Komatsu Mobile Crusher BR380JG-1E0 Shop Manual SEN01341-11 PDF DOWNLOAD

Description

Komatsu Mobile Crusher BR380JG-1E0 Shop Manual SEN01341-11 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu Mobile Crusher BR380JG-1E0 Shop Manual SEN01341-11 –  PDF DOWNLOAD

Language : English
Pages : 950
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Mobile Crusher BR380JG-1E0 Shop Manual SEN01341-11 –  PDF DOWNLOAD

• SERIAL NUMBERS 2001 and up

SEN01341-11 3
00 Index and foreword 3
Index 3
Composition of shop manual . 4
Table of contents 6
Foreword and general information . 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component . 25
Handling of connectors newly used for engines 34
How to read electric wire code . 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table . 46
Conversion table . 50
01 Specification . 57
Specification and technical data . 57
Specification dimension drawings . 58
Specifications . 59
Weight table . 61
Table of fuel, coolant and lubricants 62
10 Structure, function andmaintenance standard . 65
Engine and cooling system 65
Engine mount, damper . 66
Radiator, oil cooler and aftercooler . 67
Power train 69
Power train 70
Drive system for components 71
Final drive 72
Sprocket . 74
Undercarriage and frame 77
Track frame and recoil spring 78
Idler 80
Carrier roller . 82
Track roller . 83
Track shoe . 84
Hydraulic system, Part 1 . 89
Hydraulic piping drawing . 90
Hydraulic tank and hydraulic oil filter 91
Hydraulic pump . 92
Hydraulic system, Part 2 .113
Control valve 114
Self pressure reducing valve .122
CLSS .127
Functions and operation by valve .131
Hydraulic system, Part 3 .147
Crusher motor 148
Grizzly feeder motor .152
Conveyor motor .153
Travel motor .154
Valve control 162
Solenoid valve .172
EPC valve 174
Electromagnetic selector valve .178
Hydraulic cylinder .180
Work equipment .183
Grizzly feeder semiautomatic system 184
Abnormal load stop system 185
Primary belt conveyor 186
Grizzly feeder .190
Crusher 191
Crusher tooth tip adjustment system 196
Vibrator .199
Electrical system 203
Engine control .204
Work equipment and pump controller .214
Electronic control system 217
Machine monitor system .230
Sensor .256
KOMTRAX system .260
20 Standard value table 263
Standard service value table .263
Standard value table for engine 264
Standard value table for chassis .265
30 Testing and adjusting .271
Testing and adjusting, Part 1 271
Tools for testing, adjusting, and troubleshooting 273
Measuring engine speed .276
Measuring intake air pressure (boost pressure) .277
Checking exhaust gas color .278
Adjusting valve clearance 279
Measuring compression pressure .281
Measuring blow-by pressure .283
Measuring engine oil pressure 284
Handling fuel system parts .285
Releasing residual pressure from fuel system .285
Measuring fuel pressure 286
Measuring fuel delivery, return rate and leakage .288
Bleeding air from fuel circuit .291
Checking fuel circuit for leakage 293
Replacing fan belt .294
Checking and adjusting track shoe tension 295
Measuring and adjusting oil pressure in work equipment and travel circuits .297
Measuring control circuit basic pressure .302
Measuring and adjusting oil pressure in pump PC control circuit 303
Measuring and adjusting oil pressure in pump LS control circuit 306
Measuring solenoid valve output pressure .310
Measuring PPC valve output pressure 313
Measuring oil leakage 314
Bleeding air from each part 315
Testing travel deviation .318
Adjusting mirrors 319
Testing and adjusting, Part 2 323
Special functions of machine monitor .324
Testing and adjusting, Part 3 359
Check and adjustment of jaw crusher 360
Check and adjustment of outlet clearance .362
Adjusting tension of crusher drive V-belt 395
Check and adjustment of primary conveyor .396
Inspection and maintenance of magnetic separator .402
Check and adjustment of muck discharge conveyor 404
Handling voltage circuit of engine controller 406
Starting KOMTRAX terminal operations .407
Indicator lamps of KOMTRAX terminal 411
Preparation work for troubleshooting for electrical system .414
Procedure for testing diodes .418
40 Troubleshooting .421
Failure code table and fuse locations 421
Failure code table .422
Fuse locations .426
General information on troubleshooting .431
Points to remember when troubleshooting 432
Sequence of events in troubleshooting 433
Checks before troubleshooting 434
Classification and procedures of troubleshooting .436
Contents of troubleshooting table 440
Connection table for connector pin numbers .442
T- branch box and T- branch adapter table 478
Troubleshooting by failure code, Part 1 483
Failure code [7RC1KB] Short circuit conveyor ON switch .486
Failure code [7RC2KA] Disconnection in conveyor OFF switch .488
Failure code [7RC5KB] Short circuit in feeder ON switch 490
Failure code [7RD2KB] Short circuit in conveyor reverse relay 492
Failure code [7RD2KZ] Disconnection or short circuit in conveyorreverse relay 494
Failure code [7RE1KB] Short circuit in crusher ON switch .496
Failure code [7RE2KA] Disconnection in crusher OFF switch 498
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch .500
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch 502
Failure code [7RE8KB] Short circuit in magnetic separator ON switch 504
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch .506
Failure code [7REAKB] Short circuit in accessory input circuit .508
Failure code [7REDMA] Abnormality in primary conveyor pressure sensor 510
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor .512
Failure code [7RENKZ] Abnormality in clearance potentiometer .514
Failure code [7REPKA] Disconnection in feeder OFF switch .516
Failure code [7RESKB] Short circuit in one-touch start switch 518
Failure code [7RETKA] Disconnection in one-touch stop switch .520
Failure code [7RF2KA] Disconnection in crusher forward EPC valve .522
Failure code [7RF2KB] Short circuit in crusher forward EPC valve .523
Failure code [7RF2KY] Short circuit in crusher forward EPC valve .524
Failure code [7RF3KA] Disconnection in crusher reverse EPC valve .525
Failure code [7RF3KB] Short circuit in crusher reverse EPC valve .526
Failure code [7RF3KY] Short circuit in crusher reverse EPC valve .527
Failure code [7RF4KA] Disconnection in feeder forward EPC valve 528
Failure code [7RF4KB] Short circuit in feeder forward EPC valve 529
Failure code [7RF4KY] Short circuit in feeder forward EPC valve 530
Troubleshooting by failure code, Part 2 533
Failure code [7RFAKY] Short circuit in engine stop relay .536
Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay 538
Failure code [7RFBKB] Short circuit in muck conveyor solenoid 540
Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid .541
Failure code [7RFCKA] Disconnection in magnetic separator solenoid .542
Failure code [7RFCKB] Short circuit in magnetic separator solenoid .543
Failure code [7RFCKY] Short circuit in magnetic separator solenoid .544
Failure code [7RFHKB] Short circuit in conveyor forward relay 546
Failure code [7RFHKY] Short circuit in conveyor forward relay 548
Failure code [7RFKKB] Short circuit in lock cylinder pull relay 550
Failure code [7RFKKY] Short circuit in lock cylinder pull relay 552
Failure code [7RFLKA] Disconnection in accessory EPC solenoid 554
Failure code [7RFLKB] Short circuit in accessory EPC solenoid 555
Failure code [7RFLKY] Short circuit in accessory EPC solenoid 556
Failure code [7RFMKY] Short circuit in abnormal pressure relay .558
Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay 560
Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve .562
Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve .563
Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve .564
Failure code [7RFPKB] Short circuit in lock cylinder push relay 566
Failure code [7RFPKY] Short circuit in lock cylinder push relay 568
Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor 570
Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve 572
Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve 574
Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve 576
Failure code [7RJMMW] Lock cylinder slipping .577
Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor 578
Failure code [7RJPKB] Short circuit in radio control work-mode switch 580
Failure code [7RJQKB] Short circuit in radio control travel-mode switch 581
Failure code [7RJRKB] Short circuit on travel signal .582
Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor 584
Failure code [AA10NX] Air cleaner Clogging .586
Failure code [AB00KE] Charge voltage too low .588
Troubleshooting by failure code, Part 3 591
Failure code [B@BAZG] Engine oil pressure too low 594
Failure code [B@BAZK] Engine oil level reduction .596
Failure code [B@BCNS] Radiator coolant overheat 597
Failure code [B@BCZK] Radiator coolant level reduction .598
Failure code [B@HANS] Hydraulic oil overheat .600
Failure code [CA111] Abnormality in engine controller 600
Failure code [CA115] Abnormality in engine NE and Bkup speed sensors .601
Failure code [CA122] Charge pressure sensor too high .602
Failure code [CA123] Charge pressure sensor too low 604
Failure code [CA131] Throttle sensor too high 606
Failure code [CA132] Throttle sensor too low .608
Failure code [CA144] Coolant temperature sensor too high .610
Failure code [CA145] Coolant temperature sensor too low 612
Failure code [CA153] Charge temperature sensor too high 614
Failure code [CA154] Charge temperature sensor too low .616
Failure code [CA155] Charge temperature too high and engine speed derated 618
Failure code [CA187] Sensor power source 2 too low .620
Failure code [CA221] Ambient pressure sensor too high 622
Failure code [CA222] Ambient pressure sensor too low .624
Failure code [CA227] Sensor power source 2 too high 626
Failure code [CA234] Engine overspeed 627
Failure code [CA238] Abnormal power source for Ne speed sensor .628
Failure code [CA271] Short circuit in fuel pump actuator .629
Failure code [CA272] Disconnection in fuel pump actuator .630
Failure code [CA322] Disconnection or short circuit in injector No.1 .632
Failure code [CA323] Disconnection or short circuit in injector No.5 .634
Failure code [CA324] Disconnection or short circuit in injector No.3 .636
Failure code [CA325] Disconnection or short circuit in injector No.6 .638
Failure code [CA331] Disconnection or short circuit in injector No.2 .640
Failure code [CA332] Disconnection or short circuit in injector No.4 .642
Troubleshooting by failure code, Part 4 645
Failure code [CA342] Abnormality in engine controller data consistency .647
Failure code [CA351] Abnormality in injector drive circuit .648
Failure code [CA352] Sensor power source 1 too low .650
Failure code [CA386] Sensor power source 1 too high 652
Failure code [CA428] Water detection sensor too high .654
Failure code [CA429] Water detection sensor too low 656
Failure code [CA435] Abnormality in engine oil pressure switch .658
Failure code [CA441] Power source voltage too low 660
Failure code [CA442] Power source voltage too high .662
Failure code [CA449] Common rail pressure sensor too high (2) 664
Failure code [CA451] Common rail pressure sensor too high 666
Failure code [CA452] Common rail pressure sensor too low .668
Failure code [CA488] Charge temperature too high and torque derated 670
Failure code [CA553] Common rail pressure sensor too high (1) 671
Failure code [CA559] Supply pump no pressure .672
Failure code [CA689] Abnormality in engine Ne speed sensor .674
Failure code [CA731] Abnormal phase in engine Bkup speed sensor 676
Failure code [CA757] Loss of all engine controller data 678
Failure code [CA778] Abnormality in engine Bkup speed sensor .680
Failure code [CA1633] CAN communication error (engine controller) 682
Failure code [CA2185] Throttle pedal sensor power source too high 684
Failure code [CA2186] Throttle pedal sensor power source too low .685
Failure code [CA2249] Supply pump no pressure (2) 686
Failure code [CA2311] Abnormal resistance in pump regulator valve 688
Failure code [CA2555] Disconnection in air intake heater relay .690
Failure code [CA2556] Short circuit in air intake heater relay .692
Troubleshooting by failure code, Part 5 695
Failure code [D162KY] Short circuit in horn relay 698
Failure code [D162KZ] Disconnection or short circuit in horn relay .700
Failure code [DA22KK] Solenoid power source too low 702
Failure code [DA25KP] Abnormality in pressure sensor power source 704
Failure code [DA2RMC] CAN communication error (work equipment and pump controller) .708
Failure code [DA2SKQ] Abnormality in model code input 710
Failure code [DAFRMC] CAN communication error (monitor controller) .712
Failure code [DDA6KA] Disconnection in engine stop switch 714
Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor 716
Failure code [DHPAMA] Abnormality in F pump pressure sensor 718
Failure code [DHPBMA] Abnormality in R pump pressure sensor 720
Failure code [DUB0KY] Short circuit in beacon solid state relay 722
Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay .724
Failure code [DXA0KA] Disconnection in PC-EPC Solenoid .726
Failure code [DXA0KB] Short circuit in PC-EPC Solenoid .727
Failure code [DXA0KY] Short circuit in PC-EPC Solenoid .728
Failure code [DXE0KA] Disconnection in LS-EPC solenoid .729
Failure code [DXE0KB] Short circuit in LS-EPC solenoid .730
Failure code [DXE0KY] Short circuit in LS-EPC solenoid .731
Troubleshooting of electrical system (E-mode) 733
Information in troubleshooting table .735
E-1 Engine does not start (Engine does not turn) .736
E-2 The engine stops while it is running .740
E-3 The automatic warm-up function does not work .742
E-4 Preheater does not operate .744
E-5 The whole work equipment stops suddenly 746
E-6 The red mark of emergency stop is indicated just after the engine is started .748
E-7 The machine monitor does not display any item 752
E-8 Some items are not displayed on the machine monitor 754
E-9 Contents of display by machine monitor are different from applicable machine .754
E-10 Fuel level monitor was lighted in red while engine running 755
E-11 Engine coolant temperature gauge does not indicate normally .756
E-12 The fuel level gauge does not display normally 758
E-13 The hydraulic oil temperature gauge does not display normally .759
E-14 The travel, work, and inspection modes do not change 760
E-15 The crusher clearance adjustment mode does not change .762
E-16 The crusher rotation direction does not change 764
E-17 Machine does not travel .766
E-18 Travel cannot be controlled by radio control 768
E-19 The feeder cannot be turned ON and OFF by radio control .772
E-20 One-touch start, stop switch cannot be operated by radio control 776
E-21 The monitor switches do not work 779
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor 780
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor 781
E-24 The KOMTRAX system does not work properly .782
Troubleshooting of hydraulic and mechanical system (H-mode) 787
System chart for hydraulic and mechanical systems 790
Information contained in troubleshooting table .792
H-1 The speed or power of the whole work equipment and travel is low .794
H-2 The engine speed lowers extremely or the engine stalls .796
H-3 The work equipment and travel systems do not work 797
H-4 Abnormal sound comes out from around the hydraulic pump 797
H-5 Fine control performance or response is low 798
H-6 The conveyor does not operate 799
H-7 The speed or power of the conveyor is low 800
H-8 The crusher does not operate .801
H-9 The speed or power of crusher is low .802
H-10 The feeder does not operate .802
H-11 The feeder does not feed smoothly (Vibration frequency is low) 803
H-12 The magnetic separator does not operate .803
H-13 The speed of magnetic separator belt is low .804
H-14 The side conveyor does not operate 804
H-15 The speed or power of the side conveyor is low 805
H-16 The primary conveyor and the side conveyor do not move up and down 806
H-17 The machine deviates during travel 807
H-18 The travel speed is low .809
H-19 The machine is not steered well or steering power is low 811
H-20 The travel motor does not work (only one side) 812
H-21 When the travel switch of the radio controller is depressed, the machine does not travel 812
H-22 The crusher clearance cannot be adjusted 813
Troubleshooting of engine (S-mode) .815
Method of using troubleshooting chart 817
S-1 Starting performance is poor .820
S-2 Engine does not start 821
S-3 Engine does not pick up smoothly .824
S-4 Engine stops during operations .825
S-5 Engine does not rotate smoothly 826
S-6 Engine lack output (or lacks power) 827
S-7 Exhaust smoke is black (incomplete combustion) .828
S-8 Oil consumption is excessive (or exhaust smoke is blue) 829
S-9 Oil becomes contaminated quickly .830
S-10 Fuel consumption is excessive .831
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .832
S-12 Oil pressure drops 833
S-13 Oil level rises (Entry of coolant/fuel) .834
S-14 Coolant temperature becomes too high (overheating) 835
S-15 Abnormal noise is made 836
S-16 Vibration is excessive 837
50 Disassembly and assembly 839
General information on disassembly and assembly 839
How to read this manual 840
Coating materials list .842
Hydraulic system .847
Removal and installation of crusher lock cylinder assembly .848
Disassembly and assembly of crusher lock cylinder assembly .851
Bleeding air from crusher lock cylinder 855
Work equipment .859
Removal and installation of cheek plates .861
Removal and installation of fixed tooth 865
Removal and installation of swing tooth 869
Removal and installation of toggle plate .874
Replacement of toggle plate 879
Replacement of toggle seats 882
Removal and installation of fixed link .883
Removal and installation of swing jaw assembly .886
Removal and installation of crusher main bearing .890
Removal and installation of crusher motor V-sheave .895
Removal and installation of V-sheave and balance weight 899
Removal and installation of potentiometer 903
Removal and installation of crusher assembly .904
Removal and installation of primary belt conveyor assembly .907
Replacement of belt 910
Replacement of primary belt conveyor motor .912
Replacement of primary belt conveyor head pulley frame .914
Procedure for folding engine front cover .923
90 Diagrams and drawings .927
Hydraulic diagrams and drawings 927
Hydraulic circuit diagram (1/2) 929
Hydraulic circuit diagram (2/2) 931
Electrical diagrams and drawings .935
Electrical circuit diagram (1/4) .937
Electrical circuit diagram (2/4) .939
Electrical circuit diagram (3/4) .941
Electrical circuit diagram (4/4) .943
Connector arrangement diagram (1/2) 945
Connector arrangement diagram (2/2) 947

DESCRIPTION:

Komatsu Mobile Crusher BR380JG-1E0 Shop Manual SEN01341-11 –  PDF DOWNLOAD

• SERIAL NUMBERS 2001 and up

1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The 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 volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

G.B 25/12/24