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Galeo BR380JG-1E0
Komatsu Galeo BR380JG-1E0 User Manual
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SEN01
341-03
MOBILE CRUSHER
BR380JG
-1E0
SERIAL NUM
BERS
2001
and up
2
Table of Contents
Table of Contents
6
Safety Notice
16
Index and Foreword
16
How to Read the Shop Manual
21
Explanation of Terms for Maintenance Standard
23
Handling Electric Equipment and Hydraulic Component
25
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
Specification
56
Specification Dimension Drawings
57
Specifications
58
Weight Table
60
Table of Fuel, Coolant and Lubricants
61
Structure, Function and Maintenance Standard
64
Engine and Cooling System SEN01348-00
64
Engine Mount, Damper
65
Radiator, Oil Cooler and Aftercooler
66
Power Train
68
Structure, Function and Maintenance Standard
69
Power Train
69
Drive System for Components
70
Final Drive
71
Sprocket
73
Track Frame and Recoil Spring
77
Structure, Function and Maintenance Standard
77
Idler
79
Carrier Roller
81
Track Roller
82
Track Shoe
83
Hydraulic Sysmtem, Part 1
88
Hydraulic Piping Drawing
89
Hydraulic Tank and Hydraulic Oil Filter
90
Hydraulic Pump
91
Hydraulic System, Part 2
112
Control Valve
113
Structure, Function and Maintenance Standard
113
Self Pressure Reducing Valve
120
Clss
125
Functions and Operation by Valve
129
Hydraulic System, Part 3
144
Crusher Motor
145
Structure, Function and Maintenance Standard
145
Grizzly Feeder Motor
149
Conveyor Motor
150
Travel Motor
151
Valve Control
158
Solenoid Valve
168
EPC Valve
170
Electromagnetic Selector Valve
174
Hydraulic Cylinder
176
Grizzly Feeder Semiautomatic System
180
Structure, Function and Maintenance Standard
180
Abnormal Load Stop System
181
Primary Belt Conveyor
182
Grizzly Feeder
185
Crusher
186
Crusher Tooth Tip Adjustment System
190
Vibrator
193
Engine Control
197
Structure, Function and Maintenance Standard
197
Work Equipment and Pump Controller
206
Electronic Control System
209
Machine Monitor System
222
Sensor
246
Standard Value Table
251
Standard Value Table for Engine
252
Standard Value Table for Chassis
253
Testing and Adjusting Testing and Adjusting, Part
259
Tools for Testing, Adjusting, and Troubleshooting
261
Testing and Adjusting
261
Measuring Engine Speed
264
Measuring Intake Air Pressure (Boost Pressure)
265
Checking Exhaust Gas Color
266
Adjusting Valve Clearance
267
Measuring Compression Pressure
269
Measuring Blow-By Pressure
271
Measuring Engine Oil Pressure
272
Handling Fuel System Parts
273
Releasing Residual Pressure from Fuel System
273
Measuring Fuel Pressure
274
Measuring Fuel Return Rate and Leakage
276
Bleeding Air from Fuel Circuit
278
Checking Fuel Circuit for Leakage
280
Checking and Adjusting Track Shoe Tension
281
Measuring and Adjusting Oil Pressure in Work Equipment and Travel Circuits
283
Measuring Control Circuit Basic Pressure
287
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit
288
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit
291
Measuring Solenoid Valve Output Pressure
295
Measuring PPC Valve Output Pressure
298
Measuring Oil Leakage
299
Bleeding Air from each Part
300
Testing Travel Deviation
303
Adjusting Mirrors
304
Testing and Adjusting, Part 2
307
Special Functions of Machine Monitor
308
Testing and Adjusting, Part 3
342
Check and Adjustment of Jaw Crusher
343
Testing and Adjusting
343
Check and Adjustment of Outlet Clearance
345
Adjusting Tension of Crusher Drive V-Belt
378
Check and Adjustment of Primary Conveyor
379
Inspection and Maintenance of Magnetic Separator
385
Check and Adjustment of Muck Discharge Conveyor
387
List of Companies Which Handles Radio Controllers
389
Handling Voltage Circuit of Engine Controller
390
Procedure for Turning on KOMTRAX Terminal
391
KOMTRAX Terminal Lamp Indications
394
Preparation Work for Troubleshooting for Electrical System
397
Procedure for Testing Diodes
401
Troubleshooting
404
Failure Code Table
405
Fuse Locations
408
Points to Remember When Troubleshooting
413
Troubleshooting
413
Sequence of Events in Troubleshooting
414
Checks before Troubleshooting
415
Classification and Procedures of Troubleshooting
417
Contents of Troubleshooting Table
421
Wiring Table for Connector Pin Numbers
423
T-Adapter Box and T-Adapter Table
456
Troubleshooting by Failure Code, Part 1
460
Failure Code [7RC1KB] Short Circuit Conveyor on Switch
462
Failure Code [7RC2KA] Disconnection in Conveyor off Switch
464
Failure Code [7RC5KB] Short Circuit in Feeder on Switch
466
Failure Code [7RD2KB] Short Circuit in Conveyor Reverse Relay
468
Failure Code [7RD2KZ] Disconnection or Short Circuit in Conveyor Reverse Relay
470
Failure Code [7RE1KB] Short Circuit in Crusher on Switch
472
Failure Code [7RE2KA] Disconnection in Crusher off Switch
474
Failure Code [7RE6KB] Short Circuit in Muck Discharge Conveyor on Switch
476
Failure Code [7RE7KA] Disconnection in Muck Discharge Conveyor off Switch
478
Failure Code [7RE8KB] Short Circuit in Magnetic Separator on Switch
480
Failure Code [7RE9KA] Disconnection in Magnetic Separator off Switch
482
Failure Code [7REAKB] Short Circuit in Accessory Input Circuit
484
Failure Code [7REDMA] Abnormality in Primary Conveyor Pressure Sensor
486
Failure Code [7REEMA] Abnormality in Muck Conveyor Pressure Sensor
488
Failure Code [7RENKZ] Abnormality in Clearance Potentiometer
490
Failure Code [7REPKA] Disconnection in Feeder off Switch
492
Failure Code [7RESKB] Short Circuit in One-Touch Start Switch
494
Failure Code [7RETKA] Disconnection in One-Touch Stop Switch
496
Failure Code [7RF2KA] Disconnection in Crusher Forward EPC Valve
498
Failure Code [7RF2KB] Short Circuit in Crusher Forward EPC Valve
499
Failure Code [7RF2KY] Short Circuit in Crusher Forward EPC Valve
500
Failure Code [7RF3KA] Disconnection in Crusher Reverse EPC Valve
501
Failure Code [7RF3KB] Short Circuit in Crusher Reverse EPC Valve
502
Failure Code [7RF3KY] Short Circuit in Crusher Reverse EPC Valve
503
Failure Code [7RF4KA] Disconnection in Feeder Forward EPC Valve
504
Failure Code [7RF4KB] Short Circuit in Feeder Forward EPC Valve
505
Failure Code [7RF4KY] Short Circuit in Feeder Forward EPC Valve
506
Troubleshooting by Failure Code, Part 2
508
Failure Code [7RFAKY] Short Circuit in Engine Stop Relay
510
Failure Code [7RFAKZ] Disconnection or Short Circuit in Engine Stop Relay
512
Failure Code [7RFBKB] Short Circuit in Muck Conveyor Solenoid
514
Failure Code [7RFBKZ] Disconnection or Short Circuit in Muck Conveyor Solenoid
515
Failure Code [7RFCKA] Disconnection in Magnetic Separator Solenoid
516
Failure Code [7RFCKB] Short Circuit in Magnetic Separator Solenoid
517
Failure Code [7RFCKY] Short Circuit in Magnetic Separator Solenoid
518
Failure Code [7RFHKB] Short Circuit in Conveyor Forward Relay
519
Failure Code [7RFHKY] Short Circuit in Conveyor Forward Relay
521
Failure Code [7RFKKB] Short Circuit in Lock Cylinder Pull Relay
523
Failure Code [7RFKKY] Short Circuit in Lock Cylinder Pull Relay
525
Failure Code [7RFLKA] Disconnection in Accessory EPC Solenoid
527
Failure Code [7RFLKB] Short Circuit in Accessory EPC Solenoid
528
Failure Code [7RFLKY] Short Circuit in Accessory EPC Solenoid
529
Failure Code [7RFMKY] Short Circuit in Abnormal Pressure Relay
530
Failure Code [7RFMKZ] Disconnection or Short Circuit in Abnormal Pressure Relay
532
Failure Code [7RFNKA] Disconnection in Lock Cylinder Unlock Solenoid Valve
534
Failure Code [7RFNKB] Short Circuit in Lock Cylinder Unlock Solenoid Valve
535
Failure Code [7RFNKY] Short Circuit in Lock Cylinder Unlock Solenoid Valve
536
Failure Code [7RFPKB] Short Circuit in Lock Cylinder Push Relay
537
Failure Code [7RFPKY] Short Circuit in Lock Cylinder Push Relay
539
Failure Code [7RGAMA] Abnormality in 2Nd Conveyor Pressure Sensor
541
Failure Code [7RJAKA] Disconnection in Travel Lock EPC Solenoid Valve
543
Failure Code [7RJAKB] Short Circuit in Travel Lock EPC Solenoid Valve
545
Failure Code [7RJAKY] Short Circuit in Travel Lock EPC Solenoid Valve
547
Failure Code [7RJMMW] Lock Cylinder Slipping
548
Failure Code [7RJNMA] Abnormality in Vibratory Screen Pressure Sensor
549
Failure Code [7RJPKB] Short Circuit in Radio Control Work-Mode Switch
551
Failure Code [7RJQKB] Short Circuit in Radio Control Travel-Mode Switch
552
Failure Code [7RJRKB] Short Circuit on Travel Signal
553
Failure Code [7RJSMA] Abnormality in Magnetic Separator Pressure Sensor
555
Failure Code [AA10NX] Air Cleaner Clogging
557
Failure Code [AB00KE] Charge Voltage too Low
559
Troubleshooting by Failure Code, Part 3
562
Failure Code [B@BAZG] Engine Oil Pressure too Low
564
Failure Code [B@BAZK] Engine Oil Level Reduction
566
Failure Code [B@BCNS] Radiator Coolant Overheat
567
Failure Code [B@BCZK] Radiator Coolant Level Reduction
568
Failure Code [B@HANS] Hydraulic Oil Overheat
570
Failure Code [CA111] Abnormality in Engine Controller
570
Failure Code [CA115] Abnormality in Engine NE and Bkup Speed Sensors
571
Failure Code [CA122] Charge Pressure Sensor too High
572
Failure Code [CA123] Charge Pressure Sensor too Low
574
Failure Code [CA131] Throttle Sensor too High
576
Failure Code [CA132] Throttle Sensor too Low
578
Failure Code [CA144] Coolant Temperature Sensor too High
580
Failure Code [CA145] Coolant Temperature Sensor too Low
582
Failure Code [CA153] Charge Temperature Sensor too High
584
Failure Code [CA154] Charge Temperature Sensor too Low
586
Failure Code [CA155] Charge Temperature too High and Engine Speed Derated
588
Failure Code [CA187] Sensor Power Source 2 too Low
589
Failure Code [CA221] Ambient Pressure Sensor too High
591
Failure Code [CA222] Ambient Pressure Sensor too Low
593
Failure Code [CA227] Sensor Power Source 2 too High
595
Failure Code [CA234] Engine Overspeed
596
Failure Code [CA238] Abnormal Power Source for Ne Speed Sensor
597
Failure Code [CA271] Short Circuit in Fuel Pump Actuator
598
Failure Code [CA272] Disconnection in Fuel Pump Actuator
599
Failure Code [CA322] Disconnection or Short Circuit in Injector No.1
600
Failure Code [CA323] Disconnection or Short Circuit in Injector No.5
602
Failure Code [CA324] Disconnection or Short Circuit in Injector No.3
604
Failure Code [CA325] Disconnection or Short Circuit in Injector No.6
606
Failure Code [CA331] Disconnection or Short Circuit in Injector No.2
608
Failure Code [CA332] Disconnection or Short Circuit in Injector No.4
610
Troubleshooting by Failure Code, Part 4
613
Failure Code [CA342] Abnormality in Engine Controller Data Consistency
615
Failure Code [CA351] Abnormality in Injector Drive Circuit
616
Failure Code [CA352] Sensor Power Source 1 too Low
618
Failure Code [CA386] Sensor Power Source 1 too High
620
Failure Code [CA428] Water Detection Sensor too High
621
Failure Code [CA429] Water Detection Sensor too Low
623
Failure Code [CA435] Abnormality in Engine Oil Pressure Switch
625
Failure Code [CA441] Power Source Voltage too Low
626
Failure Code [CA442] Power Source Voltage too High
628
Failure Code [CA449] Common Rail Pressure Sensor too High (2)
630
Failure Code [CA451] Common Rail Pressure Sensor too High
631
Failure Code [CA452] Common Rail Pressure Sensor too Low
633
Failure Code [CA488] Charge Temperature too High and Torque Derated
635
Failure Code [CA553] Common Rail Pressure Sensor too High (1)
635
Failure Code [CA559] Supply Pump no Pressure
636
Failure Code [CA689] Abnormality in Engine Ne Speed Sensor
637
Failure Code [CA731] Abnormal Phase in Engine Bkup Speed Sensor
639
Failure Code [CA757] Loss of All Engine Controller Data
640
Failure Code [CA778] Abnormality in Engine Bkup Speed Sensor
642
Failure Code [CA1633] CAN Communication Error (Engine Controller)
644
Failure Code [CA2185] Throttle Pedal Sensor Power Source too High
646
Failure Code [CA2186] Throttle Pedal Sensor Power Source too Low
647
Failure Code [CA2249] Supply Pump no Pressure (2)
648
Failure Code [CA2311] Abnormal Resistance in Pump Regulator Valve
649
Failure Code [CA2555] Disconnection in Air Intake Heater Relay
651
Failure Code [CA2556] Short Circuit in Air Intake Heater Relay
653
Troubleshooting by Failure Code, Part 5
656
Failure Code [D162KY] Short Circuit in Horn Relay
658
Failure Code [D162KZ] Disconnection or Short Circuit in Horn Relay
660
Failure Code [DA22KK] Solenoid Power Source too Low
662
Failure Code [DA25KP] Abnormality in Pressure Sensor Power Source
664
Failure Code [DA2RMC] CAN Communication Error (Work Equipment and Pump Controller)
667
Failure Code [DA2SKQ] Abnormality in Model Code Input
669
Failure Code [DDA6KA] Disconnection in Engine Stop Switch
673
Failure Code [DGH2KB] Short Circuit in Hydraulic Oil Temperature Sensor
675
Failure Code [DHPAMA] Abnormality in F Pump Pressure Sensor
676
Failure Code [DHPBMA] Abnormality in R Pump Pressure Sensor
678
Failure Code [DUB0KY] Short Circuit in Beacon Solid State Relay
680
Failure Code [DUB0KZ] Disconnection or Short Circuit in Beacon Solid State Relay
682
Failure Code [DXA0KA] Disconnection in PC-EPC Solenoid
684
Failure Code [DXA0KB] Short Circuit in PC-EPC Solenoid
685
Failure Code [DXA0KY] Short Circuit in PC-EPC Solenoid
686
Failure Code [DXE0KA] Disconnection in LS-EPC Solenoid
687
Failure Code [DXE0KB] Short Circuit in LS-EPC Solenoid
688
Failure Code [DXE0KY] Short Circuit in LS-EPC Solenoid
689
Information in Troubleshooting Table
693
Engine Does Not Start (Engine Does Not Turn)
694
The Engine Stops While It Is Running
697
The Automatic Warm-Up Function Does Not Work
699
Preheater Does Not Operate
700
The Whole Work Equipment Stops Suddenly
702
The Red Mark of Emergency Stop Is Indicated Just after the Engine Is Started
704
The Machine Monitor Does Not Display any Item
707
Some Items Are Not Displayed on the Machine Monitor
709
Contents of Display by Machine Monitor Are Different from Applicable Machine
709
Fuel Level Monitor was Lighted in Red While Engine Running
710
Engine Coolant Temperature Gauge Does Not Indicate Normally
711
The Fuel Level Gauge Does Not Display Normally
713
The Hydraulic Oil Temperature Gauge Does Not Display Normally
714
The Travel, Work, and Inspection Modes Do Not Change
715
The Crusher Clearance Adjustment Mode Does Not Change
717
The Crusher Rotation Direction Does Not Change
719
Machine Does Not Travel
720
Travel Cannot be Controlled by Radio Control
722
The Feeder Cannot be Turned on and off by Radio Control
726
One-Touch Start, Stop Switch Cannot be Operated by Radio Control
729
The Monitor Switches Do Not Work
732
The Crusher Cannot be Operated with the Crusher Manual FORWARD/REVERSE Switch on the Monitor
733
The Crusher Cannot be Operated with the Crusher Manual
733
FORWARD/REVERSE Switch on the Monitor
733
The Conveyor Cannot be Operated with the Conveyor Manual FORWARD/REVERSE Switch on the Monitor
734
The Conveyor Cannot be Operated with the Conveyor Manual
734
FORWARD/REVERSE Switch on the Monitor
734
KOMTRAX System Does Not Operate Normally
735
System Chart for Hydraulic and Mechanical Systems
740
Information Contained in Troubleshooting Table
742
The Speed or Power of the Whole Work Equipment and Travel Is Low
743
The Engine Speed Lowers Extremely or the Engine Stalls
745
The Work Equipment and Travel Systems Do Not Work
746
Abnormal Sound Comes out from Around the Hydraulic Pump
746
Fine Control Performance or Response Is Low
747
The Conveyor Does Not Operate
748
The Speed or Power of the Conveyor Is Low
749
The Crusher Does Not Operate
750
The Speed or Power of Crusher Is Low
751
The Feeder Does Not Operate
751
The Feeder Does Not Feed Smoothly (Vibration Frequency Is Low)
752
The Magnetic Separator Does Not Operate
752
The Speed of Magnetic Separator Belt Is Low
753
The Side Conveyor Does Not Operate
753
The Speed or Power of the Side Conveyor Is Low
754
The Primary Conveyor and the Side Conveyor Do Not Move up and down
755
The Machine Deviates During Travel
756
The Travel Speed Is Low
758
The Machine Is Not Steered Well or Steering Power Is Low
760
The Travel Motor Does Not Work (Only One Side)
761
When the Travel Switch of the Radio Controller Is Depressed, the Machine Does Not Travel
761
The Crusher Clearance Cannot be Adjusted
762
Method of Using Troubleshooting Chart
766
Troubleshooting
766
Starting Performance Is Poor
769
Engine Does Not Start
770
Engine Does Not Pick up Smoothly
773
Engine Stops During Operations
774
Engine Does Not Rotate Smoothly
775
Engine Lack Output (or Lacks Power)
776
Exhaust Smoke Is Black (Incomplete Combustion)
777
Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)
778
Oil Becomes Contaminated Quickly
779
Fuel Consumption Is Excessive
780
Oil Is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)
781
Oil Pressure Drops
782
Oil Level Rises (Entry of Coolant/Fuel)
783
Coolant Temperature Becomes too High (Overheating)
784
Abnormal Noise Is Made
785
Vibration Is Excessive
786
Br380Jg-1E0
788
Disassembly and Assembly
789
How to Read this Manual
789
Coating Materials List
791
Disassembly and Assembly of Crusher
797
Replacing Cheek Plates
798
Turning over and Replacing Fixed Jaw Plate
799
Turning over and Replacing Swing Jaw Plate
800
Replacing Toggle Plate
802
Replacing Toggle Seats
805
Disassembly and Assembly of Lock Cylinder
806
Removal and Installation of Primary Conveyor Assembly
810
Replacement of Belt
813
Replacement Procedure for Primary Belt Conveyor Motor
815
Replacement Procedure for Primary Belt Conveyor Head Pulley Frame
817
Procedure for Folding Engine
826
Diagrams and Drawings
830
Hydraulic Circuit Diagram
831
Hydraulic Circuit Diagram (2/2)
831
Electrical Circuit Diagram
835
Electrical Circuit Diagram
836
Electrical Circuit Diagram
837
Electrical Circuit Diagram
838
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Komatsu Galeo BR380JG-1E0 Specifications
General
Brand
Komatsu
Model
Galeo BR380JG-1E0
Category
Construction Equipment
Language
English
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