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Komatsu Mobile Crusher Br380jg-1eo Shop Manual
Table of contents 1
00 Index and foreword
Index SEN01343-03
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01344-00
Safety notice............................................................................................................................... 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation.................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN01346-00
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ............................................................................................................................... 5
Table of fuel, coolant and lubricants ............................................................................................ 6
10 Structure, function and maintenance standard
Engine and cooling system SEN01348-00
Engine mount, damper ................................................................................................................ 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train SEN01349-00
Power train ................................................................................................................................. 2
Drive system for components...................................................................................................... 3
Final drive................................................................................................................................... 4
Sprocket ..................................................................................................................................... 6
Undercarriage and frame SEN01350-00
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................ 4
Carrier roller ............................................................................................................................... 6
Track roller.................................................................................................................................. 7
Track shoe.................................................................................................................................. 8
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic piping drawing ............................................................................................................. 2
Hydraulic tank and hydraulic oil filter........................................................................................... 3
Hydraulic pump ........................................................................................................................... 4
Hydraulic system, Part 2 SEN01352-00
Control valve ............................................................................................................................... 2
Self pressure reducing valve....................................................................................................... 10
CLSS.......................................................................................................................................... 15
Functions and operation by valve................................................................................................ 19
00 Index and foreword SEN01343-03
BR380JG-1E0 5
Hydraulic system, Part 3 SEN01353-00
Crusher motor ............................................................................................................................. 2
Grizzly feeder motor.................................................................................................................... 6
Conveyor motor.......................................................................................................................... 7
Travel motor ............................................................................................................................... 8
Valve control............................................................................................................................... 16
Solenoid valve............................................................................................................................ 26
EPC valve .................................................................................................................................. 28
Electromagnetic selector valve ................................................................................................... 32
Hydraulic cylinder....................................................................................................................... 34
Work equipment SEN01354-00
Grizzly feeder semiautomatic system ......................................................................................... 2
Abnormal load stop system......................................................................................................... 3
Primary belt conveyor ................................................................................................................. 4
Grizzly feeder .............................................................................................................................. 8
Crusher ...................................................................................................................................... 9
Crusher tooth tip adjustment system........................................................................................... 14
Vibrator....................................................................................................................................... 17
Electrical system SEN01355-00
Engine control ............................................................................................................................. 2
Work equipment and pump controller ......................................................................................... 12
Electronic control system............................................................................................................ 15
Machine monitor system ............................................................................................................. 28
Sensor........................................................................................................................................ 54
20 Standard value table
Standard service value table SEN02288-00
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN02303-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed............................................................................................................. 6
Measuring intake air pressure (boost pressure).......................................................................... 7
Checking exhaust gas color ........................................................................................................ 8
Adjusting valve clearance ........................................................................................................... 9
Measuring compression pressure ............................................................................................... 11
Measuring blow-by pressure ....................................................................................................... 13
Measuring engine oil pressure .................................................................................................... 14
Handling fuel system parts.......................................................................................................... 15
Releasing residual pressure from fuel system ............................................................................ 15
Measuring fuel pressure.............................................................................................................. 16
Measuring fuel return rate and leakage ...................................................................................... 18
Bleeding air from fuel circuit........................................................................................................ 20
Checking fuel circuit for leakage ................................................................................................. 22
Checking and adjusting track shoe tension................................................................................. 23
Measuring and adjusting oil pressure in work equipment and travel circuits .............................. 25
Measuring control circuit basic pressure..................................................................................... 29
Measuring and adjusting oil pressure in pump PC control circuit ............................................... 30
Measuring and adjusting oil pressure in pump LS control circuit ................................................ 33
Measuring solenoid valve output pressure.................................................................................. 37
Measuring PPC valve output pressure........................................................................................ 40
Measuring oil leakage ................................................................................................................. 41
Bleeding air from each part ......................................................................................................... 42
Testing travel deviation................................................................................................................ 45
Adjusting mirrors ......................................................................................................................... 46
SEN01343-03 00 Index and foreword
6 BR380JG-1E0
Testing and adjusting, Part 2 SEN02304-00
Special functions of machine monitor.......................................................................................... 2
Testing and adjusting, Part 3 SEN02305-01
Check and adjustment of jaw crusher ......................................................................................... 2
Check and adjustment of outlet clearance .................................................................................. 4
Adjusting tension of crusher drive V-belt ..................................................................................... 37
Check and adjustment of primary conveyor ................................................................................ 38
Inspection and maintenance of magnetic separator.................................................................... 44
Check and adjustment of muck discharge conveyor................................................................... 46
List of companies which handles radio controllers ...................................................................... 48
Handling voltage circuit of engine controller................................................................................ 49
Procedure for turning on KOMTRAX terminal ............................................................................. 50
KOMTRAX terminal lamp indications .......................................................................................... 53
Preparation work for troubleshooting for electrical system.......................................................... 56
Procedure for testing diodes ....................................................................................................... 60
40 Troubleshooting
Failure code table and fuse locations SEN02088-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02089-01
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures of troubleshooting........................................................................ 6
Contents of troubleshooting table................................................................................................ 10
Wiring table for connector pin numbers....................................................................................... 12
T-adapter box and T-adapter table .............................................................................................. 45
Table of contents 1
00 Index and foreword
Index SEN01343-03
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01344-00
Safety notice............................................................................................................................... 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation.................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN01346-00
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ............................................................................................................................... 5
Table of fuel, coolant and lubricants ............................................................................................ 6
10 Structure, function and maintenance standard
Engine and cooling system SEN01348-00
Engine mount, damper ................................................................................................................ 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train SEN01349-00
Power train ................................................................................................................................. 2
Drive system for components...................................................................................................... 3
Final drive................................................................................................................................... 4
Sprocket ..................................................................................................................................... 6
Undercarriage and frame SEN01350-00
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................ 4
Carrier roller ............................................................................................................................... 6
Track roller.................................................................................................................................. 7
Track shoe.................................................................................................................................. 8
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic piping drawing ............................................................................................................. 2
Hydraulic tank and hydraulic oil filter........................................................................................... 3
Hydraulic pump ........................................................................................................................... 4
Hydraulic system, Part 2 SEN01352-00
Control valve ............................................................................................................................... 2
Self pressure reducing valve....................................................................................................... 10
CLSS.......................................................................................................................................... 15
Functions and operation by valve................................................................................................ 19
00 Index and foreword SEN01343-03
BR380JG-1E0 5
Hydraulic system, Part 3 SEN01353-00
Crusher motor ............................................................................................................................. 2
Grizzly feeder motor.................................................................................................................... 6
Conveyor motor.......................................................................................................................... 7
Travel motor ............................................................................................................................... 8
Valve control............................................................................................................................... 16
Solenoid valve............................................................................................................................ 26
EPC valve .................................................................................................................................. 28
Electromagnetic selector valve ................................................................................................... 32
Hydraulic cylinder....................................................................................................................... 34
Work equipment SEN01354-00
Grizzly feeder semiautomatic system ......................................................................................... 2
Abnormal load stop system......................................................................................................... 3
Primary belt conveyor ................................................................................................................. 4
Grizzly feeder .............................................................................................................................. 8
Crusher ...................................................................................................................................... 9
Crusher tooth tip adjustment system........................................................................................... 14
Vibrator....................................................................................................................................... 17
Electrical system SEN01355-00
Engine control ............................................................................................................................. 2
Work equipment and pump controller ......................................................................................... 12
Electronic control system............................................................................................................ 15
Machine monitor system ............................................................................................................. 28
Sensor........................................................................................................................................ 54
20 Standard value table
Standard service value table SEN02288-00
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN02303-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed............................................................................................................. 6
Measuring intake air pressure (boost pressure).......................................................................... 7
Checking exhaust gas color ........................................................................................................ 8
Adjusting valve clearance ........................................................................................................... 9
Measuring compression pressure ............................................................................................... 11
Measuring blow-by pressure ....................................................................................................... 13
Measuring engine oil pressure .................................................................................................... 14
Handling fuel system parts.......................................................................................................... 15
Releasing residual pressure from fuel system ............................................................................ 15
Measuring fuel pressure.............................................................................................................. 16
Measuring fuel return rate and leakage ...................................................................................... 18
Bleeding air from fuel circuit........................................................................................................ 20
Checking fuel circuit for leakage ................................................................................................. 22
Checking and adjusting track shoe tension................................................................................. 23
Measuring and adjusting oil pressure in work equipment and travel circuits .............................. 25
Measuring control circuit basic pressure..................................................................................... 29
Measuring and adjusting oil pressure in pump PC control circuit ............................................... 30
Measuring and adjusting oil pressure in pump LS control circuit ................................................ 33
Measuring solenoid valve output pressure.................................................................................. 37
Measuring PPC valve output pressure........................................................................................ 40
Measuring oil leakage ................................................................................................................. 41
Bleeding air from each part ......................................................................................................... 42
Testing travel deviation................................................................................................................ 45
Adjusting mirrors ......................................................................................................................... 46
SEN01343-03 00 Index and foreword
6 BR380JG-1E0
Testing and adjusting, Part 2 SEN02304-00
Special functions of machine monitor.......................................................................................... 2
Testing and adjusting, Part 3 SEN02305-01
Check and adjustment of jaw crusher ......................................................................................... 2
Check and adjustment of outlet clearance .................................................................................. 4
Adjusting tension of crusher drive V-belt ..................................................................................... 37
Check and adjustment of primary conveyor ................................................................................ 38
Inspection and maintenance of magnetic separator.................................................................... 44
Check and adjustment of muck discharge conveyor................................................................... 46
List of companies which handles radio controllers ...................................................................... 48
Handling voltage circuit of engine controller................................................................................ 49
Procedure for turning on KOMTRAX terminal ............................................................................. 50
KOMTRAX terminal lamp indications .......................................................................................... 53
Preparation work for troubleshooting for electrical system.......................................................... 56
Procedure for testing diodes ....................................................................................................... 60
40 Troubleshooting
Failure code table and fuse locations SEN02088-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02089-01
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures of troubleshooting........................................................................ 6
Contents of troubleshooting table................................................................................................ 10
Wiring table for connector pin numbers....................................................................................... 12
T-adapter box and T-adapter table .............................................................................................. 45
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