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KOMATSU BR380JG-1 SHOP MANUAL SEBM034105 – PDF DOWNLOAD
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Description
KOMATSU BR380JG-1 SHOP MANUAL SEBM034105 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU BR380JG-1 SHOP MANUAL SEBM034105 – PDF DOWNLOAD
Language : English
Pages : 573
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU BR380JG-1 SHOP MANUAL SEBM034105 – PDF DOWNLOAD
COVER.......................................................................................................................... 1 CONTENTS....................................................................................................................... 2 LIST OF REVISED PAGES.......................................................................................................... 3 SAFETY......................................................................................................................... 7 SAFETY NOTICE.............................................................................................................. 7 FOREWORD....................................................................................................................... 9 GENERAL.................................................................................................................... 9 HOW TO READ THE SHOP MANUAL................................................................................................ 10 HOISTING INSTRUCTIONS...................................................................................................... 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................................................................. 12 COATING MATERIALS.......................................................................................................... 14 STANDARD TIGHTENING TORQUE................................................................................................. 16 ELECTRIC WIRE CODE......................................................................................................... 19 CONVERSION TABLE........................................................................................................... 20 UNITS...................................................................................................................... 26 01 GENERAL..................................................................................................................... 27 SPECIFICATION DRAWINGS..................................................................................................... 28 SPECIFICATIONS............................................................................................................. 29 WEIGHT TABLE............................................................................................................... 31 FUEL, COOLANT AND LUBRICANTS............................................................................................... 32 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................ 35 ENGINE RELATED PARTS....................................................................................................... 36 RADIATOR, OIL COOLER, AFTERCOOLER.......................................................................................... 37 POWER TRAIN................................................................................................................ 38 DRIVE SYSTEM FOR COMPONENTS................................................................................................ 39 FINAL DRIVE................................................................................................................ 40 TRACK FRAME AND RECOIL SPR................................................................................................. 42 IDLER...................................................................................................................... 44 CARRIER ROLLER............................................................................................................. 46 TRACK ROLLER............................................................................................................... 47 TRACK SHOE................................................................................................................. 48 ARRANGEMENT OF HYDRAULIC EQUIPMENT......................................................................................... 52 HYDRAULIC TANK AND HYDRAULIC OIL FILTER.................................................................................... 53 HYDRAULIC PUMP............................................................................................................. 54 CONTROL VALVE.............................................................................................................. 74 SELF-REDUCING PRESSURE VALVE............................................................................................... 82 CLSS....................................................................................................................... 87 CRUSHER MOTOR..............................................................................................................104 GRIZZLY FEEDER MOTOR.......................................................................................................108 CONVEYOR MOTOR.............................................................................................................109 TRAVEL MOTOR...............................................................................................................110 TRAVEL JUNCTION VALVE......................................................................................................117 VALVE CONTROL..............................................................................................................119 TRAVEL PPC VALVE...........................................................................................................120 SOLENOID VALVE.............................................................................................................129 EPC VALVE..................................................................................................................131 ELECTROMAGNETIC SELECTOR VALVE.............................................................................................135 GRIZZLY FEEDER SEMIAUTOMATIC SYSTEM........................................................................................137 ABNORMAL LOAD STOP SYSTEM..................................................................................................138 PRIMARY BELT CONVEYOR......................................................................................................139 GRIZZLY FEEDER.............................................................................................................140 CRUSHER....................................................................................................................143 CRUSHER TOOTH TIP ADJUSTMENT SYSTEM........................................................................................150 VIBRATOR...................................................................................................................153 ENGINE CONTROL.............................................................................................................154 ELECTRONIC CONTROL SYSTEM DEVICES..........................................................................................161 MULTI MONITOR SYSTEM.......................................................................................................175 SENSOR.....................................................................................................................202 20 TESTING AND ADJUSTING.......................................................................................................205 STANDARD VALUE TABLE FOR ENGINE............................................................................................206 STANDARD VALUE TABLE FOR CHASSIS...........................................................................................207 TESTING AND ADJUSTING......................................................................................................213 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................214 INSPECTION AND ADJUSTMENT OF ENGINE RPM................................................................................216 MEASURING EXHAUST GAS COLOR............................................................................................218 ADJUSTING VALVE CLEARANCE..............................................................................................219 MEASURING COMPRESSION PRESSURE.........................................................................................221 MEASURING BLOW-BY PRESSURE.............................................................................................222 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING.....................................................................223 MEASUREMENT OF ENGINE OIL PRESSURE.....................................................................................225 ADJUSTMENT OF ENGINE SPEED SENSOR......................................................................................226 DIODE INSPECTION PROCEDURE.............................................................................................227 EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM..................................................................228 TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT AND TRAVEL CIRCUITS..............................................229 TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF-PRESSURE)...........................................233 TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE.............................................................234 TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE.............................................................237 MEASURING SOLENOID VALVE OUTPUT PRESSURE...............................................................................241 MEASURING PPC VALVE OUTPUT PRESSURE....................................................................................243 MEASURING OIL LEAKAGE..................................................................................................244 BLEEDING AIR FROM EACH PART............................................................................................245 TESTING TRAVEL DEVIATION...............................................................................................247 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION........................................................................248 SPECIAL FUNCTIONS OF MONITOR PANEL.....................................................................................249 TESTING AND ADJUSTING JAW CRUSHER......................................................................................276 TESTING AND ADJUSTING CRUSHER DRIVE BELT TENSION.......................................................................286 TESTING AND ADJUSTING PRIMARY BELT CONVEYOR............................................................................287 TESTING AND ADJUSTING MAGNETIC SEPARATOR...............................................................................288 LIST OF COMPANIES WHICH HANDLES RADIO CONTROLLERS......................................................................290 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM.............................................................291 TROUBLESHOOTING............................................................................................................293 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................294 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................295 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................296 CHECKS BEFORE TROUBLESHOOTING..........................................................................................304 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...........................................................................307 TYPES AND LOCATIONS OF CONNECTORS......................................................................................310 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................340 T-BRANCH BOX AND T-BRANCH TABLE........................................................................................360 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED.................363 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....................................................................365 Electrical System Error Code [E201] (Disconnection in primary belt conveyor forward solenoid)......................367 Electrical System Error Code [E202] (Short circuit in primary belt conveyor forward solenoid)......................368 Electrical System Error Code [E203] (Disconnection in crusher forward EPC valve)...................................369 Electrical System Error Code [E204] (Short circuit in crusher forward EPC valve)...................................370 Electrical System Error Code [E205] (Disconnection in crusher reverse EPC valve)...................................371 Electrical System Error Code [E206] (Short circuit in crusher reverse EPC valve)...................................372 Electrical System Error Code [E207] (Disconnection in feeder forward EPC valve)....................................373 Electrical System Error Code [E208] (Short circuit in feeder forward EPC valve)....................................374 Electrical System Error Code [E211] (Short circuit in electrical intake air heater relay)..........................375 Electrical System Error Code [E212] (Disconnection in pressure abnormality processingrelay)........................376 Electrical System Error Code [E213] (Disconnection in accessory drive EPC valve)...................................377 Electrical System Error Code [E214] (Short circuit in accessory drive EPC valve)...................................378 Electrical System Error Code [E217] (Disconnection, short circuit, or abnormal input inmodel selection circuit)....379 Electrical System Error Code [E218] (Disconnection in S-NET signal line)...........................................380 Electrical System Error Code [E222] (Short circuit in LS-EPC solenoid).............................................381 Electrical System Error Code [E223] (Disconnection in LS-EPC solenoid).............................................382 Electrical System Error Code [E224] (Abnormality in F pump pressure sensor)........................................384 Electrical System Error Code [E225] (Abnormality in R pump pressure sensor)........................................386 Electrical System Error Code [E226] (Abnormality in pressure sensor power supply)..................................388 Electrical System Error Code [E227] (Abnormality in engine speed sensor)...........................................390 Electrical System Error Code [E232] (Short circuit in PC-EPC solenoid).............................................391 Electrical System Error Code [E233] (Disconnection in PC-EPC solenoid).............................................392 Electrical System Error Code [E234] (Short circuit in rotary lamp SSR).............................................393 Electrical System Error Code [E235] (Short circuit in horn relay)..................................................394 Electrical System Error Code [E240] (Short circuit in pressure abnormality processing relay).......................395 Electrical System Error Code [E241] (Disconnection in primary belt conveyor reverse solenoid)......................396 Electrical System Error Code [E242] (Short circuit in primary belt conveyor reverse solenoid)......................397 Electrical System Error Code [E243] (Disconnection in lock cylinder reset solenoid)................................398 Electrical System Error Code [E244] (Short circuit in lock cylinder reset solenoid)................................399 Electrical System Error Code [E246] (Short circuit in lock cylinder extension relay)...............................400 Electrical System Error Code [E247] (Disconnection in lock cylinder retraction sole noid)..........................401 Electrical System Error Code [E248] (Short circuit in lock cylinder retraction solenoid)...........................402 Electrical System Error Code [E249] (Disconnection in magnetic separator relay)....................................403 Electrical System Error Code [E250] (Short circuit in magnetic separator relay)....................................404 Electrical System Error Code [E301] (Disconnection in engine stop switch)..........................................405 Electrical System Error Code [E302] (Short circuit in primary belt conveyor-ON switch).............................406 Electrical System Error Code [E303] (Disconnection in primary belt conveyor-OFF switch)............................407 Electrical System Error Code [E304] (Short circuit in crusher-ON switch)...........................................408 Electrical System Error Code [E305] (Disconnection in crusher-OFF switch)..........................................410 Electrical System Error Code [E306] (Abnormality in governor potentiometer)........................................412 Electrical System Error Code [E308] (Abnormality in fuel control dial).............................................414 Electrical System Error Code [E315] (Short circuit of battery relay output)........................................416 Electrical System Error Code [E316] (Stepping out of governor motor)...............................................418 Electrical System Error Code [E317] (Disconnection in governor motor phases A and B)...............................420 Electrical System Error Code [E318] (Short circuit in governor motor phases A and B)...............................422 Electrical System Error Code [E320] (Short circuit in feeder-ON switch)............................................424 Electrical System Error Code [E321] (Disconnection in feeder-OFF switch)...........................................425 Electrical System Error Code [E322] (Short circuit in conveyor RAISE switch).......................................426 Electrical System Error Code [E323] (Short circuit in conveyor lower switch).......................................427 Electrical System Error Code [E331] (Abnormality in clearance sensor potentiometer)................................428 Electrical System Error Code [E332] (Short circuit in one-touch start switch)......................................430 Electrical System Error Code [E333] (Disconnection in one-touch stop switch).......................................432 Electrical System Error Code [E334] (Short circuit in magnetic separator-ON switch)................................434 Electrical System Error Code [E335] (Disconnection in magnetic separator-OFF switch)...............................436 Mechanical System Error Code [A000N1] (Engine high idling speed out of standard)...................................438 Mechanical System Error Code [A000N2] (Engine low idling speed out of standard)....................................438 Mechanical System Error Code [AA10NX] (Clogged air cleaner)........................................................439 Mechanical System Error Code [AB00KE] (Abnormal lowering of charging voltage)......................................440 Mechanical System Error Code [B@BAZG] (Abnormal lowering of engine oil pressure)...................................441 Mechanical System Error Code [B@BAZK] (Abnormal lowering of engine oil level)......................................442 Mechanical System Error Code [B@BCNS] (Overheating of engine coolant)..............................................443 Mechanical System Error Code [B@BCZK] (Abnormal lowering of radiator coolant level)................................444 Mechanical System Error Code [B@HANS] (Overheating of hydraulic oil)...............................................445 TROUBLESHOOTING OFELECTRICAL SYSTEM (E-MODE)...........................................................................447 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....................................................................448 E-1 The engine does not start (The engine does not crank)..........................................................450 E-2 The engine stops while it is running...........................................................................453 E-3 The engine rotation is unstable (The engine hunts).............................................................454 E-4 The engine does not stop.......................................................................................456 E-5 The whole work equipment stops suddenly........................................................................458 E-6 The automatic warm-up function does not work...................................................................459 E-7 The engine preheater does not operate..........................................................................460 E-8 The red mark of emergency stop is indicated just after the engine is started...................................462 E-9 The monitor panel does not display any item....................................................................464 E-10 Some items are not displayed on the monitor panel.............................................................465 E-11 The fuel level monitor lights red while the engine is running.................................................466 E-12 The engine coolant temperature gauge does not display normally................................................467 E-13 The fuel level gauge does not display normally................................................................468 E-14 The hydraulic oil temperature gauge does not display normally.................................................469 E-15 The travel, work, and inspection modes do not change..........................................................470 E-16 The crusher clearance adjustment mode does not change.........................................................472 E-17 The crusher rotation direction does not change................................................................474 E-18 Travel cannot be controlled by radio control..................................................................475 E-19 The feeder cannot be turned ON and OFF by radio control.......................................................478 E-20 The crusher cannot be turned ON and OFF by radio control......................................................480 E-21 The monitor switches do not work..............................................................................482 E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor..................483 E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor................484 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)............................................................485 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS..................................................................486 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.....................................................................488 H-1 The speed or power of the whole work equipment and travel is low...............................................489 H-2 The engine speed lowers extremely or the engine stalls.........................................................491 H-3 The work equipment and travel systems do not work..............................................................492 H-4 Abnormal sound comes out from around the hydraulic pump........................................................492 H-5 Fine control performance or response is low....................................................................493 H-6 The conveyor does not operate..................................................................................494 H-7 The speed or power of the conveyor is low......................................................................495 H-8 The crusher does not operate...................................................................................495 H-9 The speed or power of crusher is low...........................................................................496 H-10 The feeder does not operate...................................................................................496 H-11 The feeder does not feed smoothly (Vibration frequency is low)................................................497 H-12 The magnetic separator does not operate.......................................................................497 H-13 The speed of magnetic separator belt is low...................................................................498 H-14 The side conveyor does not operate............................................................................498 H-15 The speed or power of the side conveyor is low................................................................499 H-16 The primary conveyor and the side conveyor do not move up and down............................................499 H-17 The machine deviates during travel............................................................................500 H-18 The travel speed is low.......................................................................................501 H-19 The machine is not steered well or steering power is low......................................................502 H-20 The travel motor does not work (only one side)................................................................503 H-21 When the travel switch of the radio controller is depressed, the machine does not travel......................503 H-22 The crusher clearance cannot be adjusted......................................................................504 TROUBLESHOOTING OF ENGINE (S-MODE).....................................................................................505 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................506 S-1 Starting performance is poor (Starting always takes time)......................................................510 S-2 Engine does not start..........................................................................................512 (1) Engine does not turn.......................................................................................512 (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)...................................513 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected).................................514 S-3 Engine does not pick up smoothly (Follow-up is poor)...........................................................515 S-4 Engine stops during operations.................................................................................516 S-5 Engine does not rotate smoothly (Hunting)......................................................................517 S-6 Engine lacks output (or lacks power)...........................................................................518 S-7 Exhaust smoke is black (Incomplete combustion).................................................................519 S-8 Oil consumption is excessive (or exhaust smoke is blue)........................................................520 S-9 Oil becomes contaminated quickly...............................................................................521 S-10 Fuel consumption is excessive.................................................................................522 S-11 Oil is in cooling water, or water spurts back, or water level goes down.......................................523 S-12 Oil pressure monitor lights up (Drop in oil pressure).........................................................524 S-13 Oil level rises (Water, fuel in oil)..........................................................................525 S-14 Water temperature becomes too high (Overheating)..............................................................526 S-15 Abnormal noise is made........................................................................................527 S-16 Vibration is excessive........................................................................................528 30 DISASSEMBLY AND ASSEMBLY....................................................................................................529 METHOD OF USING MANUAL.....................................................................................................531 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................533 DISASSEMBLY AND ASSEMBLY OF CRUSHER........................................................................................535 DISASSEMBLY AND ASSEMBLY OF LOCK CYLINDER..................................................................................543 REMOVAL ANDINSTALLATION OF PRIMARYCONVEYOR ASSEMBLY........................................................................547 REPLACEMENT OF BELT........................................................................................................550 REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR MOTOR......................................................................552 REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR HEAD PULLEY FRAME..........................................................554 PROCEDURE FOR FOLDING ENGINE FRONT COVER...................................................................................564 90 OTHERS......................................................................................................................567 HYDRAULIC CIRCUIT DIAGRAM (1/2)............................................................................................569 HYDRAULIC CIRCUIT DIAGRAM (2/2)............................................................................................570 ELECTRICAL CIRCUIT DIAGRAM (1/3)...........................................................................................571 ELECTRICAL CIRCUIT DIAGRAM (2/3)...........................................................................................572 ELECTRICAL CIRCUIT DIAGRAM (3/3)...........................................................................................573
DESCRIPTION:
KOMATSU BR380JG-1 SHOP MANUAL SEBM034105 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 22/12/24
