female 37 B15 female 2 Resis tance Ma...

Page 720: ...tua tion switch B38 male Emergency travel actua tion switch Resistance 1 3 Ordinary side Max 1 z Unordinary side Min 1 Mz 6 8 Ordinary side Max 1 z Unordinary side Min 1 Mz 3 Disconnection in wiring harness Disconnection or defec tive contact a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON a Turn the emergency travel actuation switch to ordinary...

Page 721: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 35 Electrical circuit diagram related to travel system When the radio controller OPT is not equipped directly connect A08 marked a ...

Page 722: ...fective radio control power supply circuit Disconnection or short circuit aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Receiver connector A33 female Radio control selector switch Voltage Between 1 2 Panel Max 1 V Remote control 20 30 V If the above power supply circuit is found to be defective carry out troubleshooting for 2 1 to 2 4 below 2 1 Defect...

Page 723: ...16 RR4 female 2 Resistance Max 1 z Wiring harness between A33 female 1 RR04 female 1 Resistance Max 1 z Wiring harness between A33 female 1 A44 1 RR07 female 4 5 Resistance Max 1 z Wiring harness between A33 female 1 A44 1 RR08 female 4 5 Resistance Max 1 z Wiring harness between A33 female 1 A44 1 RR09 female 4 5 Resistance Max 1 z Wiring harness between A33 female 1 A44 1 RR10 female 4 5 Resista...

Page 724: ...arry out troubleshooting without turning starting switch ON Check the connector D10 according to Testing procedure for diodes in Testing and adjusting 6 Defective travel lock EPC pressure switch When the machine travels immediately after the switch is pressed but stops soon travel lock EPC pressure switch may be defective Check with monitoring function of the machine monitor Code 25001 Radio contr...

Page 725: ...40 Troubleshooting SEN02095 00 BR380JG 1E0 39 Electrical circuit diagram related to travel system When the radio controller OPT is not equipped directly connect A08 marked a ...

Page 726: ...connection or short circuit aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Receiver connector A33 female Radio control selector switch Voltage Between 1 2 Panel Max 1 V Remote control 20 30 V If the above power supply circuit is found to be defective carry out troubleshooting for 2 1 to 2 4 below 2 1 Defective radio controller selec tor switch Inter na...

Page 727: ... 1 z Wiring harness between RR01 female 3 chassis ground Resistance Max 1 z Wiring harness between A33 female 12 A44 10 A20 10 C03 female 19 Resistance Max 1 z Wiring harness between B50 female 2 C03 female 39 Resistance Max 1 z Wiring harness between A33 female 16 RR04 female 2 Resistance Max 1 z 4 Defective relay Internal disconnection or short circuit aPrepare with starting switch OFF then carr...

Page 728: ...SEN02095 00 40 Troubleshooting 42 BR380JG 1E0 Electrical circuit diagram related to radio control system ...

Page 729: ...radio control power supply circuit Disconnection or short circuit aPrepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Receiver connector A33 female Radio control selector switch Voltage Between 1 2 Panel Max 1 V Remote control 20 30 V If the above power supply circuit is found to be defective carry out troubleshooting for 2 1 to 2 4 below 2 1 Defective radi...

Page 730: ...RR02 female 6 A44 8 A20 8 C02 female 6 Resistance Max 1 z Wiring harness between RR02 female 3 chassis ground Resistance Max 1 z Wiring harness between A33 female 12 A44 10 A20 10 C03 female 9 Resistance Max 1 z Wiring harness between B50 female 2 C03 female 39 Resistance Max 1 z Wiring harness between A33 female 16 RR04 female 2 Resistance Max 1 z 4 Defective relay Internal disconnection or short...

Page 731: ...SEN02095 00 40 Troubleshooting 46 BR380JG 1E0 Electrical circuit diagram related to radio control system ...

Page 732: ... state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor Troubleshooting cannot be carried out since the defect is in the machine monitor Trouble 3 When the feeder speed setting screen selector switch is operated the setting screen does not appear Relative information Possible causes and standard value in normal state Cause Standard value in normal state R...

Page 733: ...If failure code DA2RMC CAN communication error pump controller is displayed carry out troubleshooting for it first 2 Disconnection in crusher forward EPC valve If failure code 7RF2KA Disconnection in crusher forward EPC solenoid is displayed carry out troubleshooting for it first 3 Short circuit in crusher forward EPC valve If failure code 7RF2KB 7RF2KY Short circuit in crusher forward EPC solenoi...

Page 734: ...ard value in normal state Remarks on troubleshooting 1 Communication abnormality If failure code DA2RMC CAN communication error pump controller is displayed carry out troubleshooting for it first 2 Short circuit in con veyor forward relay If failure code 7RFHKB 7RFHKY Short circuit in conveyor forward relay is displayed carry out troubleshooting for it first 3 Disconnection or short circuit in con...

Page 735: ...fective GPS aTurn starting switch ON and carry out troubleshooting LED 2 Normal state LED A2 Lighted up 3 Defective starting switch ACC signal and alternator R signal aStart engine and carry out troubleshooting LED 6 Normal state LED C1 Lighted up aPrepare with starting switch OFF then start engine and carry out trou bleshooting G01 Signal Voltage Between 36 37 38 Starting switch ACC 20 30 V Betwe...

Page 736: ...s not transmitted yet aTurn starting switch ON and carry out troubleshooting LED 12 Normal state 7 segment 0 9 7 Defective state of posi tioning with GPS aTurn starting switch ON and carry out troubleshooting See LED 13 Normal state Dot ON In an outdoor location within radio waves penetration range it some times takes more than a minute from turning on of the starting switch to completion of the p...

Page 738: ... 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 i...

Page 739: ... 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 adjuste...

Page 740: ...SEN02306 01 40 Troubleshooting 4 BR380JG 1E0 System chart for hydraulic and mechanical systems 1 ...

Page 741: ...02306 01 BR380JG 1E0 5 a This is a system chart that has been drawn up by simplifying the whole hydraulic and mechanical circuit chart Use it as a reference material when troubleshooting the hydraulic and mechanical systems ...

Page 742: ...hine Related information Information on occurred failures and troubleshooting Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Cause that presumably triggered failure in question The assigned No is for filing purpose only It does not stand for any priority Content Included Standard value in normalcy by which to pass Good or No goo...

Page 743: ... relief valve may have a malfunction or a defect in it Check the main relief valve directly 3 Malfunction of self reducing pressure valve aPrepare with engine stopped then run engine at high idle and carry out troubleshooting Work equipment switches and travel lever Control circuit basic pressure Turn all switches OFF and set lever in neutral 2 83 3 43 MPa 29 35 kg cm2 4 Defective adjustment or ma...

Page 744: ...g Oil pressure to be measured Ratio of oil pressure Turn all work equipment switches OFF Turn all work equipment switches ON with no load Pump discharge pressure Almost same 1 LS valve output pressure Approx 3 5 If the oil pressure does not become normal after adjustment the LS valve may have a malfunction or a defect in it Check the LS valve directly 7 Malfunction of servo piston The servo piston...

Page 745: ...repare with engine stopped then run engine at high idle and carry out troubleshooting Oil pressure to be measured Measurement condition Ratio of oil pressure Pump discharge pressure Relieve travel circuit Note 1 1 PC valve output pressure Approx 3 5 If the oil pressure does not become normal after adjustment the PC valve may have a malfunction or a defect in it Check the PC valve directly 3 Defect...

Page 746: ...lowing method Remove the oil pressure pickup plug and crank the engine If oil flows out the piston pump is normal 3 Defective damper The pump shaft may not rotate because of a defect in the damper Check the damper directly Trouble Abnormal sound comes out from around the hydraulic pump Relative information Possible causes and standard value in normal state Cause Standard value in normal state Rema...

Page 747: ...pprox 4 kg cm2 Medium or Low speed Neutral position Approx 2 34 MPa Approx 23 9 kg cm2 2 Clogging of LS circuit orifice The LS circuit orifice may be clogged Check it directly 3 Defective adjustment or malfunction of LS valve aPrepare with engine stopped then run engine at high idle and carry out troubleshooting Oil pressure to be measured Ratio of oil pressure Turn all work equipment switches OFF...

Page 748: ... 5 MPa Min 26 kg cm2 2 Malfunction of acces sory control valve spool The accessory control valve spool may have a malfunction Check it directly 3 Malfunction of con veyor rotation solenoid valve The conveyor rotation solenoid valve may have a malfunction Check it directly 4 1 Disconnection or short circuit in con veyor ON OFF switch system 2 Disconnection or short circuit in accessory EPC valve sy...

Page 749: ...witch ON Approx 2 34 MPa Approx 23 9 kg cm2 2 Malfunction of acces sory control valve spool The accessory control valve spool may have a malfunction Check it directly 3 Malfunction of pressure compensation valve or pressure compensa tion piston The pressure compensation valve or pressure compensation piston of the control valve may have a malfunction Check them directly 4 Disconnection in accessor...

Page 750: ...ry out troubleshooting in the WORK mode Operation EPC valve output pressure Set the crusher speed to the maximum rotation speed Min 2 55 MPa Min 26 kg cm2 2 Malfunction of crusher control valve spool The crusher control valve spool may have a malfunction Check it directly 3 1 Disconnection or short circuit in crusher ON OFF switch system 2 Disconnection or short circuit in crusher forward EPC valv...

Page 751: ...ccording to failure codes 7RF2KA and 7RF3KA 5 Defective crusher motor Pulley Rotation direction Crusher speed Maximum speed Standard Normal rotation 280 380 rpm Reverse rotation 224 336 rpm Small torque up Normal rotation 246 334 rpm Reverse rotation 196 295 rpm Trouble The feeder does not operate Relative information Carry out the following troubleshooting when the travel system and other work eq...

Page 752: ...A 5 Defective operation of safety valve and suc tion valve for feeder The safety valve and suction valve for control valve feeder may be defec tive Check it directly 6 Defective feeder motor Feeder vibration frequency Maximum vibration 1 000 1 100 cpm Trouble The magnetic separator does not operate Relative information Carry out the following troubleshooting when the travel system and other work e...

Page 753: ...e a malfunction Check it directly 5 Defective magnetic separator motor Magnetic separator belt speed 66 108 m min Trouble The side conveyor does not operate Relative information Carry out the following troubleshooting when the travel system and other work equipment are nor mal Muck discharge conveyor does not work when it is folded Possible causes and standard value in normal state Cause Standard ...

Page 754: ... LS EPC output pressure Turn side conveyor switch ON Approx 2 34 MPa Approx 23 9 kg cm2 2 Malfunction of side conveyor control valve spool The side conveyor control valve spool may have a malfunction Check it directly 3 Malfunction of pressure compensation valve or pressure compensa tion piston The pressure compensation valve or pressure compensation piston of the control valve may have a malfunct...

Page 755: ...d then run engine at high idle and carry out troubleshooting aCarry out troubleshooting in the WORK mode Operation EPC valve output pressure Turn conveyor elevator switch ON Min 2 5 MPa Min 26 kg cm2 2 Malfunction of acces sory control valve spool The accessory control valve spool may have a malfunction Check it directly 3 Malfunction of con veyor elevator solenoid valve The conveyor elevator sole...

Page 756: ...4 3 43 MPa 29 35 kg cm2 3 Defective adjustment or malfunction of LS valve aPrepare with engine stopped then run engine at high idle and carry out troubleshooting aSet the mode selector switch in the WORK mode and carry out trouble shooting Oil pressure to be measured Ratio of oil pressure Turn all work equipment switches OFF Turn all work equipment switches ON with no load Pump discharge pressure ...

Page 757: ...all adapters to block the ends Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 9 Defective final drive The final drive may have a defect in it Check it directly aYou may check the final drive by abnormal sound abnormal heating metal powder in drain oil etc ...

Page 758: ...ve aPrepare with engine stopped then run engine at high idle and carry out troubleshooting Mode Travel speed Travel lever LS EPC output pressure Travel High speed Neutral position Approx 0 39 MPa Approx 4 kg cm2 Medium or Low speed Neutral position Approx 2 34 MPa Approx 23 9 kg cm2 4 Malfunction of travel control valve spool The travel control valve spool may have a malfunction Check it directly ...

Page 759: ...alue in normal state Remarks on troubleshooting 8 Defective travel motor aPrepare with engine stopped then run engine at high idle and carry out troubleshooting Travel lever Leakage from travel motor Relieve travel circuit Note 1 Max 27 2 l min 9 Defective final drive The final drive may have a defect in it Check it directly aYou may check the final drive by abnormal sound abnormal heating metal p...

Page 760: ...n valve may have a malfunction Check it directly 4 Malfunction of travel control valve spool The travel control valve spool may have a malfunction Check it directly 5 Malfunction of travel control valve pressure compensation valve The pressure compensation valve of the travel control valve may have a malfunction Check it directly 6 Malfunction of travel control valve suction valve The suction valv...

Page 761: ...Malfunction of travel motor parking brake Parking brake of travel motor may have malfunction Check it directly 5 Defective travel motor aPrepare with engine stopped then run engine at high idle and carry out troubleshooting Travel lever Leakage from travel motor Relieve travel circuit Note 1 Max 27 2 l min 6 Defective final drive The final drive may have a defect in it Check it directly aYou may c...

Page 762: ...rance open or close switch on monitor ON 2 84 3 43 MPa 29 35 kg cm2 3 Malfunction of lock cyl inder reset control valve spool The lock cylinder reset control valve spool may have a malfunction Check it directly 4 Malfunction of pressure compensation valve or pressure compensa tion piston The pressure compensation valve or pressure compensation piston of the control valve may have a malfunction Che...

Page 764: ...ps 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 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 ...

Page 765: ...SEN02307 00 40 Troubleshooting 2 BR380JG 1E0 S 16 Vibration is excessive 23 ...

Page 766: ...their level Check items Simple check items used by the serviceman to narrow the causes They correspond to C in the chart on the right Causes Items to be narrowed from the questions and check items The serviceman narrows down the probable causes from A B and C Troubleshooting Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable one by applyi...

Page 767: ...aust gas is black Let us assume that a trouble of Exhaust gas is black occurred and we checked the Questions and Check items and found the following 3 items to be the causal symptoms Exhaust gas slowly became black Power slowly became weaker and Dust indicator is lighting red ...

Page 768: ...sal relationship between 3 items in the Questions and Check items sections and 5 items in the Causes section The method of pinpointing the cause from the causal relationship and approaching the troubleshooting is explained according to Step 1 Step 3 shown below ...

Page 769: ... is preheated or when temperature is low preheating monitor does not indicate normally w During operation charge level monitor indicates abnormal charge w w Dust indicator is red w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Q When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine slowly w Check items While engine i...

Page 770: ...w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion moves out but Speed of rotation is low w Makes grating noise w w Soon disengages again w Makes rattling noise and does not turn Q Q Q Troubleshooting Inspect flywheel ring gear directly q Carry out troubleshooting on E mode When specific gravity of e...

Page 771: ...cement of filters has not been carried out according to Operation and Mainte nance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are found when fuel tank is drained Q E E E Check items When fuel filter is removed there is not fuel in it w w Fuel is leaking from fuel piping w When priming pump is operated it makes...

Page 772: ...re frequently w When engine is preheated or when temperature is low preheating monitor does not indicate normally w Dust indicator is red w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Starting motor cranks engine slowly w Check items When...

Page 773: ...Dust indicator is red w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes no reaction or it is heavy w Q Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w Color of exhaust gas Blue under light load w Black...

Page 774: ...ine stopped w Q Q Q Non specified fuel is being used Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w Fuel level monitor indicates low level if monitor is installed w When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged w Fuel is leaking from fuel piping w Check items When priming pump is operated i...

Page 775: ... range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out according to Operation and Maintenance Manual w When fuel tank is inspected it is found to be empty w Check items Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained Q Fuel is leaking from fuel piping w When...

Page 776: ...be added more frequently Q Q Dust indicator is red w w Air breather hole of fuel tank cap is clogged w w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of operation w Check items Color of exhaust gas Black w w Blue under light load w When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low w w When engine is cranked in...

Page 777: ... more frequently w Power was lost Suddenly w Q Q Q Gradually Q Q Q Q Dust indicator is red w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operated in low temperature mode at normal temperature Q Q Q When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low Q w When engine is cranked int...

Page 778: ... E E Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in intake system w Check items Inside of turbocharger intake outlet pipe is dirty with oil w Inside of turbocharger exhaust outlet pipe is dirty with oil Q w There is oil in coolant w Oil level in damper...

Page 779: ...ir history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Engine oil must be added more frequently w Metal particles are found when oil is drained Q Q w Inside of exhaust pipe is dirty with oil w Engine oil temperature rises quickly w Check items Color of exhaust gas color Blue under light load w Black w Amount of blow by gas Excessive Q Q w Q None w T...

Page 780: ...n More than for other machines of same model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil smells of diesel fuel w w Check items When exhaust manifold is touched immediately after starting engine temperature of some cylinders is low w Low idle speed is high Q Pump relief speed is high ...

Page 781: ...e of use of machine Operated for long period E E Oil level Suddenly increased Q Q Q Gradually increased Q Q Hard water is being used as coolant Q Q Oil level has risen oil is milky Q Q w Check items There are excessive air bubbles in radiator coolant spurts back w Hydraulic oil on applicable machine side is milky w When hydraulic oil on applicable machine side is drained water is found w Trouble s...

Page 782: ...t of filters has not been carried out according to Operation and Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Indicates pressure drop at low high idle Q w w w Q Indicates pressure drop on slopes w Sometimes indicates pressure drop w Q Oil level monitor indicates oil level drop w w Oil level in oil pan is low w Check items External hydraulic piping is...

Page 783: ...nt must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check items When radiator cap is removed and engine is run at low idle an abnormal number of bubbles appear or coolant spurts back w Q Exhaust smoke is white Q Oil level in damper chamber of applicable machine is low w Oil l...

Page 784: ...isen and oil is milky w Q Fan belt tension is low w Check items When fan belt is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When light bulb is held behind radiator core no light passes through w Radiator shroud inside of underguard on applicable machine side are clogged with dirt or mud w w Coolant is leaking because of...

Page 785: ...chine Operated for long period E Condition of abnormal noise Gradually occurred Q Q Sudden occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are found when oil filter is drained w w Air leaks between turbocharger and cylinder head w Check items When engine is cranked interference sound is generated around turbocharger w When engine is cranked abn...

Page 786: ...licable machine side Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specified oil is being used Q Q Metal particles are found when oil filter is drained w w Metal particles are found when oil pan is drained w w Check items Oil pressure is low at low idle Q Q Vibration occurs...

Page 788: ... 00 MOBILE CRUSHER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 50 Disassembly and assembly1 General information on disassembly and assembly How to read this manual 2 Coating materials list 4 ...

Page 789: ...ally made parts a General tools that are necessary for removal or installation are described as 1 2 etc and their part names part numbers and quantities are not described Removal q The Removal section contains procedures and precautions for implementing the work know how and the amount of oil or coolant to be drained q Various symbols used in the Removal Section are explained and listed below k Th...

Page 790: ...l tools starting with 79 T means that they can not be supplied from Komatsu in Japan i e locally made parts a General tools that are necessary for disassembly and assembly are described as 1 2 etc and their part names part numbers and quanti ties are not described Disassembly q In Disassembly section the work procedures precautions and know how for carrying out those procedures and quantity of the...

Page 791: ...129 9140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene container Quick setting adhesive Quick setting type max strength is obtained after 30 minutes Used mainly to stick rubbers plastics and metals Loctite 648 50 79A 129 9110 50 cc Polyethylene container Featu...

Page 792: ...T G0 T For cold district SYG2 400T A SYG2 16CNT SYG0 400T A SYG0 16CNT 400 g 16 kg Bellows type container Can Seizure resistance and heat resistance higher than molybdenum disulfide grease Not conspicuous on machine since color is white Biogrease G2 B G2 BT For use at high tempera ture and under high load SYG2 400B SYGA 16CNB SYG2 400BT SYGA 16CNBT 400 g 16 kg Bellows type container Can Since this...

Page 793: ...glass Using limit 6 months after date of manu facture SUNSTAR PENGUINE SUPER 560 22M 54 27210 320 ml Ecocart Special container Used as adhesive for glass Using limit 6 months after date of manu facture Caulking material SUNSTAR PENGUINE SEAL No 2505 417 926 3920 320 ml Polyethyl ene con tainer Used to seal joints of glass parts Using limit 4 months after date of manu facture SEKISUI SILICONE SEALA...

Page 794: ...50 Disassembly and assembly SEN02737 00 BR380JG 1E0 7 ...

Page 796: ...ing 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 fo...

Page 797: ... crusher 1 1 Cheek plate 10 Toggle seat 2 Protector 11 Swing jaw 3 V belt 12 Swing jaw plate 4 Lock cylinder 13 Crusher chamber 5 Crusher motor 14 Fixed jaw plate 6 Swing jaw plate wedge bolt 15 Front frame 7 Fixing link 16 Tension rod 8 Toggle seat 17 Tension spring 9 Toggle plate ...

Page 798: ...late 74 kg 2 Remove dirt and sand in hanging hole A of lower cheek plate 2 with an air gun or a wire brush then lift off upper cheek plate 2 with the special tool 4 Lower cheek plate 36 kg 3 After removing the upper and lower cheek plates remove all dirt and sand from the cheek plate mounting faces front rear right and left a In particular remove all dirt and sand from both sides of the fixed jaw ...

Page 799: ...er removeing the fixed jaw plate remove all dirt and sand from the fixed jaw plate mounting faces the front frame and the top of the fixed jaw plate mount stop per 4 Measure the clearance on each side of fixed jaw plate 3 and determine the point where the fixed jaw plate is aligned with the crusher frame 5 Insert block B wood block etc between fixed jaw plate 3 and swing jaw plate 4 6 Referring to...

Page 800: ...ning bolt and keep that bolt inserted 3 Check that swing jaw plate wedge 3 is loos ened fully Install wire A to the center remove the remaining bolt and sling the swing jaw plate wedge a Push out the swing jaw plate about 30 mm so that you can easily install wire A to it 4 Install hooks A to the hooks on the top of the swing jaw plate 4 and sling the swing jaw plate 4 Swing jaw plate 735 kg a Afte...

Page 801: ...wires on the opposite side and insert the swing jaw plate in the crusher frame When replacing swing jaw plate 4 lower it to the stand Sling a new swing jaw plate with the wires and insert it in the crusher frame 2 Install swing jaw plate wedge 2 and swing jaw plate wedge bolt 1 Set length L of the swing jaw plate wedge spring to 108 110 mm ...

Page 802: ...ht and left of the crusher 3 Wind nylon sling onto toggle plate 1 and lift it up temporarily 4 Start the engine 5 Set mode selector switch 3 in the inspection position k Put a warning tag to the starting switch to notify the persons around the machine that you are working on the machine 6 Press crusher clearance decrease switch 4 on the control box to move the fixing link until the swing jaw plate...

Page 803: ...case and the track frame and fix them in position 10 Start the engine 11 Press the crusher clearance increase switch 5 on the control box to pull the fixing link slowly 12 Stop the engine 13 Take out toggle plate 1 4 Toggle plate 101 kg 14 Wind the nylon sling onto new toggle plate 1 Lower the toggle plate to set it to the center of the seat on the fixing link side 15 Start the engine 16 Set mode ...

Page 804: ...ightening length Set tightening length L of the tension spring to 258 260 mm when the crusher outlet clearance is 50 OSS 21 Install rubber cover 1 piece to the top of the toggle plate 22 Loosen the chain block installed under the swing jaw and remove the wire 23 Close the crusher inspection hatch and fix it with the bolt 24 Install the dust prevention rubber plates to the sides right and left of t...

Page 805: ...o Replacing toggle plate remove the toggle plate 2 Remove toggle seat holding plates 1 on both sides on the swing jaw side 3 Tighten eyebolts in tap holes h on both sides of the toggle seat and install a wire to them 4 Sling the toggle seat 4 Toggle seat on swing jaw side 44 3 kg 5 Remove toggle seat holding plate 2 from only one side on the fixing link side 6 Tighten an eyebolt into the side wher...

Page 806: ...lock screw be sure to clean the screw hole with compressed air and apply anti sei zure compound to it 2 Lock screw hole Anti seizure compound Molybdenum spray etc 2 Using a pipe of a proper size remove cle vis 1 and washer 3 a Protect the pipe contact parts with cloths a After clevis 1 is loosened discon nect it slowly so that it will not be seized 3 Fit the hook spanner to flange 2 and hit it wit...

Page 807: ...t rings 8 and 9 will not be damaged a Check the positions of the seal and ring and the direction of the lip 2 Disassembly of clevis 1 Remove ring 10 with snap ring pliers 2 Using tool 11 shown below and a ham mer remove bushing 12 Tool 11 q Material SS400 or equivalent q Heat treatment Unnecessary ...

Page 808: ...p ring pliers 2 Installation of clevis and flange 1 Install seals 4 5 6 and 7 a Take care not to mistake the positions of the seal and ring or the direction of the lip a If there is rust or a flaw on the fitting part remove it 2 Install flange 2 with the hook spanner 2 Fitting part Same oil as currently applied one grease etc Apply thinly 2 Threaded part Anti seizure compound Molybdenum spray etc ...

Page 809: ...y thinly 2 Threaded part Anti seizure compound Molybdenum spray etc a Tighten the flange slowly so that it will not be seized or will not catch some thing a Retighten the clevis by using a ham mer 3 Clevis 706 784 Nm 72 80 kgm 4 Tighten the lock screw of clevis 1 and flange 2 3 Screw 59 Nm 6 kgm a Do not reuse the used lock screw a If the lock screw hole is deviated by retightening make a new lock...

Page 810: ...2 sets 2 Install a dummy plug to the block on the machine side 3 Remove either lock bracket 2 Prevention of interference when the conveyor is inserted a Bolt size M16 4 pieces 4 Install slings to conveyor sling bracket 3 and lift up the conveyor assembly a Note that sling hook positions depend on the serial No 4 Weight of conveyor assembly Approx 1 310 kg 5 Remove magnetic separator chutes 4 2 pla...

Page 811: ...4 pieces 2 places on the bright and left sides 8 Lower the crane to lower the conveyor a Note that sling hook positions depend on the serial No 4 Weight of conveyor assembly Approx 1 310 kg 9 Lower the cylinder a Place wooden blocks under the conveyor in advance 10 Remove the pin 11 Move the machine in reverse to remove the conveyor assembly a Take care that the conveyor will not collide with the ...

Page 812: ...50 Disassembly and assembly SEN02738 00 BR380JG 1E0 17 12 Place stable stands under the conveyor and lift off the conveyor assembly Installation q Carry out installation in the reverse order to removal ...

Page 813: ...ion adjustment bolts fully a Make a mark at the original tension point in advance The following is shown for reference Contents of work performed by the subcontractor 2 Cut the belt a The cut point shown in the figure is for ref erence only a Cut the belt in a place where you can work easily a If right and left head pulley joints 3 and 4 are removed the motor will be mis aligned and may be broken ...

Page 814: ...C a At this time do not remove the right and left joints of the head pulley assembly 5 Stick the belt a Ask the belt sticking work subcontractor See Operation and Maintenance Manual 7 15 to stick the belt 6 Referring to the value marked in step 1 adjust the belt tension Stick belt ...

Page 815: ...For removal see Removal and installation of primary belt conveyor 3 Disconnect conveyor motor hoses 2 from the body a After removing the hoses put dummy plugs to their ends and motor ports q Size 03 Flat face to face O ring seal 1 set q Size 04 Flat face to face O ring seal 2 sets 4 Fix the head pulley with a block so that it will not be misaligned with the frame a If right and left frame joints 3...

Page 816: ...ve from the frame 6 Remove motor flange mounting bolts 4 to remove flange 5 from motor 6 a Bolt size M12 10 pieces 7 Replace the motor and install the flange to the new motor a Bolt size M12 10 pieces 8 Install the flange to the pulley a At this time take care that the pulley shaft will not move from the frame 9 Install the motor flange to the frame 10 Increase the belt tension to the value marked...

Page 817: ... lateral swing D a If lateral swing is detected replace the pulley frame according to the following procedure Reference If lateral swing is 3 mm or larger it can be checked visually 3 Loosen tension adjustment bolt 1 to reduce the belt tension a Loosen the tension adjustment bolts fully a Make a mark at the original tension point in advance 4 Lower the conveyor assembly For removal see Removal and...

Page 818: ...ses 2 from the body a After removing the hoses put dummy plugs to their ends and motor ports q Size 03 Flat face to face O ring seal 1 set q Size 04 Flat face to face O ring seal 2 sets 6 Fix the head pulley with a V block and wooden block as shown below so that it will not be mis aligned with the frame A Insert wooden block to fix pulley B Fix head pulley assembly with V block to prevent misalign...

Page 819: ...ing frame 4 with a crane in advance a Bolt size M12 10 pieces 9 Remove upper bracket 5 a M16 3 2 places on right and left sides 10 Remove lower bracket 6 a M16 3 2 places on right and left sides 11 Remove bolts 7 and cover 8 a Bolt size M12 8 pieces 12 Remove bolts 9 pulley and motor flange a Bolt size M12 10 pieces ...

Page 820: ...t 14 Install motor 12 and flange 13 to new frame 11 15 Sling frame assembly 14 with the crane 16 Position the head pulley and motor flange and connect them with bolts 15 17 Install cover 16 to the head pulley frame and secure it with bolts 17 18 Go to step 29 Sub assembly of head pulley frame ...

Page 821: ...e 19 Sling frame 18 with the crane in advance 20 Remove upper bracket 19 a M16 3 2 places on right and left sides 21 Remove lower bracket 20 a M16 3 2 places on right and left sides 22 Remove bolts 21 and cover 22 23 Remove bearing cover 23 24 Loosen bearing lock screws 24 2 places in total ...

Page 822: ...ey frame and secure it with bolts 28 Sub assembly of head pulley frame 29 Apply jig 29 to measuring points f1 E f2 F and f3 G in the figure and adjust the frame width a When adjusting the frame width adjust the bearing side with a jack 30 Apply jig 29 to measuring points h1 and h2 and check that contact of jig 29 and belt is even at points J and K a If contact is uneven adjust the position a Dimen...

Page 823: ...SEN02738 00 50 Disassembly and assembly 28 BR380JG 1E0 ...

Page 824: ...es on right and left sides 33 Tighten bearing lock screws 27 2 places in total a Before tightening the screws see steps 29 and 30 and check the dimensions again 34 Remove bearing cover 28 a Before tightening the screws see steps 29 and 30 and check the dimensions again 35 Install the shaft to the frame 36 Insert spring pin 29 37 Install conveyor assembly to the body ...

Page 825: ...ease the belt tension a Increase the belt tension to the mark made when he belt was loosened 39 Referring to steps 29 and 30 check again that the distance between the head pulley and frame is in the standard range 40 Start the belt conveyor and check that it rotates smoothly a Engine speed High idle ...

Page 826: ...a or another electric electronic device can be troubled by the magnetism do not take them near the magnetic separator 1 Remove the wiring harnesses from the wiring harness clamps of the headlamp and rotary lamp installed to engine front cover 1 in advance 2 Remove 2 caps 2 from the front side of engine front cover 1 3 Remove engine front cover bottom mounting bolts 3 Right and left side 1 place ea...

Page 827: ...toward the magnetic separator and rest it against the magnetic separator frame a Weight of engine front cover assembly Approx 130 kg a Put pads between the cover and magnetic separator frame to protect the paint of the cover a Clearance A about 200 mm wide can be secured by the above work Pads ...

Page 828: ...50 Disassembly and assembly SEN02738 00 BR380JG 1E0 33 ...

Page 830: ...361 00 MOBILE CRUSHER 1SHOP MANUAL BR380JG 1E0 Machine model Serial number BR380JG 1E0 2001 and up 90 Diagrams and drawings 1 Hydraulic diagrams and drawings Hydraulic circuit diagram 1 2 3 Hydraulic circuit diagram 2 2 5 ...

Page 831: ...3 Hydraulic circuit diagram 1 2 BR380JG 1E0 BR380JG 1E0 SEN001361 00 Hydraulic circuit diagram 1 2 1 ...

Page 832: ...90 Diagrams and drawings SEN01361 00 BR380JG 1E0 5 Hydraulic circuit diagram 2 2 BR380JG 1E0 Hydraulic circuit diagram 2 2 ...

Page 834: ...er BR380JG 1E0 2001 and up 90 Diagrams and drawings 1 Electrical diagrams and drawings Electrical circuit diagram 1 4 3 Electrical circuit diagram 2 4 5 Electrical circuit diagram 3 4 7 Electrical circuit diagram 4 4 9 Connector arrangement diagram 1 2 11 Connector arrangement diagram 2 2 13 ...

Page 835: ...3 Electrical circuit diagram 1 4 BR380JG 1E0 BR380JG 1E0 SEN01362 01 Electrical circuit diagram 1 4 ...

Page 836: ...5 Electrical circuit diagram 2 4 BR380JG 1E0 BR380JG 1E0 SEN01362 01 Electrical circuit diagram 2 4 ...

Page 837: ...7 Electrical circuit diagram 3 4 BR380JG 1E0 BR380JG 1E0 SEN01362 01 Electrical circuit diagram 3 4 ...

Page 838: ...9 Electrical circuit diagram 4 4 BR380JG 1E0 BR380JG 1E0 SEN01362 01 Electrical circuit diagram 4 4 ...

Page 839: ... oil level sensor FA 3 E06 DT 2 Intermediate connector Water in fuel sensor FJ 1 E07 L 2 Fusible link Y 1 E08 X 1 Intermediate connector Alternator FB 8 E09 X 2 Starting motor safety relay Terminal B AB 1 E12 Connector 3 Alternator FC 7 FUEL RAIL PRESS 3 Common rail pressure sensor FK 7 G01 DRC 40 KOMTRA controller If equipped BN 7 G02 X 1 KOMTRA test connector If equipped BN 6 G03 X 1 KOMTRA test...

Page 840: ...BR380JG 1E0 13 SEN01362 01 Connector arrangement diagram 2 2 BR380JG 1E0 Connector arrangement diagram 2 2 ...

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Summary of Contents for BR380JG-1E0

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Komatsu BR380JG-1E0, Shop Manual, Page: 777 / 841

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Summary of Contents for BR380JG-1E0

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