WA320-3 Shop Custom

SEBM034104
MACHINE MODEL SERIAL NUMBER
BR380JG-1 1001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• BR380JG-1 mounts the SAA6D102E-2 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
© 2007
All Rights Reserved
Printed in Japan 02-07(01)
00-1
(4)
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
00-2 BR380JG-1
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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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00-2-4 BR380JG-1
(4)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
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 judge-
ments. 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 fur-
ther 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 under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance 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 com-
ponent, 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.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
01 GENERAL
SPECIFICATION DRAWINGS ........................................................................................................................01- 2

SPECIFICATIONS ..........................................................................................................................................01- 3
WEIGHT TABLE..............................................................................................................................................01- 5
FUEL, COOLANT AND LUBRICANTS ...........................................................................................................01- 6
BR380JG-1 01-1
GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
Unit: mm
A Overall length 12,500

B Overall height 3,200
C Overall width (when transporting) 2,950 (2,815)
D Width of track 500
E Tread 2,280
F Length of track on ground 3,275
01-2 BR380JG-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model BR380JG-1
Serial Number 1001 and up
Operating weight kg 33,000

Maximum feed-in material dimensions
mm 1,000 x 900 x 475
(Concrete)
Performance
Maximum feed-in material dimensions

mm 425 x 425 x 425
(Stone)
km/h Lo: 2.4, Hi: 3.0
Travel speed
(Fixed to Lo during radio-controlled travel)
deg. 25
Gradeability
kPa {kg/cm2} 97.9 {1.00}
Ground pressure
Overall length mm 12,500
Overall width (During work) 2,950
mm
(During transportation) 2,815
Dimensions
Overall width of track mm 2,780

Overall height (Including grouser) mm 3,200
Minimum ground (During work) 100 / 200
mm
clearance (During travel) 300
Length of track on ground mm 3,275
Track gauge mm 2,280
Name – SAA6D102E-2
Type – 4-stroke, water-cooled, vertical, direct injection
type with turbocharger and aftercooler
Number of cylinders – Bore x Stroke mm 6 – 102 x 120
Total displacement l {cc} 5.883 {5,883}
Rated output kW/rpm {HP/rpm} 133.9 / 2,050 {182 / 2,050}
Engine
Max. torque Nm/rpm {kgm/rpm} 718 / 1,500 {73.3 / 1,500}

Performance Max. speed at no load rpm 2,250
Min. speed at no load rpm 1,000
Min. fuel consumption g/kWh {g/HP} 225 {165}
Starting motor – 24 V, 45 kW
Alternator – 24V, 35 A
Battery – 12 V, 110 Ah x 2
Type of radiator – CF19-5
Number of Carrier roller (Each side) piece 2
rollers Track roller (Each side) piece 5
Undercarriage
Type of track shoe – Assembly-type triple grouser,

45 pieces on each side
Track
Shoe width mm 500
Tension adjuster – Grease cylinder type (With cushion spring)
Type of travel brake – Hydraulic lock
Model name and type – KCJ4222 single toggle jaw crusher
Crusher
Nominal dimensions mm 1,065 x 550

Speed rpm 170 – 330
Drive method – Hydraulic motor V-belt drive
BR380JG-1 01-3
(3)
GENERAL SPECIFICATIONS
Serial Number 1001 and up
Type – Grizzly feeder with 2-level deck

and speed controller
Feeder
Type of vibrator – Horizontal double shaft type

Dimensions of trough mm 1,000 x 3,220
Vibration frequency c.p.m Variable, 1,000 (Rating)
Drive method – Direct coupling with hydraulic motor
Type – Fixed hopper
Hopper
Overall capacity m3 3.7

Capacity
Capacity above trough m3 1.9
Hydraulic pump
Type and number of units – HPV 95 + 95,

variable displacement piston type x 2
Delivery l/min 212 x 2
Set pressure MPa {kg/cm2} 37.2 {380}
Type and number of units – 8-spool valve (10-spool valve, if equipped)

Control valve
Operating method – Hydraulic
Travel motor – HMV110ADT-2, piston type x 2
(With brake valve and shaft brake)
Crusher motor – KFM125B-5,
piston type (With safety valve) x 1
Hydraulic
Hydraulic equipment (For travel and work)
Feeder motor – MSF-53, gear type x 1

motor
Conveyor motor – MSE02-2-123-A02-1240, piston type x 1
Magnetic separator motor – S-280AD2S-K2875 x 1
Side conveyor motor – 2-200AS2S-E3343
(If equipped)
Conveyor ele- Crusher outlet Side conveyor
Section – vator adjuster elevator
(Standard) (Standard) (If equipped)
Type – Double acting Double acting, Double acting,
type bear lock type bear lock type
Hydraulic Cylinder bore mm 35 130 50
cylinder Piston rod diameter mm 20 90 25
Stroke mm 220 480 270
Max. distance between pins mm 620 1,798 740
(To rod end)
Min. distance between pins mm 400 1,318 470
(To rod end)
Hydraulic tank – Enclosed box type
Hydraulic oil filter – Return side of tank
Hydraulic oil cooler – Air-cooled
01-4 BR380JG-1
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a reference for handling and transportation of components.
Unit: kg
Serial Number 1001 – 1200 1201 and up
Engine assembly 749 749

• Engine 598 598
• Damper 6 6
• Hydraulic pump 145 145
Radiator and oil cooler assembly 119 119
Hydraulic tank and filter assembly (Excluding hydraulic oil) 123 123
Fuel tank assembly (Excluding fuel) 121 121
Main frame 412 412
Rear cover 115 115
Control valve 297 297
Travel motor 98 x 2 98 x 2
Crusher motor 53 53
Primary conveyor motor assembly 21 21
Grizzly feeder motor 17 17
Track frame assembly 5,712 5,712
• Track frame 3,918 3,918
• Idler 99 x 2 99 x 2
• Idler cushion 135 x 2 135 x 2
• Carrier roller 16 x 4 16 x 4
• Track roller 36 x 10 36 x 10
• Final drive (Including travel motor) 451 x 2 451 x 2
Track shoe assembly
• Standard triple shoe (500 mm) 2,310 2,310
Hopper 1,272 1,272
Grizzly feeder assembly 1,952 1,952
Crusher assembly 13,095 12,700
Primary conveyor assembly 2,310 2,310
BR380JG-1 01-5
(3)
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

Ambient Temperature
Recommended
Reservoir Fluid Type -22 -4 14 32 50 68 86 104 122 Komatsu Fluids
-30 -20 -10 0 10 20 30 40 50
Komatsu
SAE10W30DH
EO10W30DH
Komatsu
Engine oil pan Engine oil SAE15W40DH
EO15W40DH
Komatsu
SAE30DH
EO30DH
Jaw crusher motor

bearing case
Final drive case
Power train oil TO30 TO30
Grizzly feeder
vibrator case
Damper case
Power train oil TO10 TO10
Hydraulic oil HO46-HM HO46-HM
Hydraulic system
Komatsu
SAE10W30DH
EO10W30DH
Engine oil
Komatsu
SAE15W40DH
EO15W40DH
Hyperwhite grease G2-T G2-T
Grease fitting
Lithium EP grease G2-LI G2-LI
Supercoolant
Cooling system AF-NAC AF-NAC
AF-NAC
No.2-D ASTM No.2-D

Fuel tank Diesel Fuel
No.1-D ASTM No.1-D
01-6 BR380JG-1
(3)
Jaw crusher
Final drive Grizzly feader
Engine oil pan Damper case motor bearing
case (each) vibrator case
case
Liters 26.3 0.75 4.7 3.5 15

Specified capacity
US gal 6.95 0.20 1.24 0.92 3.96
Liters 24 – 4.7 3.5 15
Refill capacity
US gal 6.34 – 1.24 0.92 3.96
Hydraulic system
Fuel tank Cooling system
1001-1200 1201 and up
Liters 240 209 400 43.9

Specified capacity
US gal 63.41 55.22 105.68 11.6
Liters 143 112 – –
Refill capacity
US gal 37.78 29.59 – –
BR380JG-1 01-7
(3)
Remark
• When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in the Operation & Maintenance manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
• When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
(50°F) more or less during the day.
• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to
half.
• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
• We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.
• The power train oil and the engine oil are different from each other.
• When working in a river, sea, seaside, forest, etc. where the environment must be preserved carefully, it is
recommended to use bio-hydraulic oil and bio-grease.
• Hyper white grease (G0-T, G2-T) is high-performance white grease. It is recommended to use it for the fol-
lowing purposes.
(1) To improve the lubricating ability of the grease to prevent squeaking of pins and bushings.
(2) To avoid using black grease which can stain the outside of the machine.
• Do not use molybdenum disulfide grease for the main bearing of the jaw crusher.
• Supercoolant
(1) Supercoolant has functions of preventing freezing and corrosion. Accordingly, it is required even in an
area where the coolant is not frozen.
(2) The ratio of Supercoolant to water must be 30% or higher. Referring to the following table, decide the
quantity of Supercoolant from the minimum atmospheric temperature. Apply the value for a tempera-
ture 10°C below the actual minimum atmospheric temperature, however.
Minimum atmospheric temperature (°C)
-10 -15 -20 -25 -30
Supercoolant 13.2 15.8 18.0 20.2 21.9

Quantity (l)
Water 30.7 28.1 25.9 23.7 21.9
Volumetric ratio (%) 30 36 41 46 50
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Change interval of oil
Fuel sulphur content
in engine oil pan
0.5 – 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
01-8 BR380JG-1
(3)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
ENGINE RELATED PARTS........................................................................................................................ 10- 2
RADIATOR, OIL COOLER, AFTERCOOLER ............................................................................................. 10- 3
POWER TRAIN........................................................................................................................................... 10- 4
DRIVE SYSTEM FOR COMPONENTS ...................................................................................................... 10- 5
FINAL DRIVE .............................................................................................................................................. 10- 6
TRACK FRAME AND RECOIL SPRING..................................................................................................... 10- 8
IDLER ......................................................................................................................................................... 10- 10
CARRIER ROLLER .................................................................................................................................... 10- 12
TRACK ROLLER......................................................................................................................................... 10- 13
TRACK SHOE............................................................................................................................................. 10- 14
ARRANGEMENT OF HYDRAULIC EQUIPMENT ...................................................................................... 10- 18
HYDRAULIC TANK AND HYDRAULIC OIL FILTER .................................................................................. 10- 19
HYDRAULIC PUMP .................................................................................................................................... 10- 20
CONTROL VALVE ...................................................................................................................................... 10- 40
SELF-REDUCING PRESSURE VALVE ..................................................................................................... 10- 48
CLSS........................................................................................................................................................... 10- 53
CRUSHER MOTOR .................................................................................................................................... 10- 70
GRIZZLY FEEDER MOTOR ....................................................................................................................... 10- 74
CONVEYOR MOTOR ................................................................................................................................. 10- 75
TRAVEL MOTOR........................................................................................................................................ 10- 76
TRAVEL JUNCTION VALVE ...................................................................................................................... 10- 83
VALVE CONTROL ...................................................................................................................................... 10- 85
TRAVEL PPC VALVE ................................................................................................................................. 10- 86
SOLENOID VALVE ..................................................................................................................................... 10- 95
EPC VALVE ................................................................................................................................................ 10- 97
ELECTROMAGNETIC SELECTOR VALVE ............................................................................................... 10-101
GRIZZLY FEEDER SEMIAUTOMATIC SYSTEM....................................................................................... 10-103
ABNORMAL LOAD STOP SYSTEM .......................................................................................................... 10-104
PRIMARY BELT CONVEYOR .................................................................................................................... 10-105
GRIZZLY FEEDER ..................................................................................................................................... 10-106
CRUSHER .................................................................................................................................................. 10-109
CRUSHER TOOTH TIP ADJUSTMENT SYSTEM ..................................................................................... 10- 116
VIBRATOR.................................................................................................................................................. 10- 119
ENGINE CONTROL.................................................................................................................................... 10-120
ELECTRONIC CONTROL SYSTEM DEVICES.......................................................................................... 10-127
MULTI MONITOR SYSTEM........................................................................................................................ 10-141
SENSOR..................................................................................................................................................... 10-168
BR380JG-1 10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS
ENGINE RELATED PARTS
1. Drive plate 5. Damper assembly Outline

2. Torsion spring 6. Muffler • The damper assembly is a wet type.
3. Stopper pin 7. Rear engine mount Oil capacity: 0.75 l
4. Friction plate 8. Front engine mount
10-2 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR, OIL COOLER, AFTERCOOLER
RADIATOR, OIL COOLER, AFTERCOOLER
1. Reservoir tank 6. Radiator outlet hose Specifications

2. Oil cooler 7. Radiator cap Radiator: CF19-5
3. Radiator 8. Net Oil cooler: CF40-1
4. Fan 9. Shroud
5. Radiator inlet hose 10. Aftercooler
BR380JG-1 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Idler 9. Primary belt conveyor motor (KSE02-2-123-A02-1240)

2. Jaw crusher motor (KFM125B-5) 10. Control valve
3. Final drive 11. Option connection port (debris discharge conveyor)
4. Travel motor (HMV110ADT-2) 12. Primary belt conveyor lift cylinder
5. Option connection port (magnetic separator) 13. Grizzly feeder motor (MSF-53)
6. Hydraulic pump 14. Grizzly feeder
7. Engine 15. Jaw crusher
8. Primary belt conveyor
10-4 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SYSTEM FOR COMPONENTS
DRIVE SYSTEM FOR COMPONENTS
BR380JG-1 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Level plug 8. Sprocket

2. Drain plug 9. Floating seal
3. No. 2 sun gear (Number of teeth: 21) 10. Travel motor
4. No. 1 sun gear (Number of teeth: 10) 11. Hub
5. No. 1 planetary carrier 12. No. 2 planetary gear (Number of teeth: 36)
6. Cover 13. Ring gear (Number of teeth: 95)
7. No. 2 planetary carrier 14. No. 1 planetary gear (Number of teeth: 42)
10-6 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
Specifications
Reduction ratio: – ((10 + 95)/10) x ((21 + 95) / 21) + 1 = – 57.000
Unit: mm
No. Check item Criteria Remedy
Backlash between No. 2 sun Standard clearance Clearance limit

15
gear and No. 2 planetary gear 0.15 – 0.49 1.00
Backlash between No. 2
16 0.17 – 0.57 1.10
planetary gear and ring gear
17 0.06 – 0.25 —
planetary carrier and motor
Backlash between No. 1 sun
18 gear and No. 1 planetary 0.14 – 0.46 1.00
gear Replace
Backlash between No. 1 plan-
19 0.17 – 0.57 1.10
etary gear and ring gear
20 planetary carrier and No. 2 0.38 – 0.66 1.00
sun gear
21 End play of sprocket shaft 0 – 0.10 —
Wear of tooth profile of
22 Repair limit: 6
sprocket
Standard size Repair limit Repair hard
23 Tooth width sprocket chrome plat-
71 68 ing or replace
BR380JG-1 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
1. Idler 5. Track roller Specifications

2. Track frame 6. Track shoe Number of track rollers: 5 (Each side)
3. Carrier roller 7. Recoil spring Standard shoe
4. Final drive 8. Front guard Shoe width: 500 mm
Link pitch: 190 mm
Number of shoes (Each side): 45
10-8 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
Unit: mm
Vertical width of idler guide Standard size Tolerance Repair limit

9 Track frame 107
Repair by
Idler support 105 build-up
Lateral width of idler guide welding or
replace
10 Track frame 250
Idler support 247.4
Standard size Repair limit
Free length
Installed Installed Free Installed
x Outside
11 Recoil spring length load length load Replace
diameter
603.5 x 126.5 kN 101 kN
466 576
239 {12,900 kg} {10,300 kg}
BR380JG-1 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-10 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm
Outside diameter of protrud- Standard size Repair limit

1
ing 538 —
2 Outside diameter of tread 500 488 Rebuild or
3 Thickness of tread 26 20 replace
4 Total width 159 —

5 Width of tread 37.5 43.5
Standard Tolerance Standard Clearance

Clearance between shaft size Shaft Hole clearance limit
6
and bushing
–0.250 +0.074
65 0.214 – 0.424 1.5
–0.350 –0.036 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler size Shaft Hole Interference limit
7
and bushing
+0.089 –0.006
72 0.065 – 0.161 —
+0.059 –0.072
BR380JG-1 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
145 —
2 Outside diameter of tread 120 106
3 Width of tread 43 —
4 Thickness of tread 36.5 29.5
5 Width of flange 14 —

6 Replace
and bushing
–0.179 +0.284
40 0.339 – 0.474 —
–0.190 –0.169
Standard Tolerance Standard Interference

Interference between roller size Shaft Hole interference limit
7
and bushing
–0.061 –0.040
47 0.036 – 0.101 —
–0.036 –0.040
Standard clearance Clearance limit
8 Axial clearance of roller
0.44 – 0.76 —
10-12 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
188 —
2 Outside diameter of tread 156 144
3 Thickness of tread 44.5 38.5 Rebuild or
4 Overall width 225 — replace
5 Inside width 85 —
6 Width of tread 44.5 —
7 Width of flange 25.5 —

8
and bushing
–0.215 +0.195
60 0.215 – 0.510 1.5
–0.315 +0.195 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
–0.153 +0.030
67 0.023 – 0.153 —
–0.053 +0.030
BR380JG-1 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
a P portion shows the link of bushing press fitting end.
10-14 BR380JG-1
Unit: mm

1 Link pitch
190.25 193.25
Reverse or
When turned
Standard size replace
2 Bushing outside diameter Normal load Impact load
59 — 54
3 Link height
104 96 Repair or
replace
Thickness of link metal
4 27.5 19.5
(bushing press-fitting portion)
5 160.4
6 Shoe bolt pitch 62
7 18
8 Inside width 82.8
9 Link Overall width 42.7
10 Tread width 36.9
Protrusion of Regular 2.5 Adjust or

11
pin Master 2.5 replace
Protrusion of Regular 3.75

12
bushing Master 0.0
Overall length Regular 212

13
of pin Master 212
Overall length Regular 137.5

14
of bushing Master 129.2
Standard 10.2
Thickness of Reverse or
15 When turned
bushing metal 5.2 replace
/ Impact Load
16 Thickness of spacer —
17 Bushing 88.2 – 245 kN {9 – 25 ton}
Press-fitting —
18 Regular pin 127.4 – 274.4 kN {13 – 28 ton}
force
*19 Master pin 78.4 – 147 kN {8 – 15 ton}
* : Dry type track link
BR380JG-1 10-15
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
490 ± 49
Triple shoe 120 ± 10
Shoe bolt {50 ± 5} Retighten
20
Tightening torque Additional tightening Lower limit torque
b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
— — —
No. of shoes (each side) 45 —
Standard Tolerance Standard

Interference between size Shaft Hole interference
21
bushing and link
+0.250 –0.160
59 0.160 – 0.390
+0.000 –0.230
Interference between +0.100 –0.230
22 38 0.230 – 0.380
regular pin and link +0.000 –0.280

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.100 +0.200 Adjust or
38 0.200 – 0.400
+0.000 –0.300 replace

Interference between master size Shaft Hole interference
*24
pin and bushing
–0.100 +0.030
37.8 0.02 – 0.17
–0.200 –0.080

Clearance between master pin size Shaft Hole clearance
*25
and bushing
–0.300 +1.200
38 1.00 – 1.60
–0.400 +0.700
Lug weld-
Height of
— Triple-grouser ing, rebuild
grouser 26 16 or replace
* : Dry type track link
10-16 BR380JG-1
Triple grouser shoe
Unit: mm

1 Height
26 16
2 Thickness 8.5
3 26
Length of base
4 19 Rebuild or
5 20 replace
6 Length at tip 14
7 19
8 Thickness
34.5 24.5
BR380JG-1 10-17
ARRANGEMENT OF HYDRAULIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EQUIPMENT
ARRANGEMENT OF HYDRAULIC EQUIPMENT
1. Left travel motor 5. Control valve

2. Crusher motor 6. Hydraulic pump
3. Lock cylinder 7. Right travel motor
4. Hydraulic tank 8. Feeder motor
10-18 BR380JG-1
HYDRAULIC TANK AND HYDRAULIC OIL
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FILTER
HYDRAULIC TANK AND HYDRAULIC OIL FILTER
1. Hydraulic tank Specifications

2. Oil filler cap Tank capacity: 200 l
3. Filter element Amount of oil inside tank: 143 l
4. Strainer Pressure valve
5. Bypass valve Relief cracking pressure: 16.7 ± 6.9 kPa
6. Suction strainer {0.17 ± 0.07 kg/cm2}
7. Sight gauge Suction cracking pressure: 0 – 0.49 kPa
{0 – 0.005 kg/cm2}
Bypass valve set pressure: 150 ± 30 kPa
{1.5 ± 0.3 kg/cm2}
BR380JG-1 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
HPV95 + 95
1. Front main pump IM: PC mode selector current PENR: Rear pump control pressure detec-
2. Rear main pump ISIG: LS set selector current tion port
3. LS valve PAF: Front pump delivery port PLSF: Front load pressure input port
4. PC valve PFC: Front pump delivery pressure PLSFC: Front load pressure detection port
5. LS-EPC valve detection port PLSR: Rear load pressure input port
6. PC-EPC valve PAR: Rear pump delivery port PLSRC:Rear load pressure detection port
PRC: Rear pump delivery pressure PS: Pump suction port
detection port PSIG: LS set selector pressure detection
PBF: Pump pressure input port port
PD1F: Case drain port PM: PC set selector pressure detection
PENF:Front pump control pressure port
detection port PEPC: EPC basic pressure input port
Outline
• This pump consists of 2 variable capacity swash
plate piston pumps, PC valve, LS valve, and
EPC valve.
10-20 BR380JG-1
1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston
BR380JG-1 10-21
Function Structure
• The rotation and torque transmitted to the pump • Cylinder block (7) is supported to shaft (1) by a
shaft are converted into hydraulic energy, and spline, and shaft (1) is supported by the front and
pressurized oil is discharged according to the rear bearings.
load. • The tip of piston (6) is a concave ball, and shoe
• It is possible to change the discharge amount by (5) is caulked to it to form one unit. Piston (6) and
changing the swash plate angle. shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface A, and shoe (5)
is always pressed against this surface while slid-
ing in a circular movement.
Rocker cam (4) brings high pressure oil at cylin-
der surface B with cradle (2), which is secured
to the case, and forms a static pressure bearing
when it slides.
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• The cylinder block seals the pressure oil to valve
plate (8) and carries out relative rotation. This
surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil in-
side each cylinder chamber of cylinder block (7)
is sucked in and discharged through valve plate
(8).
10-22 BR380JG-1
Operation
1. Operation of pump
1) Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)
2) Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F – E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged dur-
ing that stroke. On the other hand, the vol-
ume of chamber F becomes larger, and as
the volume becomes bigger, the oil is
sucked in.
3) If center line X of rocker cam (4) is in line
with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference
between volumes E and F inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
BR380JG-1 10-23
2. Control of discharge amount

• If the swash plate angle becomes larger,
the difference between volumes E and F be-
comes larger and discharge amount Q in-
creases.
• Swash plate angle is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement ( ) according to the signal pres-
sure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and rock-
er cam (4), which is supported by the cylin-
drical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the small
diameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).
10-24 BR380JG-1
LS valve
1. Plug 5. Seat PP: Pump port

2. Locknut 6. Spool PDP: Drain port
3. Sleeve 7. Piston PLP: LS control pressure output port
4. Spring 8. Sleeve PLS: LS pressure input port
PPL: PC control pressure input port
PSIG: LS mode selection pilot port
PC valve
1. Servo piston assembly 5. Retainer PP1: Pump port

2. Plug 6. Seat PP2: Pump pressure pilot port
3. Pin 7. Cover PT: Drain port
4. Spool 8. Wiring PM: PC mode selector pressure pilot port
PPL: PC control pressure output port
PLP: LS control pressure output port
BR380JG-1 10-25
Function
1. LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge
amount Q according to differential pressure
EPLS (= PP – PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port pres-
sure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output, and pressure Psig {called the LS selec-
tor pressure} from the proportional solenoid
valve enter this valve. The relationship between
discharge amount Q and differential pressure
E PLS, (the difference between main pump
pressure PP and LS pressure PLS) (= PP –
PLS) changes as shown in the diagram at the
right according to LS pressure selector current
isig of the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to
this, and the selector point for the pump dis-
charge amount changes at the rated central
value between 0.69 2.2 MPa {7 22 kg/
cm2}.
2. PC valve
When the pump discharge pressure PP1 (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In
this way, it carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump. The relationship between the average
of the front and rear pump discharge pressures
(average discharge amount of F, R pumps (PP1
+ PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to the
PC-EPC valve solenoid shown as a parameter.
The controller senses the actual speed of the
engine, and if the speed drops because of an
increase in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In
other words, when the load increases and the
engine speed drops below the set value, the
command current to the PC-EPC valve solenoid
from the controller increases according to the
drop in the engine speed to reduce the pump
swash plate angle.
10-26 BR380JG-1
Operation
1. LS valve At this point, spool (6) is pushed to the left,and

1) When control valve is at neutral position port C and port D are connected. Pump pres-
• The LS valve is a three-way selector valve, sure PP enters the large diameter end of the
with pressure PLS (LS pressure) from the piston from port K and the same pump pressure
outlet port of the control valve brought to PP also enters port J at the small diameter end
spring chamber B, and main pump dis- of the piston, so the swash plate is moved to the
charge pressure PP brought to port H of minimum angle by the difference in the area of
sleeve (8). The size of this LS pressure PLS the piston (12).
+ force Z of spring (4) and the main pump
pressure (self pressure) PP determines the
position of spool (6). However, the size of the
output pressure PSIG (the LS selection pres-
sure) of the EPC valve for the LS valve en-
tering port G also changes the position of
spool (6). (The set pressure of the spring
changes).
• Before the engine is started, servo piston
(12) is pushed to the right. (See the diagram
on the right)
• When the engine is started and the control
lever is at the neutral position, LS pressure
PLS is 0 MPa {0 kg/cm2}. (It is interconnect-
ed with the drain circuit through the control
valve spool.)
BR380JG-1 10-27
(1)
2) Operation in increase direction for pump • For this reason, the pressure at the large di-
discharge amount ameter end of servo piston (12) becomes
• When the difference between the main pump drain pressure PT, and pump pressure PP
pressure PP and LS pressure PLS, in other enters port J at the small diameter end, so
words, LS differential pressure EPLS, be- servo piston (12) is pushed to the right.
comes smaller (for example, when the area Therefore, the swash plate moves in the di-
of opening of the control valve becomes larg- rection to make the discharge amount larger.
er and pump PP drops), spool (6) is pushed • If the output pressure of the EPC valve for
to the right by the combined force of LS pres- the LS valve enters port G, this pressure cre-
sure PLS and the force of spring (4). ates a force to move piston (7) to the left. If
• When spool (6) moves, port D and port E are piston (7) is pushed to the left, it acts to make
joined and connected to the PC valve. When the set pressure of spring (4) weaker, and
this happens, the PC valve is connected to the difference between PLS and PP chang-
the drain port, so circuit D – K becomes drain es when ports D and E of spool (6) are con-
pressure PT. (The operation of the PC valve nected.
is explained later).
10-28 BR380JG-1
3) Operation in decrease direction for pump • Main pump pressure PP also enters port J at
discharge amount the small diameter end of the piston, but be-
• The following explains the situation if the ser- cause of the difference in area between the
vo piston (12) moves to the left (the dis- large diameter end and the small diameter
charge amount becomes smaller). When LS end of servo piston (12), servo piston (12) is
differential pressure EPLS becomes larger pushed to the left.
(for example, when the area of opening of • As a result, the swash plate moves in the di-
the control valve becomes smaller and pump rection to make angle smaller.
pressure PP rises), pump pressure PP push- • If LS selection pressure PSIG enters port G,
es spool (6) to the left. it acts to make the set pressure of spring (4)
• When spool (6) moves, main port pressure weaker.
PP flows from port C and port D and from
port K, it enters the large diameter end of the
piston.
BR380JG-1 10-29
4) When servo piston is balanced • At this point, the relationship between the
• Let us take the area receiving the pressure at area receiving the pressure at both ends of
the large diameter end of the piston as A1, piston (12) is A0 : A1 = 3 : 5, so the pressure
the area receiving the pressure at the small applied to both ends of the piston when it is
diameter end as A0, and the pressure flow- balanced becomes PP : PEN = 5 : 3.
ing into the large diameter end of the piston • The position where spool (6) is balanced and
as PEN. If the main pump pressure PP of the stopped is the standard center, and the force
LS valve and the combined force of force Z of spring (4) is adjusted so that it is deter-
of spring (4) and LS pressure PLS are bal- mined when PP – PLS = 2.2 MPa {22 kg/
anced, and the relationship is A0 x PP = A1 cm2}. However, if PSIG (the output pressure
x PEN, servo piston (11) will stop in that po- of 0 2.9 MPa {0 30 kg/cm2} of the EPC
sition, and the swash plate will be kept at an valve of the LS valve) is applied to port G, the
intermediate position. (It will stop at a posi- balance stop position will change in propor-
tion where the opening of the throttle from tion to pressure PSIG between PP – PLS =
port D to port E and from port C to port D of 2.2 0.69 MPa {22 7 kg/cm2}.
spool (6) is approximately the same.)
10-30 BR380JG-1
(1)
2. PC Valve • the pressure (pressure of port C) output

1) When pump controller is normal from the PC valve changes according to
a. When the load on the actuator is small this position.
and pump pressures PP1 and PP2 are • The size of command current X is deter-
low mined by the nature of the operation (le-
i) Movement of PC-EPC solenoid (1) ver operation), the selection of the
• The command current from the pump working mode, and the set value and ac-
controller flows to PC-EPC solenoid (1). tual value for the engine speed.
This command current acts on the PC-
EPC valve and outputs the signal pres-
sure. When this signal pressure is re-
ceived, the force pushing piston (2) is
changed.
• On the opposite side to the force push-
ing this piston (2) is the spring set pres-
sure of springs (4) and (6) and pump
pressure PP1 (self pressure) and PP2
(other pump pressure) pushing spool
(3). Piston (2) stops at a position where
the combined force pushing spool (3) is
balanced, and
BR380JG-1 10-31
ii) Action of spring • If the command circuit input to PC-EPC

• The spring load of springs (4) and (6) in valve solenoid (1) changes further, the
the PC valve is determined by the swash force pushing piston (2) changes, and
plate position. the spring load of springs (4) and (6) also
• If piston (9) moves to the left, spring (6) changes according to the value of the
is compressed, and if it moves further to PC-EPC valve solenoid command cur-
the left, spring (6) contacts seat (5) and rent.
is fixed in position. In other words, the
spring load is changed by piston (9) ex-
tending or compressing springs (4) and
(6).
10-32 BR380JG-1
• Port C of the PC valve is connected to

port E of the LS valve (see 1. LS valve).
Self pressure PP1 enters port B and the
small diameter end of servo piston (9),
and other pump pressure PP2 enters
port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the right. At this
point, ports C and D are connected, and
the pressure entering the LS valve be-
comes drain pressure PT. If port E and
port G of the LS valve are connected
(see 1. LS valve), the pressure entering
the large diameter end of the piston from
port J becomes drain pressure PT, and
servo piston (9) moves to the right. In
this way, the pump discharge amount
moves in the direction of increase.
• As servo piston (9) moves further,
springs (4) and (6) expand and the
spring force becomes weaker. When the
spring force becomes weaker, spool (3)
moves to the left, so the connection be-
tween port C and port D is cut, and the
pump discharge pressure ports B and C
are connected. As a result, the pressure
at port C rises, and the pressure at the
large diameter end of the piston also ris-
es, so the movement of piston (9) to the
right is stopped.
• In other words, the stop position for pis-
ton (9) (= pump discharge amount) is de-
cided at the point where the force of
springs (4) and (6) and the pushing force
from the PC-EPC valve solenoid and the
pushing force created by the pressures
PP1 and PP2 acting on the spool (3) are
in balance.
BR380JG-1 10-33
b. When load on actuator is large and pump • If main pump pressure PP increases further
discharge pressure is high and spool (3) moves further to the left, main
• When the load is large and pump discharge pump pressure PP1 flows to port C and acts
pressures PP1 and PP2 are high, the force to make the discharge amount the minimum.
pushing spool (3) to the left becomes larger When piston (9) moves to the left, springs (4)
and spool (3) moves to the position in the di- and (6) are compressed and push back
agram above. When this happens, as shown spool (3). When spool (3) moves to the left,
in the diagram above, part of the pressurized the opening of port C and port D becomes
oil from port A flows out through port C larger. As a result, the pressure at port C (=
where the LS valve is actuated to port D, and J) drops, and piston (9) stops moving to the
the pressurized oil flowing from port C to the left.
LS valve becomes approximately half of • The position in which piston (9) stops when
main pump pressure PP. this happens is further to the left than the po-
• When port E and port G of the LS valve are sition when pump pressures PP1 and PP2
connected (see 1. LS valve), the pressure are low.
from port J enters the large diameter end of
servo piston (9), and servo piston (9) stops.
10-34 BR380JG-1
• The relation of average pump pressure (PP1

+ PP2)/2 and the position of servo piston (9)
forms a bent line because of the double-
spring effect of springs (4) and (6). The rela-
tionship between average pump pressure
(PP1 + PP2)/2 and pump discharge amount
Q is shown in the figure at the right.
• If command voltage X sent to PC-EPC valve

solenoid (1) increases further, the relation-
ship between average pump pressure (PP1
+ PP2)/2, and pump discharge amount Q is
proportional to the pushing force of the PC-
EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC
solenoid (1) is added to the force pushing to
the left because of the pump pressure ap-
plied to the spool (3), so the relationship be-
tween the average pump pressure (PP1 +
PP2)/2 and Q moves from A to B in accord-
ance with the increase in X.
BR380JG-1 10-35
LS(PC)-EPC valve
1. Body 5. Coil PSIG (PM): To LS(PC) valve

2. Spool 6. Plunger PT: To tank
3. Spring 7. Connector PEPC: From self-reducing pressure valve
4. Rod
10-36 BR380JG-1
Function
• The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
• When it receives signal current i from the pump
controller, it generates the EPC output pressure
in proportion to the size of the signal, and outputs
it to the LS valve.
Operation
1. When signal current is 0 (coil deenergized)
• When there is no signal current flowing from
the controller to coil (5), coil (5) is deener-
gized.
• For this reason, spool (2) is pushed to the left
in the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pres-
surized oil from the main pump does not flow
to the LS valve.
• At the same time, the pressurized oil from
the LS valve passes from port PSIG(PM)
through port PT and is drained to the tank.
BR380JG-1 10-37
2. When signal current is very small (coil ener-

gized)
• When a very small signal current flows to coil
(5), coil (5) is energized, and a propulsion
force is generated which pushes plunger (6)
to the right.
• Rod (4) pushes spool (2) to the right, and
pressurized oil flows from port PEPC to port
PSIG(PM).
• When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting
on surface of spool (2) becomes greater than
the propulsion force of plunger (6), spool (2)
is pushed to the left. The circuit between port
PEPC and port PSIG(PM) is shut off, and at
the same time, port PSIG(PM) and port PT
are connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is bal-
anced with the load of spring (3) + pressure
of port PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
3. When signal current is maximum (coil ener-

gized)
• When the signal current flows to coil (5), coil
(5) is energized.
• When this happens, the signal current is at
its maximum, so the propulsion force of
plunger (6) is also at its maximum.
• For this reason, spool (2) is pushed fully to
the left by rod (4).
• As a result, the maximum flow of pressurized
oil from port PEPC flows to port PSIG(PM),
and the circuit pressure between the EPC
valve and LS valve becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.
10-38 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
8-spool valve
10-40 BR380JG-1
1. Cover 1 P1. From 4-spool EPC valve

2. Cover 2 P2. To hydraulic tank
3. 6-spool valve P3. From travel PPC valve
(Lock cylinder reset valve, right travel valve, crusher motor P4. From travel PPC valve
valve, feeder motor valve, left travel valve, accessory valve) P5. From 4-spool EPC valve
4. Service valve (Side conveyor motor valve) P6. To hydraulic tank
5. Service valve (Magnetic separator motor valve) P7. From 4-spool EPC valve
P8. From 4-spool EPC valve
A1. To conveyor motor and cylinder solenoid selector valve P9. From travel PPC valve
A2. To left travel motor port PA P10. From travel PPC valve
A3. To grizzly feeder motor P11. From 5-spool ON/OFF valve
A4. To crusher motor port MA P12. To hydraulic tank
A5. To right travel motor port PB P-1. From 5-spool ON/OFF valve
A6. To bear lock cylinder P-2. To hydraulic tank
A-1. To side conveyor motor P-3. From 5-spool ON/OFF valve
A-2. To magnetic separator motor P-4. To hydraulic tank
B1. To conveyor motor and cylinder solenoid selector valve PLS1. To rear pump control
B2. To left travel motor port PB PLS2. To front pump control
B3. To grizzly feeder motor PP1. From self-reducing pressure valve
B4. To crusher motor port MB PP2. From rear pump
B5. To right travel motor port PA PS. From self-reducing pressure valve
B6. Plug PST. From 5-spool ON/OFF valve
B-1. To side conveyor motor PR. From self-reducing pressure valve
B-2. To magnetic separator motor T. To oil cooler
TS. To hydraulic tank
TSW. To crusher motor
BP1. From 5-spool ON/OFF valve
Outline
• This control valve consists of a 6-spool valve and 2 service
valves and is equipped with a merge-divider valve.
• The component valves are assembled into 1 unit with bolts
and the paths are connected internally.
BR380JG-1 10-41
1. Unload valve 6. Left travel spool

2. Main relief valve 7. Grizzly feeder spool
3. Magnetic separator spool 8. Crusher spool
4. Side conveyor spool 9. Right travel spool
5. Accessory spool 10. Lock cylinder reset spool
10-42 BR380JG-1
1. Lock cylinder reset spool 5. Suction valve

2. Right travel spool 6. Pressure compensation valve
3. Crusher spool 7. Pressure compensation valve
4. Safety-suction valve 8. Plug
Unit: mm

Free length x Installed Installed Free Installed
9 Spool return spring Outside diameter length load length load
120.6 N 96.5 N
54.5 x 34.8 53.5 —
{12.3 kg} {9.8 kg}
If spring is
139.3 N 111.4 N
10 Spool return spring 54.6 x 34.8 53.5 — damaged or
{14.2 kg} {11.4 kg}
deformed,
94.1 N 75.3 N replace it.
11 Spool return spring 54.2 x 34.8 53.5 —
{9.6 kg} {7.7 kg}
17.5 N 13.9 N
{1.78 kg} {1.42 kg}
29.4N 23.5 N
{3.0 kg} {2.4 kg}
BR380JG-1 10-43
1. Feeder spool 8. Unload valve

2. Left travel spool 9. Main relief valve
3. Accessory spool 10. Pressure compensation valve
4. Safety-suction valve 11. Pressure compensation valve
5. Safety-suction valve 12. Merge-divider valve (Travel junction valve)
6. Suction valve 13. Return spring
7. Safety-suction valve 14. LS shuttle valve
10-44 BR380JG-1
Unit: mm

15 Spool return spring Outside diameter length load length load
94.1 N 75.3 N
54.2 x 34.8 53.5 —
{9.6 kg} {7.7 kg}
If spring is
139.3 N 111.4 N
16 Spool return spring 54.6 x 34.8 53.5 — damaged or
{14.2 kg} {11.4 kg}
deformed,
120.6 N 96.5 N replace it.
{12.3 kg} {9.8 kg}
17.5 N 13.9 N
{1.78 kg} {1.42 kg}
29.4 N 23.5 N
{3.0 kg} {2.4 kg}
BR380JG-1 10-45
1. Side conveyor and magnetic separator spool 5. Main relief valve

2. Safety-suction valve 6. Merge-divider valve (For LS)
3. Pressure compensation valve 7. Merge-divider valve (Main)
4. Unload valve 8. LS bypass valve
Unit: mm

9 Spool return spring Outside diameter length load length load If spring is
damaged or
120.6 N 96.5 N deformed,
54.2 x 34.8 53.5 —
{12.3 kg} {9.8 kg} replace it.
17.5 N 13.9 N
{1.78 kg} {1.42 kg}
10-46 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF-REDUCING PRESSURE VALVE
SELF-REDUCING PRESSURE VALVE
a. Port P1 (from front pump)

b. Port PR (supply to electromagnetic valve, PPC valve, EPC valve)
c. Port T (to hydraulic tank)
d. Port PC (to front pump LS valve)
10-48 BR380JG-1
1. Sequence valve
2. Poppet
3. Pressure reducing valve
4. Ball
Unit: mm

Spring (reducing pres-
5 Outside diameter length load length load
sure valve, main)
16.9 N 17.7 N Replace
19.2 x 7.2 16.1 — spring if any
{2 kg} {1.8 kg}
damages or
Spring (reducing pres- 20.6 N 18.6 N deforma-
6 16.5x 7.2 12.7 —
sure valve, pilot) {2.1 kg} {1.9 kg} tions are
199.8 N 186.2 N found.
7 Spring 71 x 18 59 —
{20.4 kg} {19 kg}
61.7 N 58.8 N
8 Spring (safety valve) 16.1 x 7.8 13.4 —
{6.3 kg} {6 kg}
BR380JG-1 10-49
Function
• This valve reduces the discharge pressure of the
main pump and supplies it as the control pres-
sure for the solenoid valve and PPC valve.
Operation
1. When engine is stopped
• Poppet (5) is pushed against the seat by
spring (6), and the passage from port PR o
T is closed.
• Valve (8) is pushed to the left by spring (7),
and the passage from port P1 o PR is open.
• Valve (2) is pushed to the left by spring (3),
so the passage between port P1 o P2 is
closed. (See Fig. 1)
10-50 BR380JG-1
2. At hold and when load pressure P2 is low

(when moving down under own weight).
NOTE: When load pressure P2 is lower than
output pressure PR of the self-reducing pres-
sure valve.
• Valve (2) receives force in the direction to
close the passage from port P1 o P2 from
spring (3) and pressure PR (when the engine
is stopped, the pressure is 0 MPa {0 kg/cm2).
However, when hydraulic oil flows in from
port P1, the pressure is balanced so that
pressure P1 = force of spring (7) + (area Ød
x pressure PR), and the opening from port
P1 o P2 is adjusted so that pressure P1 is
kept at a certain value above pressure PR.
• When pressure PR goes above the set pres-
sure, poppet (5) opens, and the hydraulic oil
flows in the following circuit: port PR o hole
a inside spool (8) o opening of poppet (5) o
tank port T.
• As a result, a pressure difference is created
on both sides of hole a inside spool (8), so
spool (8) moves in the direction to close the
opening from port P1 o PR. Pressure P1 is
reduced to a certain pressure (set pressure)
by the amount of opening at this point, and is
supplied as pressure PR. (See Fig. 2)
3. When load pressure P2 is high.

• If load pressure P2 increases and the pump
discharge amount also increases because of
digging operations, pressure P1 also in-
creases (pressure P1 > force of spring (7) +
(area Ød x pressure PR), so valve (2) moves
to the right to the end of the stroke.
• As a result, the amount of opening from port
P1 o P2 increases and the resistance in the
passage is reduced, so the loss of engine
horsepower is reduced.
• If pressure PR goes above the set pressure,
poppet (5) opens and the hydraulic oil flows
in the following circuit: port PR o hole a in-
side spool (8) o opening of poppet (5) o
tank port T.
• As a result, a pressure difference EP is cre-
ated on both sides of hole a inside spool (8),
so spool (8) moves in the direction to close
the opening from port P1 o PR. Pressure P1
is reduced to a certain pressure (set pres-
sure) by the amount of opening at this point,
and is supplied as pressure PR. (See
Fig. 3)
BR380JG-1 10-51
4. When there is abnormally high pressure.

• When pressure PR of the self reducing pres-
sure valve becomes abnormally high, ball
(10) pushes against the force of spring (9),
separates from the seat, and allows hydrau-
lic oil to flow from output port PR o T, so
pressure PR goes down. This action protects
the equipment at the destination for the hy-
draulic pressure supply (PPC valve, electro-
magnetic valve, etc.) from abnormally high
pressure. (See Fig. 4)
10-52 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
Outline of CLSS
Features Structure
• CLSS stands for Closed center Load Sensing • The CLSS consists of a main pump (2 pumps),
System, and has the following features. control valve, and actuators for the work equip-
ment.
1) Control enabling digging even with fine con- • The main pump body consists of the pump itself,
trol the PC valve and LS valve.
2) Ease of compound operation ensured by
flow divider function using area of opening
of spool during compound operations
3) Energy saving using variable pump control
BR380JG-1 10-53
(1)
Basic principle
1. Control of pump swash plate
• The pump swash plate angle (pump dis-
charge amount) is controlled so that LS dif-
ferential pressure E PLS (the difference
between pump pressure PP and control
valve outlet port LS pressure PLS) (load
pressure of actuator) is constant.
(LS pressure E PLS = Pump discharge
pressure PP – LS pressure PLS)
• If LS differential pressure EPLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high),
the pump swash plate moves towards the
maximum position; if it becomes higher than
the set pressure of the LS valve (when the
actuator load pressure is low), the pump
swash plate moves towards the minimum
position.
10-54 BR380JG-1
(1)
2. Pressure compensation
• A pressure compensation valve is installed
to the outlet port side of the control valve to
balance the load.
• When two actuators are operated together,
this valve acts to make pressure difference
EP between the upstream (inlet port) and
downstream (outlet port) of the spool of each
valve the same regardless of the size of the
load (pressure).
In this way, the flow of oil from the pump is
divided (compensated) in proportion to the
area of openings S1 and S2 of each valve.
BR380JG-1 10-55
(1)
Operation of each function
1. Relief valve
(Set pressure: 37.2 ± 0.5 MPa {380 ± 5 kg/cm2})
2. Unload valve
(Cracking pressure: 2.9 ± 0.5 MPa {30 ± 5 kg/
cm2})
3. Magnetic separator spool
4. Side conveyor spool
5. Accessory spool
6. Left travel spool
7. Grizzly feeder spool
8. Crusher spool
9. Right travel spool
10. Lock cylinder reset spool
11. Safety-suction valve
(13.7 ± 0.5 MPa {140 ± 5 kg/cm2})
(When normal: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2},
when pilot pressure is applied:
(When normal: 10.8 ± 0.5 MPa {110 ± 5 kg/cm2})
13. Suction valve
(17.2 ± 0.5 MPa {175 ± 5 kg/cm2})
(31.4 ± 0.5 MPa {320 ± 5 kg/cm2})
16. Merge-divider valve
17. Pressure compensation valve
18. Pressure compensation valve
10-56 BR380JG-1
System diagram
a This shows actuator (6A) at stroke end relief in the merge mode (on the BR380JG-1, this is always in the
divide mode).
1A. Main pump 5A. Control valve 9A. Tank passage

1B. Main pump 5B. Control valve 9B. Tank passage
2A. Main relief valve 6A. Actuator 10A. Valve
2B. Main relief valve 6B. Actuator 10B. Valve
3A. Unload valve 7A. Pump passage 11A. Spring
3B. Unload valve 7B. Pump passage 11B. Spring
4. Merge / flow divider valve 8A. LS circuit 12. LS bypass valve
8B. LS circuit
BR380JG-1 10-57
When unload valve is actuated
Function
• When all the control valves are at neutral, the oil When this pressure becomes larger than the
discharged when the pump is at the minimum force of springs (11A, 11B), valves (10A, 10B)
swash plate angle is drained. When this hap- move to the left, ports B and C are connected
pens, the pump pressure becomes a pressure and the pump pressure flows to tank passages
that matches the set load of springs (11A, 11B) (9A, 9B).
inside the valve (P1 pressure). The LS pressure • In addition, the pressurized oil in LS circuits (8A,
is drained from LS bypass valve (12), so LS pres- 8B) passes from orifice A through port C, and is
sure C tank pressure C 0 MPa {0 kg/cm2}. drained to tank passages (9A, 9B). Therefore,
• When operated (for operations in the discharge when the valve is actuated, LS pressure C tank
range for the minimum swash plate angle), the pressure.
discharge pressure of the oil discharged with the • When the unload operation is carried out, the dif-
pump at the minimum swash plate angle is LS ferential pressure (pump discharge pressure –
pressure + P1 pressure. In other words, the LS LS circuit pressure) is greater than the pump LS
control differential pressure (EPLS) of the oil control pressure, so a signal is sent to move the
discharged at the minimum swash plate angle is pump swash plate to the minimum angle.
the P1 pressure.
Operation
• The pressure in pump passages (7A, 7B) is re-
ceived by the end face of valves (10A, 10B). The
control valve is at neutral, so the pressure in LS
circuits (8A, 8B) is 0 MPa {0 kg/cm2}.
• The pressurized oil in pump passages (7A, 7B)
is stopped by valves (10A, 10B). There is no way
for the pressurized oil discharged by the pump to
escape, so the pressure rises.
10-58 BR380JG-1
Operation of relief valve

(Cut-off Control Actuated)
Function
• When cut-off control is being carried out on the
pump by the PC valve, the pump swash plate an-
gle is at the minimum.
• The relief valve acts to relieve the oil flow when
the pump is at the minimum swash plate angle in
order to maintain the overall balance.
Operation
• When the cylinder reaches the end of its stroke,
main relief valves (2A, 2B) open and pump dis-
charge amount Q is relieved to tank passages
(9A, 9B).
• When pump delivery pressure PP comes close
to the relief pressure, the engine throttle and
pump controller sends a signal to the solenoid of
the PC valve and carries out the cut-off function
to make pump discharge amount Q the mini-
mum.
• The spool is at the end of its stroke, so there is
no flow of oil upstream or downstream from the
spool. As a result, the pump delivery pressure
PP and LS pressure PLS are almost the same
pressure, and LS differential pressure EPLS be-
comes 0.
• LS differential pressure EPLS is lower than the
LS set pressure of the LS valve, so the LS valve
acts to try to move the pump swash plate angle
to the maximum. However, because of the struc-
ture, the action of the PC valve is given priority
over the action of the LS valve, so the pump is
held at the minimum swash plate angle by the
cut-off function of the PC valve.
BR380JG-1 10-59
Introduction of LS pressure
1. Main pump 5. Ball valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function Operation
• The upstream pressure (=spool meter-in down- • When spool (2) is operated, the pump pressure
stream pressure) of pressure compensation passes through introduction hole a, enters port
valve (3) is introduced and goes to shuttle valve C, and is taken to the LS circuit. When the pump
(7) as the LS pressure. When this happens, it is pressure rises and reaches the load pressure of
connected to port B of the actuator through valve port B, ball valve (5) opens.
(4), and LS pressure C actuator load pressure.
Introduction hole a inside the spool has a small
diameter, so it also acts as a throttle.
10-60 BR380JG-1
LS bypass valve
1. Main pump 4. LS shuttle valve

2. Main spool 5. LS bypass valve
3. Pressure compensation valve 6. LS circuit
Function
• The residual pressure in LS circuit (6) is released
from orifices a and b.
• This reduces the speed of the rise in the LS pres-
sure, and prevents any sudden change in the oil
pressure. Furthermore, a pressure loss is gener-
ated by the circuit resistance between throttle c
of main spool (2) and LS shuttle valve (4) accord-
ing to the bypass flow from LS bypass valve (5).
As a result, the effective LS differential pressure
drops, and the dynamic stability of the actuator is
increased.
BR380JG-1 10-61
Pressure compensation valve
1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
1. During independent operation and at maxi- Operation

mum load pressure during compound opera- • If the pump pressure (LS pressure) is lower than
tions, when load pressure is higher than the load pressure at port C, shuttle valve (3) in-
other work equipment. side pressure compensation valve piston (4)
moves to interconnect spring chamber E and
Function port C. From this condition, the force of spring (5)
• The pressure compensation valve acts as a load acts to move piston (4) and valve (2) in the direc-
check valve. tion of closing.
10-62 BR380JG-1
2. When receiving compensation during com- Operation

pound operations, when load pressure is • Spring chamber E is interconnected with port D.
lower than other work equipment. Piston (4) and valve (2) are actuated by the LS
circuit pressure from the other work equipment at
Function port F in the direction of closing (to the right). In
• The pressure compensation valve is closed by other words, the valve upstream pressure of port
the LS pressure of port D, and the spool meter-in B (= spool meter-in downstream pressure) is
downstream pressure of port B becomes the controlled by the LS pressure.
same as the maximum pressure of the other
work equipment. The spool meter-in upstream
pressure of port A is the pump pressure, so spool
meter-in differential pressure (upstream pres-
sure (pressure of port A) – downstream pressure
(pressure of port B)) becomes the same for all
spools that are being operated. In this way, the
pump flow is divided in proportion to the area of
the meter-in opening.
BR380JG-1 10-63
Shuttle valve inside pressure compensation valve
1. Main pump
2. Valve
3. Shuttle valve inside pressure compensation valve
4. Piston
Function
1. When holding pressure at port A > LS pres-
sure in spring chamber B.
Shuttle valve (3) is pushed to the right by the
pressure of port A, and the circuit between ports
A and C is shut off. In this condition, the holding
pressure at port A is taken to spring chamber B,
and pushes piston (4) to the left to prevent pis-
ton (4) and valve (2) from separating.
10-64 BR380JG-1
2. For travel
No holding pressure is generated at port A in
the travel circuit, so a pressure compensation
valve without a shuttle valve is used.
3. When there is no shuttle valve (reference)

If there is no shuttle valve, piston (4) and valve
(2) will separate. In this condition, if another
actuator is operated, the piston acts as an accu-
mulator, so there is a time lag.
BR380JG-1 10-65
4. Area ratio of pressure compensation valve

The dividing condition changes according to the area ratio of part A1 to part A2 of the pressure compensa-
tion valve.
Area ratio = A2/A1
• When the area ratio = 1: Spool meter-in downstream pressure = Max. load pressure, and the oil is di-
vided according to the open area ratio.
• When the area ratio > 1: Spool meter-in downstream pressure > Max. load pressure, and the oil is di-
vided less than the open area ratio.
• When the area ratio < 1: Spool meter-in downstream pressure < Max. load pressure, and the oil is di-
vided larger than the open area ratio.
Area ratio of each work equipment

Port A side Port B side
Orifice diameter Orifice diameter
Area ratio Area ratio
(mm) (mm)
Magnetic separator 0.98 2.0 0.98 2.0
Side conveyor (If equipped) 0.98 2.0 0.98 2.0
Accessory 0.98 2.0 0.98 2.0
Left travel 0.96 1.0 0.96 1.0
Grizzly feeder 0.98 2.0 0.98 2.0
Crusher 0.98 2.0 0.98 2.0
Right travel 0.96 1.0 0.96 1.0
Lock cylinder reset 0.98 2.0 0.98 2.0
10-66 BR380JG-1
Merge flow divider valve

a On the BR380JG-1, PS is always ON and the flow is always divided.
1. Main spool 5. LS circuit (option 4 end)

2. Spring 6. LS circuit (conveyor RAISE/LOWER end)
3. LS spool 7. LS circuit (conveyor RAISE/LOWER end)
4. Spring 8. LS circuit (option 4 end)
Function
• This acts to merge or divide (send each to its own • Therefore, pressurized oil flows P1 and P2
control valve group) oil flows P1 and P2 of pres- discharged from the two pumps are merged
surized oil discharged from the two pumps. at ports E and F, and are sent to the control
• At the same time, it also carries out merging and valve that demands the oil.
dividing of the LS circuit pressure. • In the same way, LS spool (3) is also pushed
fully to the left by spring (4), so the ports are
Operation connected as follows. Connected ports: A
1. When merging pump flow (when pilot pres- D, B C.
sure PS is OFF) • Therefore, the LS pressure supplied from the
• Pilot pressure PS is OFF, so main spool (1) spools of each control valve to LS circuits
is pushed fully to the left by spring (2), and (5), (6), (7), and (8) is all sent to the pressure
ports E and F are interconnected. compensation valve and other valves.
BR380JG-1 10-67
2. When dividing pump flow (when pilot pres- • In the same way, LS spool (3) is also moved
sure PS is ON) to the right by the PS pressure, and the ports
• When pilot pressure PS is ON, main spool are connected as follows.
(1) is moved to the right by the PS pressure, Connected ports: B D, others are not
and ports E and F are disconnected. There- connected.
fore, the pressurized oil discharged from • Therefore, LS circuits (5), (6), (7), and (8) are
each pump is sent to its own control valve all connected to their own control valve
group. group.
Pressure P1: To crusher
Pressure P2: To grizzly feeder, primary con-
veyor, debris discharge con-
veyor, and magnetic separator
10-68 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CRUSHER MOTOR
CRUSHER MOTOR
Model: KMF125B-5
S. From back pressure compensation valve Specifications

T. To tank Model: KMF125B-5
MA. From control valve Theoretical delivery: 125.0 cm3/rev
MB. From control valve Set pressure of safety valve: 36.7 MPa {375 kg/cm2}
Rated speed: 1,780 rpm
10-70 BR380JG-1
1. Drive shaft 6. Cylinder block 11. Check valve

2. Spacer 7. Valve blade 12. Check valve spring
3. Case 8. Center shaft 13. Shuttle valve
4. Housing 9. Center spring 14. Shuttle valve spring
5. Piston 10. Safety valve
BR380JG-1 10-71
Unit: mm

Free length × Installed Installed Free Installed If damaged
1 Check valve spring Outside diameter length load length load or
62.5 × 20.0 35 — replace
{0.36 kg} {0.29 kg}
spring
13.7 N 10.8 N
2 Shuttle valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.1 kg}
10-72 BR380JG-1
Relief valve portion
Outline
The relief valve portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief valve
(1).
Function
When the crusher is stopped, the outlet port circuit
of the motor from the control valve is closed, but the
motor continues to rotate under inertia, so the pres-
sure at the output side of the motor becomes abnor-
mally high, and this may damage the motor.
To prevent this, the abnormally high pressure oil is
relieved to port S from the outlet port of the motor
(high-pressure side) to prevent any damage.
Operation
1. When starting crusher
• When the crusher ON switch is pressed, the
pressure oil from the pump passes through the
control valve and is supplied to port MA. As a re-
sult, the pressure at port MA rises, the starting
torque is generated in the motor, and the motor
starts to rotate. The oil from the outlet port of the
motor passes from port MB thought the control
valve and returns to the tank. (Fig. 1)
2. When stopping crusher

• When the crusher OFF switch is pressed, the
supply of pressure oil from the pump to port MA
is stopped. With the oil from the outlet port of the
motor, the return circuit to the tank is closed by
the control valve, so the pressure at port MB ris-
es. As a result, rotation resistance is generated
in the motor, so the braking effect starts.
• If the pressure at port MB becomes higher than
the pressure at port MA, it pushes shuttle valve
A (4) and chamber C becomes the same pres-
sure as port MB. The oil pressure rises further
until it reaches the set pressure of relief valve (1).
As a result, a high braking torque acts on the mo-
tor and stops the motor. (Fig. 2)
• When relief valve (1) is being actuated, the relief
oil and the oil from port S passes through check
valve B (3) and is supplied to port MA. This pre-
vents cavitation at port MA.
BR380JG-1 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GRIZZLY FEEDER MOTOR
GRIZZLY FEEDER MOTOR
P1. From control valve Specifications

P2. From control valve Model: MSF-53
T. To hydraulic tank Theoretical delivery: 53.4 cc/rev
Rated pressure: 20.6 MPa {210 kg/cm2}
Max. speed: 3,000 rpm
10-74 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONVEYOR MOTOR
CONVEYOR MOTOR
R. From control valve Specifications

L. From control valve Model: MSE02-2-123-A02-1240
1. To hydraulic tank Theoretical delivery: 398 cc/rev
Max. pressure: 34.3 MPa {350 kg/cm2}
Max. speed: 165 rpm
BR380JG-1 10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
HMV110-2
P. From travel speed solenoid valve Specifications

T. To tank Model
PA. From control valve BR380JG-1
Item
PB. From control valve
MA. MA pressure pickup port Type HMV110ADT-2
MB. MB pressure pickup port Theoretical
Max. 106.2 cm3/rev
delivery
Set pressure 37.3 MPa {380 kg/cm2}
Max.
Rated speed 1,842 rpm
capacity
Brake releasing pressure 1.2 MPa {12 kg/cm2}
10-76 BR380JG-1
1. Regulator piston 9. Check valve spring 17. Valve plate

2. Spring 10. Output shaft 18. Counterbalance valve
3. Regulator valve 11. Rocker cam 19. Ring
4. Spring 12. Retainer guide 20. Spool return spring
5. Motor case 13. Pin 21. Brake piston
6. Suction safety valve spring 14. Piston 22. Plate
7. Suction safety valve 15. Retainer 23. Disc
8. Check valve 16. Cylinder 24. Ball
BR380JG-1 10-77
Unit: mm

1 Check valve spring Outside diameter length load length load
2.55 N 1.96 N If damaged
31.6 x 6.5 24.2 —
{0.26 kg} {0.2 kg} or
2 Check valve spring 13.0 x 6.5 9.5 — replace
{0.2 kg} {0.16 kg}
spring
411 N 329 N
3 Return spring 58.43 x 30 42.6 —
{41.9 kg} {33.5 kg}
55 N 44 N
4 Regulator valve spring 21.5 x 11.1 17.1 —
{5.6 kg} {4.5 kg}
10-78 BR380JG-1
Operation of parking brake

1. When starting to travel
When the travel lever is operated, the pressur-
ized oil from the pump actuates counterbalance
valve spool (19), opens the circuit to the parking
brake, and flows into chamber A of the brake
piston (12).
It overcomes the force of spring (11), and
pushes piston (12) to the left in the direction of
the arrow.
When this happens, the force pushing plate (13)
and disc (14) together is lost, so plate (13) and
disc (14) separate and the brake is released.
2. When stopping travel

When the travel lever is placed in neutral, coun-
terbalance valve spool (19) returns to the neu-
tral position and the circuit to the parking brake
is closed.
The pressurized oil in chamber A of brake piston
(12) is drained to the case from the orifice in the
brake piston, and brake piston (12) is pushed to
the right in the direction of the arrow by spring
(11).
As a result, plate (13) and disc (14) are pushed
together, and the brake is applied. A time delay
is provided by having the pressurized oil pass
through a throttle in slow return valve (22) when
the brake piston returns, and this ensures that
the brake is still effective after the machine
stops.
BR380JG-1 10-79
Operation of brake valve

• The brake valve consists of a suction safety
valve (18A), counterbalance valve (18) in a cir-
cuit as shown in the diagram on the right. (Fig. 1)
• The function and operation of each component is
as given below.
1. Counterbalance valve, check valve

Function
• When traveling downhill, the weight of the
machine makes it try to travel faster than the
speed of the motor.
As a result, if the machine travels with the
engine at low speed, the motor will rotate
without load and the machine will run away,
which is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine
speed (pump discharge amount).
Operation when pressure oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port PA. It pushes open suction safety
valve (18A) and flows from motor inlet port
MA to motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18B) and spool (19),
so the pressure at the supply side rises.
(Fig. 2)
• The pressurized oil at the supply side flows

from orifices E1 and E2 in spool (19) to
chamber S1. When the pressure in chamber
S1 goes above the spool switching pressure,
spool (19) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate. (Fig.
3)
10-80 BR380JG-1
Operation of brake when traveling downhill

• If the machine tries to run away when
traveling downhill, the motor will turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
S1 through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops be-
low the spool switching pressure, spool (19)
is returned to the left, in the direction of the
arrow by spring (20), and outlet port MB is
throttled.
As a result, the pressure at the outlet port
side rises, resistance is generated to the
rotation of the motor, and this prevents the
machine from running away.
In other words, the spool moves to a posi-
tion where the pressure at the outlet port
MB balances the pressure at the inlet port
and the force generated by the weight of the
machine. It throttles the outlet port circuit
and controls the travel speed according to
the amount of oil discharged from the pump.
(Fig. 4)
2. Safety valve
Function
• When travel is stopped (or when traveling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counter-
balance valve, but the motor is rotated by in-
ertia, so the pressure at the outlet port of the
motor will become abnormally high and dam-
age the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the inlet port side of the motor to
prevent damage to the equipment.
Operation
1) When travel is stopped (or when traveling
downhill, rotating to right)
• When the motor inlet port pressure (pressure
PA) goes down, the pressure in chamber S1
also goes down. When it goes below the
switching pressure of the spool, spool is re-
turned to the left by spring (20), and outlet
port passage B1 is throttled. When this hap-
pens, the motor continues to rotate under in-
ertia, so the outlet pressure (pressure MB)
rises. (Fig. 5)
• If the pressure goes above the set pressure
of suction-safety valve (18A), the poppet
opens. The oil then passes through large
notch A1 in counterbalance valve spool (19)
and flows to chamber MA in the circuit on the
opposite side. (Fig. 6)
2) When rotating to left
The operation is the rever se of when
rotating to the right.
BR380JG-1 10-81
3) When starting travel (or during normal

travel)
• When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When this
happens, the passage to the suction-safety
valve becomes the circuit flowing through
the small notch B2 in the counterbalance
valve spool. As a result, a big difference in
pressure is created, and the pump pressure
rises to provide a powerful drawbar pull. (Fig.
7)
10-82 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE

Function Operation
• This valve connects both travel circuits to each When pilot pressure is turned ON
other so that the hydraulic oil will be supplied • If the pilot pressure from the travel junction sole-
evenly to both travel motors and the machine will noid valve becomes higher than the force of
travel straight. spring (1), travel junction spool (2) moves to the
• When the machine is steered, outside pilot pres- left stroke end and the junction circuit between
sure PST closes the travel junction valve to se- port PTL (Left travel circuit) and PTR (Right trav-
cure high steering performance. el circuit) is closed.
BR380JG-1 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
When pilot pressure is turned OFF • If the oil flow rates in both travel motors become
• If pilot pressure PST from the solenoid valve is 0, different from each other, the oil flows through
travel junction spool (2) is pressed by the force of the route between port PTL, travel junction spool
spring (1) against the right side and the pass be- (2), and port PTR so that the oil flow rates will be
tween ports PTL and PTR is open. equalized again.
10-84 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
1. Hydraulic pump 6. Travel PPC valve Positions of lever

2. Control valve 7. EPC valve A. Neutral
3. Left travel lever 8. Solenoid selector valve B. Travel "Forward"
4. Right travel lever 9. Hydraulic block C. Travel "Reverse"
5. Solenoid valve
BR380JG-1 10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P: From main pump P3: Left forward

T: To tank P4: Left reverse
P1: Right forward P5: Travel signal
P2: Right reverse P6: Steering signal
10-86 BR380JG-1
1. Plate 6. Centering spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring
BR380JG-1 10-87
Unit: mm

1 Metering spring Outside diameter length load length load
If damaged
16.7 N 13.7 N or
26.5 x 8.15 24.7 —
{1.7 kg} {1.4 kg} deformed,
replace
108 N 86.3 N
2 Centering spring 48.1 x 15.5 32.5 — spring
{11 kg} {8.8 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}
10-88 BR380JG-1
Operation
1. At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
2. Fine control (neutral o fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed. Spool (1) is also pushed
by metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time,
it is connected to pump pressure chamber PP,
and the pilot pressure of the main pump is sent
from port A through fine control hole f to port
P1.
When the pressure at port P1 rises, spool (1) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time, it is connected to drain chamber D, so the
pressure at port P1 escapes.
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port P1.
The relationship of the position of spool (1) and
body (10) (fine control hole f is in the middle
between drain hole D and pump pressure cham-
ber PP) does not change until retainer (9) con-
tacts spool (1).
Therefore, metering spring (2) is compressed in
proportion to the travel of the control lever, so
the pressure at port P1 also rises in proportion
to the travel of the control lever. In this way, the
spool of the control valve spool moves to a posi-
tion where the pressure of chamber A (same as
pressure at port P1) and the force of the return
spring of the control valve spool are balanced.
(Fig. 2)
BR380JG-1 10-89
3. Fine control (control lever returned)

When lever (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
If the pressure at port P1 drops too much, spool
(1) is pushed down by metering spring (2), so
fine control hole f is shut off from drain chamber
D. At almost the same time, it is connected to
pump pressure chamber PP, so the pressure at
port P1 supplies the pump pressure until the
pressure recovers to a pressure equivalent to
the position of the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f’ of
the valve on the side that is not moving.
It passes through port P2 and goes to chamber
B to charge the oil. (Fig. 3)
4. At full stroke
Lever (5) pushes down piston (4), and retainer
(9) pushes down on spool (1). Fine control hole f
is shut off from drain chamber D, and is con-
nected to pump pressure chamber PP. There-
fore, the pilot pressure oil from the main pump
passes through fine control hole f and flows to
chamber A from port P1 to push the control
valve spool. The return oil from chamber B
passes from port P2 through fine control hole f’
and flows to drain chamber D. (Fig. 4)
10-90 BR380JG-1
Travel signal/Steering function

• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the
travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.
• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher
one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neu-
tral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
Operation
1. While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
BR380JG-1 10-91
2. While travelling straight

(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also
operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber k and right
spring chamber l of steering signal valve j are set high. Accordingly, the steering signal valve is kept in neu-
tral and the steering signal (Port P6) is not output.
10-92 BR380JG-1
3. When steered or pivot-turned

(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the dif-
ference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output
as the steering signal.
In the case of the following drawing, the pressure in left spring chamber k of steering signal valve j is P2.
The pressure in right spring chamber l is P4.
If (P4 – P2) x (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow
and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the
steering signal to port P6.
BR380JG-1 10-93
4. When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber l of
steering signal valve j is set high. Accordingly, the steering signal valve moves to the left and outputs the
steering signal (port P6).
10-94 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
For straight travel and 2-stage relief, magnetic separator, side conveyor, bear lock reset, and travel lock
1. Straight travel and 2-stage relief T. To tank

2. Magnetic separator A1. Control valve PST (Straight travel) (2-stage relief)
3. Side conveyor A2. Control valve (Port P-3) (Magnetic separator)
4. Bear lock reset A3. Control valve (Port P-1) (Side conveyor)
5. Travel lock A4. Control valve (Port P11) (Bear lock reset)
A5. To travel PPC port P
P1. From self-reducing pressure valve
ACC. 2-spool ON/OFF valve
PPC. TO EPC valve
BR380JG-1 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
1. Connector
2. Movable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
Operation
When solenoid is de-energized
• When the signal current does not flow from the
controller, solenoid (3) is de-energized.
For this reason, spool (5) is pushed fully to the
left by spring (6).
As a result, the circuit between ports P and A
closes and the pressurized oil from the control
pump does not flow to the actuator.
At the same time, the pressurized oil from the
actuator flows from port A to port T, and is then
drained to the tank.
When solenoid is energized

• When the signal current flows from the controller
to solenoid (3), solenoid (3) is energized.
For this reason, spool (5) is pushed to the right
in the direction of the arrow.
As a result, the pressurized oil from the control
pump flows from port P through the inside of
spool (5) to port A, and then flows to the actua-
tor. At the same time, port T is closed, and this
stops the oil from flowing to the tank.
10-96 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EPC VALVE
EPC VALVE
1. Accessory EPC valve 7. Spool T. To hydraulic tank

2. Feeder forward EPC valve 8. Spring C1. To control valve (Port P1)
3. Crusher forward EPC valve 9. Push pin C2. To control valve (Port P5)
4. Crusher reverse EPC valve 10. Coil C3. To control valve (Port P7)
5. Block 11. Plunger C4. To control valve (Port P8)
6. Body 12. Connector P. From 5-spool solenoid valve
BR380JG-1 10-97
1. Body 4. Coil C. To control valve

2. Spool 5. Plunger P. From 5-spool solenoid valve
3. Push pin 6. Connector T. To hydraulic tank
Unit: mm
Standard size Repair limit Replace

EPC valve
assembly if
7 Return spring Outside diameter length load length load
there is
3.14 N damage or
9.0 8.4 — —
{0.32 kg} deformation
10-98 BR380JG-1
Function
• The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
• When it receives signal current i from the control-
ler, it generates the EPC output pressure in pro-
portion to the size of the signal, and outputs it to
the control valve.
Operation
1. When signal current is 0 (coil de-energized)
• There is no signal current flowing from the
controller to coil (14), coil (14) is de-ener-
gized.
• For this reason, spool (11) is pushed to the
right by spring (12). As a result, port P closes
and the pressurized oil from the pump does
not flow to the control valve. At the same
time, the pressurized oil from the control
valve passes from port C through port T and
is drained to the tank.
BR380JG-1 10-99
2. When signal current is very small (coil ener-

gized, fine control)
• When a very small signal current flows to coil
(5), coil (5) is energized, a propulsion force is
generated, and this pushes plunger (6) to the
left.
• Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port P to port C.
When the pressure at port C rises and the
load of spring (3) + the force acting on sur-
face a of spool (2) becomes greater than the
propulsion force of plunger (6), spool (2) is
pushed to the right. The circuit between port
P and port C is shut off, and at the same
time, port C and port T are connected.
• As a result, spool (2) moves up and down so
that the propulsion force of plunger (6) is bal-
anced with the load of spring (3) + pressure
of port C. Therefore, the circuit pressure be-
tween the EPC valve and the control valve is
controlled in proportion to the size of the sig-
nal current.
3. When signal current is maximum (coil ener-

gized, operated fully)
• When the signal current flows to coil (5), coil
(5) is energized. When this happens, the sig-
nal current is at its maximum, so the propul-
sion force of plunger (6) is also at its
maximum. For this reason, spool (2) is
pushed fully to the left by push pin (4).
• As a result, the flow of pressurized oil from
port P flows at its maximum to port C, and
the circuit pressure between the EPC valve
and control valve becomes the maximum. At
the same time, port T closes and stops the oil
from flowing to the tank.
10-100 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTROMAGNETIC SELECTOR VALVE
ELECTROMAGNETIC SELECTOR VALVE

For lock cylinder
1. Body A. To lock cylinder head Specifications

2. Spring To conveyor RAISE/LOWER cylinder bottom Model: DSG-01-3C4-D24
3. Coil assembly B. To lock cylinder bottom Rated pressure:30.9 MPa {315 kg/cm2}
4. Push pin To conveyor RAISE/LOWER cylinder head Rated oil flow: 40 l/min.
5. Spool P. Control valve (from accessory port A1) Voltage: DC 24 V
6. Cap nut T. To hydraulic tank
BR380JG-1 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTROMAGNETIC SELECTOR VALVE
For Conveyor motor cylinder
1. Body A. To conveyor motor R Specifications

2. Spring B. To conveyor motor L Model: DSG-01-3C2-D24
3. Coil assembly P. Control valve (from accessory port B6) Rated pressure:30.9 MPa {315 kg/cm2}
4. Push pin T. To hydraulic tank Rated oil flow: 20 l/min.
5. Spool Voltage: DC 24 V
6. Cap nut
10-102 BR380JG-1
GRIZZLY FEEDER SEMIAUTOMATIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SYSTEM
GRIZZLY FEEDER SEMIAUTOMATIC SYSTEM
Function
• This system is installed to main pump outlet cir- • While this function is operating, the rotary lamp
cuit (1). (red) installed to the machine lights up.
If the pump outlet pressure is kept above the set If the pump outlet pressure is kept below the set
crusher load for 0.5 seconds, this system lowers crusher motor for 0.3 seconds, the grizzly feeder
the EPC current through CR700 controller (2) to is automatically reset to the flow rate in accor-
reduce the speed of grizzly feeder (3) to the dance with the feeder speed level of the multi-
minimum. monitor in the upper control box.
Set pressure of pressure

Set crusher load
switch
10.8 – 19.1 MPa
Crusher load
{110 – 195 kg/cm2}
a See FUNCTION OF SETTING CRUSHER

LOAD.
BR380JG-1 10-103
(3)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ABNORMAL LOAD STOP SYSTEM
ABNORMAL LOAD STOP SYSTEM

Function
• This system is installed to the inlet circuit of each • After the work equipment is stopped by this func-
actuator. If the inlet pressure of each actuator tion, the lamp to show the abnormal section
rises above the set pressure, the whole work lights up on the multi-monitor.
equipment, excluding the engine, stops immedi- a For the lamp, see DISPLAY OF WORKING
ately. MODE, Condition for turning working lamp ON.
• If the lock cylinder slips, the crusher stops imme-
diately. Set abnormal
a For slip of the lock cylinder, see CRUSHER Contents of error load pressure
TOOTH TIP ADJUSTMENT SYSTEM, Judg- MPa {kg/cm2}
ment of slip of lock cylinder. Abnormal pressure on primary conveyor 19.6 {200}
• If this function operates, the horn sounds for 5
seconds. Abnormal pressure on side conveyor 12.3 {125}
Abnormal pressure on magnetic sepa-
12.5 {125}
rator
Pressure switch
1. Connector Specifications
2. Wiring harness Model name: CE11-174-H
3. Pressure switch Pressure range: 0 – 34.3 MPa {0 – 350 kg/cm2}
Set pressure
a This pressure switch is different from the grizzly Primary conveyor pressure switch:
feeder semiautomatic pressure switch. 19.6 ± 0.6 MPa {200 ± 6 kg/cm2}
Magnetic separator pressure switch:
12.3 ± 0.4 MPa {125 ± 3.8 kg/cm2}
Side conveyor pressure switch:
12.3 ± 0.4 MPa {125 ± 3.8 kg/cm2}
10-104 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIMARY BELT CONVEYOR
PRIMARY BELT CONVEYOR
1. Conveyor belt 7. Return roller (Outside) 13. Rubber

2. Bearing unit 8. Rubber 14. Bearing
3. Rubber 9. Scraper rubber 15. Frame
4. Belt cleaner 10. Rubber 16. Head pulley
5. Carrier roller 11. Rubber 17. Primary conveyor motor
6. Guide roller 12. Slide plate 18. Tail pulley
BR380JG-1 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GRIZZLY FEEDER
GRIZZLY FEEDER
1. Hopper (Fixed type) 6. M-type chute

2. M-type chute selector lever 7. Vibrator
3. Upper grizzly bar 8. Grizzly feeder
4. Lower grizzly bar
5. Feeder fixing pin (For transportation) A. Trough surface
10-106 BR380JG-1
Basic operation
The grizzly feeder is installed to separate dirt and 1. Hopper
sand from stones or concrete debris. Accordingly, 2. Crusher
check the condition of screen (3). 3. Screen
a If a large quantity of stone or debris is supplied 4. Grizzly feeder
to part "a" of the screen, dirt and sand cannot be
separated.
Example of bad supply of material
Example of good supply of material
BR380JG-1 10-107
Example of good operation

1. The optimum quantity of the material for each
supply is 0.5 – 0.7 m3, which is about 50% of the
hopper capacity (top of the trough). Adjust the
supply rate, however, checking the condition of
the material on the feeder.
2. If the supply rate of the material is proper, the

screen separates the dirt, sand, and crushed
concrete perfectly.
a Do not supply the next lot of the material just
after supplying the first lot.
3. When the supplied material is reduced to about

a half, supply the next lot.
Repeat this operation.
10-108 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CRUSHER
CRUSHER
1. Supply opening guard 6. Oil filler plug

2. Scattering prevention guard 7. V-sheave
3. Water sprinkler pipe 8. Drain plug
4. V-belt 9. Turnbuckle
5. Crusher motor 10. Crusher assembly
BR380JG-1 10-109
10-110 BR380JG-1
1. Cheek plate
2. Protector
3. V-belt
4. Lock cylinder
5. Crusher motor
6. Swing tooth wedge bolt
7. Fixing link
8. Toggle seat
9. Toggle plate
10. Toggle seat
11. Swing jaw
12. Swing tooth
13. Crusher chamber
14. Fixed tooth
15. Front frame
16. V-sheave
17. Bearing (Frame)
18. Bearing (Swing jaw)
19. Main shaft (Crankshaft)
20. Balance weight
21. Tension rod
22. Tension spring
BR380JG-1 10-111
Principle of crushing
• With the movement of swing jaw (1), contact a
caused by the eccentricity of crankshaft (2) and
the rocking motion of toggle plate (3) moves in a
circle. The closer it comes to contact c, the more
it moves in a narrow oval movement.
• Movable jaw plate (5) installed to swing jaw (1)
repeat the movement in Step 1 against fixed jaw
plate (4). As a result, the rock or rubble loaded
into crushing chamber (6) moves to the bottom of
the crushing chamber, is subjected to a powerful
compression force, and is crushed.
• If lumps of metal or other hard substances that
cannot be crushed are loaded inside crushing
chamber (6), toggle plate (3) functions to auto-
matically change shape and protect the bearing
of crankshaft (2) from any big impact load.
• The clearance of the discharged port of fixed jaw
plate (4) and movable jaw plate (5) can be ad-
justed by changing the combination of shim
plates, so it is possible to change the particle size
of the crushed material.
• When fixed jaw plate (4) and movable jaw plate
(5) become worn, it is possible to reverse the top
and bottom. This operation can be carried out
once only.
• The wear of fixed jaw plate (4) and movable jaw
plate (5) differs according to the conditions and
the material being crushed, but generally speak-
ing, these parts wear more rapidly if the crushed
material includes large amounts of sand or mois-
ture. The speed of wear also increases if the
clearance at the discharge port is made small.
10-112 BR380JG-1
Method of using jaw crusher
Catalog particle distribution, adjustment of crusher jaw, and crushed volume definition of 40
and under rating.
• The value of 0 – 40 mm given in the catalog refers to the size of the pieces of concrete after crushing. It
means that the maximum size is 50 mm and the distribution of pieces smaller than 40 mm is approximately
95% of the total.
Adjustment of crusher discharge port clearance

• The value given in mm is the clearance when the discharge port is fully opened. If the value states 50 mm
adjustment, the size of the crushed material discharged more or less achieves the 40 and under rating, as-
suming that the material is concrete, that the jaw plate is new, that the opening of the debris bar is 50 mm,
and that the content of debris is approximately 30%.
• The dimension of the particle distribution is generally defined as follows:
Dimension of particle distribution = Clearance of discharge port – 10 mm
Particle distribution
• The shape of the discharge port of the jaw crush-
er is as shown in the diagram on the right. Direc-
tion a (amplification stroke of crusher) can be
adjusted, but distance b (width of crusher itself)
and the vertical direction cannot be adjusted.
• Therefore, for material like concrete, it is possible
to crush approximately 95% into small cubes of 0
– 40 mm when the setting is 50 (OSS), but for
close grain material such as natural rock, when
crushing with the jaw crusher, pieces which
crack along the grain and are flat are also dis-
charged from the crusher discharge port, so the
proportion of oversized material is large.
a If you look at piled material after crushing, larger pieces are easy to see, but this is because large pieces
have a lower specific gravity and stay on the surface, while the smaller pieces sink down. For this reason,
product normally consists of smaller particles than are seen on the surface. When crushing natural rock, the
minimum discharge port clearance is 50 mm. If it is set to less than that, it may cause breakage of the
crusher or premature wear of the jaw plates.
Crushed volume
• The crushed volume given in the catalog is the measured value under the optimum conditions of adjustment.
• Therefore, for general operations, the actual value is the optimum value multiplied by a production efficiency
of 0.6 to 0.75.
BR380JG-1 10-113
Prevention of wear of teeth
Causes of premature wear
Faster Slower
Discharge port clearance Narrow Wide
Water content High Low
Ratio of debris High Low
Ratio of silica High Low
Hardness of rock Hard Soft
a Of the above factors, those having the greatest effect are the clearance of the discharge port and the silica
content.
Prevention of wear
• For reasons of efficiency also, the ideal way to increase the life of the fixed jaw plate and moveable jaw plate
is not to make the clearance of the discharge port as small as possible, but to make it larger and use a sieve.
• Keep the minimum clearance of the jaw crusher at 50 mm.
Precautions
Precautions when operating machine

• When loading the inside of the crusher, adjust
the grizzly feeder to a maximum of approximately
80% (average: approximately 60%), and never
fill it completely. If it is overfilled, there will be ab-
normal wear from the center to the top of the
crusher fixed jaw plate and movable jaw plate.
• When handling materials which may cause the
machine to stop, such as large pieces of material
(rubble) or rubble including a large amount of re-
inforcing iron rods, leave such material to the end
of the day’s operation.
Preparation of materials
1. Break rubble so that the maximum dimensions are 1000 x 900 x 475 mm. If there are large amounts of
material of the maximum dimension and shape loaded into the crusher, the production will drop. (In the
case of natural rock, break it into pieces of 425 mm.)
2. When handling debris, make sure that it does not contain excessive water that makes the debris itself turn
into mud.
3. The production efficiency is better with material that does not include reinforcing iron rods. (The reinforcing
iron rods narrow the clearance of the discharge port and reduce the discharge efficiency.
4. The production efficiency is the best if the content of the debris is approximately 20% – 30%. (If there is a
large amount of debris, this will act as a cushion and reduce the production. In addition, it will also cause
premature wear of the fixed jaw plate ad movable jaw plate.)
5. Do not load other materials (wood, paper, etc.). These materials will clog the discharge port. It may be
impossible to discharge them, and this will cause breakage of the crusher and toggle plate.
10-114 BR380JG-1
CRUSHER TOOTH TIP ADJUSTMENT
CRUSHER TOOTH TIP ADJUSTMENT SYSTEM
1. Fixed tooth 5. Rod

2. Swing tooth 6. Fixing link
3. Revolution angle sensor 7. Toggle plate
4. Lock cylinder 8. Swing jaw
10-116 BR380JG-1
Function
Revolution angle sensor (3) senses tooth moving
distance (b) through swing jaw (8), toggle plate (7),
fixing link (6), and rod (5). The controller operate
lock cylinder (4) so that tooth clearance (a) set by
the multi-monitor will be obtained.
Crusher clearance adjustment mode

1. Manual adjustment
When measuring and adjusting the tooth clear-
ance simultaneously, adjust it in the "manual
mode".
a For the operation of the multi-monitor, see
MULTI MONITOR SYSTEM, Inspection
mode: Manual (M).
2. Semiautomatic adjustment
When adjusting the tooth clearance by setting a
target moving distance, adjust it in the "semiau-
tomatic mode".
a For the operation of the multi monitor, see
mode: Semiautomatic (S).
3. Automatic adjustment
When adjusting the tooth clearance by setting a
target tooth clearance, adjust it in the "automatic
mode".
a For the operation of the multi monitor, see
mode: Automatic (A).
Restriction of opening of crusher clearance

If the revolution angle sensor exceeds 127°, opera-
tion of the lock cylinder is restricted.
Judgment of slip of lock cylinder

The crusher angle is measured at the moment when
the inspection mode is changed last to another
mode. If the sensor angle increases more than 2°
from this crusher angle, it is judged that the lock cyl-
inder has slipped.
BR380JG-1 10-117
Revolution angle sensor
1. Revolution angle sensor Specifications

2. Wiring harness Type of sensor: Resistance board type
3. Connector Total resistance: 5 kz ± 20%
Mechanical revolution angle:200° ± 4°
Electrical revolution angle: 180° ± 2°
Rated voltage: 0.5 W (25°C)
10-118 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VIBRATOR
VIBRATOR
1. Grizzly feeder motor 6. Unbalance weight

2. Shaft 7. Drain plug
3. Bearing 8. Oil level gauge
4. Gear 9. Filler plug
5. Housing 10. Breather
BR380JG-1 10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Starting motor Outline

2. Linkage • The engine can be started and stopped with
3. Fuel control dial starting switch (4) only.
4. Starting switch • The dial-type engine control controls the engine
5. Engine throttle and pump controller speed by sending drive signal of fuel control dial
6. Battery relay (3) to governor motor (9) to control the governor
7. Battery lever angle of fuel injection pump (8).
8. Fuel control pump
9. Governor motor
10-120 BR380JG-1
1. Operation of system
Starting engine
• When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine throttle and
pump controller checks the signal from the fuel
control dial and sets the engine speed to the
speed set by the fuel control dial.
Engine speed control

• The fuel control dial sends a signal to the engine
throttle and pump controller according to the po-
sition of the dial. The engine throttle and pump
controller calculates the angle of the governor
motor according to this signal, and sends a sig-
nal to drive the governor motor so that it is at that
angle.
When this happens, the operating angle of the
governor motor is detected by the potentiome-
ter, and feedback is sent to the engine throttle
and pump controller, so that it can observe the
operation of the governor motor.
Stopping engine
• When the starting switch is turned to the STOP
position, the engine throttle and pump controller
drives the governor motor so that the governor
lever is set to the NO INJECTION position.
• When this happens, to maintain the electric pow-
er in the system until the engine stops complete-
ly, the engine throttle and pump controller itself
drives the battery relay.
BR380JG-1 10-121
2. Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
Function
• The fuel control dial is installed back of the mon-
itor panel, and a potentiometer is installed under
the knob. The potentiometer shaft is turned by
turning the knob.
• As the potentiometer shaft is turned, the resist-
ance of the variable resistor in the potentiometer
changes and a throttle signal is sent to the en-
gine throttle and pump controller.
The hatched area in the graph shown at right is
the abnormality detection area.
10-122 BR380JG-1
Governor motor
1. Potentiometer 5. Bearing
2. Cover 6. Motor
3. Shaft 7. Gear
4. Dust seal 8. Connector
Function Operation
• The motor is turned according to the drive signal • While motor is stopped
from the engine throttle and pump controller to Electric power is applied to both phases A and B
control the governor lever of the fuel injection of the motor.
pump. • While motor is running
This motor used as the motive power source is a The engine throttle and pump controller supplies
stepping motor. a pulse current to phases A and B, and the
• A potentiometer for feedback is installed to mon- motor revolves, synchronizing to the pulse.
itor the operation of the motor.
• Revolution of the motor is transmitted through
the gear to the potentiometer.
BR380JG-1 10-123
Engine throttle and pump controller
Input and output signals
CN-C1
Pin Pin
Signal name Input/Output Signal name Input/Output
No. No.
1 NC Input 13 Governor motor FB potentiometer Input
2 R pump pressure sensor Input 14 Magnetic separator OFF switch Input
3 One-touch stop switch Input 15 NC Input
4 GND (SIG) 16 SENS_PWR Output
5 Mode selector switch, travel Input 17 Key switch (Terminal C) Input
6 Crusher OFF switch Input 18 Conveyor OFF switch Input
7 Clearance sensor potentiometer Input 19 Throttle potentiometer Input
8 F pump pressure sensor Input 20 Magnetic separator ON switch Input
9 One-touch starting switch Input 21 GND (Analog GND)
10 GND (SIG) 22 POT_PWR Output
11 Mode selector switch, work Input 23 Key switch (Terminal ACC) Input
12 Crusher ON switch Input 24 Conveyor ON switch Input
10-124 BR380JG-1
CN-C2 CN-C3
Pin Pin
Signal name Input/Output Signal name Input/Output
No. No.
1 NC Output 1 VB (Controller PWR) Input
2 Clearance adjustment mode selection Input 2 VIS (Solenoid PWR) Input
3 Engine stop switch Input 3 SOL_COM (Solenoid common GND)
4 232C_RxD Input 4 Battery relay drive Output
5 Radio control selector switch Input 5 Governor motor phase A (+) Output
6 Magnetic separator pressure switch Input 6 LS-EPC Output
7 Model selection 2 Input 7 Conveyor reverse SOL Output
8 Magnetic separator relay Output 8 Conveyor forward SOL Output
9 Rotary lamp relay Output 9 Crusher manual forward switch Input
10 NC Input 10 Feeder ON switch Input
11 NC Output 11 VB (Controller PWR) Input
12 CAN shield 12 VIS (Solenoid PWR) Input
13 Model selection 3 Input 13 SOL_COM (Solenoid common GND)
14 RS232C_TxD Output 14 KEY_SIG Input
15 Travel Hi/Lo selector switch Input 15 Governor motor phase A (–) Output
16 Side conveyor pressure switch Input 16 PC-EPC Output
17 Model selection 1 Input 17 Lock cylinder reset SOL Output
18 Pressure abnormality processing relay Output 18 Heater relay drive Output
19 Horn relay Output 19 Crusher manual reverse switch Input
20 NC Input 20 Feeder OFF switch Input
21 S_NET Input/Output 21 GND (Controller GND)
22 CAN0_L Input/Output 22 VIS (Solenoid PWR) Input
23 (CAN1_L) Input/Output 23 SOL_COM (Solenoid common GND)
24 Flash memory write permission signal Input 24 KEY_SIG Input
25 Overfeed sensor Input 25 Governor motor phase B (+) Output
26 Conveyor pressure switch Input 26 Crusher forward EPC Output
27 Vibratory screen pressure switch Input 27 Lock cylinder extension relay Output
28 Magnetic separator use/disuse sensing Input 28 Accessory EPC Output
29 NC 29 Clearance increase Input
30 NC Input 30 Conveyor raise switch Input
31 GND (S_NET_GND) 31 GND (Controller GND)
32 CAN0_H Input/Output 32 GND (Controller GND)
33 (CAN1_H) Input/Output 33 GND (Controller GND)
34 GND (232C_GND) 34 NC
Crusher forward/reverse selector 35 Governor motor phase B (–) Output
35 Input
switch
36 Crusher reverse EPC Output
36 Emergency stop switch Input
37 Lock cylinder retraction SOL Output
37 Secondary conveyor pressure switch Input
38 Feeder forward EPC Output
38 Clearance adjustment mode selection Input
39 Clearance reduction Input
39 GND (Pulse GND)
40 Conveyor lower switch Input
40 Engine speed sensor Input
BR380JG-1 10-125
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM DEVICES
ELECTRONIC CONTROL SYSTEM DEVICES

Control function
a For the self-diagnosis function, see Troubleshooting.
BR380JG-1 10-127
Travel control function
10-128 BR380JG-1
BR380JG-1 10-129
1. Engine and pump compound control function
10-130 BR380JG-1
Control method
• Matching point:
106.6 kW/1,900 rpm {143 HP/1,900 rpm}
• If the pump load increases and the pressure ris-

es, the engine speed lowers.
At this time, the controller lowers the pump dis-
charge so that the engine speed will be near the
full output point. If the pressure lowers, the con-
troller increases the pump discharge so that the
engine speed will be near the full output point.
By repeating these operations, the controller
constantly uses the engine near the full output
point.
BR380JG-1 10-131
2. Pump and valve control function
10-132 BR380JG-1
LS control function
• The change point (LS set differential pressure) of
the pump discharge in the LS valve is changed
by changing the output pressure from the LS-
EPC valve to the LS valve according to the oper-
ating condition of the actuator.
• By this operation, the start-up time of the pump
discharge is optimized and the composite opera-
tion and fine control performance is improved.
BR380JG-1 10-133
3. Automatic engine warm-up and overheat prevention function
Function
• After the engine is started, if the engine coolant
temperature is low, the engine speed is raised
automatically to warm up the engine. If the en-
gine coolant temperature rises too high during
work, the pump load is reduced to prevent over-
heating.
10-134 BR380JG-1
1) Automatic engine warm-up function

• After the engine is started, if the engine coolant
temperature is low, the engine speed is raised
automatically to warm up the engine.
Operating condition (All) Operated

Coolant temperature: Below 30°C.
Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one) Reset

Coolant temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec. or
Manual
longer
2) Overheat prevention function

• If the engine coolant temperature rises too high • This function is turned on when the coolant tem-
during work, the pump load and engine speed perature rises above 95°C.
are reduced to prevent overheating.
Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below 105°C
Work mode Fuel control dial: Return to low idle
Coolant tempera- Engine speed: Low idle position once.
ture: Above 105°C Monitor alarm lamp: Lights up • Under above condition, controller is
Alarm buzzer: Sounds set to condition before operation of
function. (Manual reset)

Work mode Coolant temperature: Below 102°C
Coolant tempera- Engine speed: Keep as is. • Under above condition, controller is
ture: Above 102°C Monitor alarm lamp: Lights up. set to condition before operation of
Lower pump discharge. function. (Automatic reset)

Coolant temperature: Below 100°C
Work mode
Coolant tempera- • Under above condition, controller is
Engine speed: Keep as is.
ture: Above 100°C set to condition before operation of
Lower pump discharge.
function. (Automatic reset)
BR380JG-1 10-135
4. Travel control function
Function
• This function is used to control the pump and se-
lect the manual or automatic travel speed
change mode for travel performance matched to
the contents of work and jobsite during travel.
10-136 BR380JG-1
(1)
Travel speed change function

1) Manual change with travel speed switch
If the travel speed switch is changed between
Lo and Hi, the engine throttle and pump control-
ler controls the pump capacity at each gear
speed as shown below to change the travel
speed.
Lo Hi
Travel speed switch
(Low speed) (High speed)
Pump capacity (%) 80 100
Motor capacity Max. Max.
Travel speed (km/h) 2.4 3.0
2) Automatic change by engine speed

If the engine speed is lowered to 1,500 rpm or
less with the fuel control dial, the travel speed is
set to 1.8 km/h and does not change even if the
travel speed switch is changed.
3) Automatic change by radio control

While the machine is driven by radio control, its
travel speed is kept at the Lo speed, regardless
of the position (Hi or Lo) of the travel speed
switch.
BR380JG-1 10-137
5. System component parts
1) Engine revolution sensor
1. Sensor Function
2. Locknut • The engine revolution sensor is installed to the
3. Wiring harness ring gear of the engine flywheel. It electrically
4. Connector calculates the number of the gear teeth which
pass in front of it and transmits the result to the
engine throttle and pump controller.
• A magnet is used to sense the gear teeth. Each
time a gear tooth passes in front of the magnet,
a current is generated.
10-138 BR380JG-1
2) PPC oil pressure switch
1. Plug Specifications
2. Switch Type of contacts: Normally open contacts
3. Connector Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 0.3 ± 0.05 MPa
{3.0 ± 0.5 kg/cm2}
Function
• The junction block has 9 pressure switches,
which check the operating condition of each ac-
tuator by the PPC pressure and transmit it to the
engine throttle and pump controller.
BR380JG-1 10-139
3) Pump pressure sensor
1. Sensor
2. Connector
Function
• The pump pressure sensor is installed to the inlet
circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits
it to the engine throttle and pump controller.
Operation
• The oil pressure applied from the pressure intake
part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the
amplifier (voltage amplifier).
• The amplifier amplifies the received voltage and
transmits it to the engine throttle and pump con-
troller.
• Relationship between pressure P (MPa {kg/cm2})
and output voltage (V) is as follows.
V = 0.08 {0.008} x P + 0.5
10-140 BR380JG-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MULTI MONITOR SYSTEM
MULTI MONITOR SYSTEM
SJP08775
OR
08931
• The monitor system monitors the condition of the • The monitor panel also has various mode selec-
machine with sensors installed on various parts tor switches and functions to operate the ma-
of the machine. It processes and immediately chine control system.
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)
BR380JG-1 10-141
Monitor panel
Outline
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
10-142 BR380JG-1
Input and output signals
CN 1 CN 3
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
1 KEY ON Input 1 NC Input
2 KEY ON Input 2 NC Input
3 NC Output 3 NC Input
4 Start signal Input 4 NC Input
5 NC Input 5 NC Input
6 GND 6 NC Input
7 GND 7 (RS230C CTS) Input
8 VB + Input 8 (RS230C RXD) Input
9 NC Output 9 (RS230C RXD) Input/Output
10 NC Output 10 (RS230C RXD) Input/Output
11 (Buzzer ON signal) Input 11 (BOOT switch) Input
12 NC Input 12 NC Input
13 GND
14 CAN (SHIELD) Input
CN 2
15 CAN (+) Input
Pin No. Signal name Input/Output
16 CAN (–) Input
1 Engine coolant temperature Input
2 Fuel level Input
3 Radiator coolant level Input
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC Input
7 Engine oil pressure Input
8 Engine oil level Input
9 N/W signal Input/Output
10 N/W signal Input/Output
11 Charge level Input
Hydraulic oil temperature
12 Input
(Analog)
13 GND (For analog signal)
14 Personal cord relay (Lo) Input
15 NC Input
16 (Buzzer cancel) Input
17 NC Input
18 Preheating Input
19 Light switch Input
20 N/W GND
BR380JG-1 10-143
Monitor display and operation section
Display section
10-144 BR380JG-1
1. Preheating monitor
2. Engine coolant temperature monitor
3. Radiator coolant level caution
4. Engine coolant temperature gauge
5. Charge level caution
6. Engine oil pressure caution
7. Travel speed monitor
8. Service meter
9. Engine oil level caution
10. Air cleaner clogging
11. Fuel level gauge
12. Fuel level monitor
13. Working mode monitor
14. Operating condition monitor
15. Engine coolant temperature gauge
16. Fuel level gauge
17. Hydraulic oil temperature gauge
18. Hydraulic oil temperature monitor
19. Maintenance time warning
20. Inspection mode monitor
21. Actual crusher clearance monitor
22. Clearance adjustment execution
23. Set crusher clearance monitor
BR380JG-1 10-145
Monitoring items and display
Symbol Displayed item Display method
Condition of preheating
Time to continue setting
monitor
Preheating Up to 30 sec Lighting

30 sec – 40 sec Flashing
After 40 sec OFF
Engine coolant temperature
Hydraulic oil temperature See the display of the gauges on the next page.
Fuel level
10-146 BR380JG-1
Gauge Range Temperature/Level Indicator Buzzer

A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
Hydraulic oil B3 100 Green

temperature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level (l)
C4 100 Green
C5 60 Green
C6 41 Red
BR380JG-1 10-147
Display
Symbol Displayed item Display range Display method
section
Working mode In working mode Set mode is displayed.
In travel mode
Travel speed Set mode is displayed.
Lo, Hi
In inspection mode
Inspection mode Set mode is displayed.
A, S, M
Monitor
Actual crusher Actual crusher clearance is

In inspection mode
clearance monitor displayed. (*1)
Set crusher clearance In inspection mode Set crusher clearance is

monitor (A, S) displayed. (*2)
Condition of each Displayed in working Condition of each device is

device mode displayed.
Service Service meter While service meter is Lights up while service meter is
meter indicator in operation in operation.
*1. The displayed clearance and the measured clearance may not be the same.
*2. In the semiautomatic (S) mode, the quantity of adjustment of the clearance is displayed. If the clearance
is set toward the + side (– side), it is increased (decreased).
In the automatic (A) mode, the clearance to be set is displayed.
10-148 BR380JG-1
When any item has exceeded the maintenance period when check before starting is performed
(all caution lamps light up)
When the check before starting is performed, if an item which has exceeded the maintenance period lights up,
the hydraulic oil temperature gauge and hydraulic oil temperature monitor are turned OFF and the following
cautions are displayed.
Displayed Item checked by While engine is
Symbol While engine is running
item check before starting stopped
Engine oil Lamp lights up and buzzer sounds

pressure
q —
when abnormal.
Charge level q — Lamp lights up when abnormal.

SAP00522
Radiator Lamp lights up Lamp lights up and buzzer sounds

coolant level
q when abnormal. when abnormal.
Engine oil Lamp lights up

level
q when abnormal.
—
Air cleaner
clogging
q — Lamp lights up when abnormal.
Lamp lights up when forecast/warning is given.

Maintenance Lamp lights up for only 30 seconds after key is turned ON,
then goes off.
The cautions are displayed from the left upper corner in order of the time when they occurred.
If the hydraulic oil temperature rises or lowers abnormally while the above cautions are displayed, only the sym-
bol is displayed.
Hydraulic oil temperature Colors of symbol

Low (Below B6 or equivalent) Black on white background
Normal (B6 – B2) Not displayed
High (Above B2) White on red background
BR380JG-1 10-149
When machine is stopped in emergency

If the machine is stopped in an emergency, the fol-
lowing are displayed.
Emergency stop switch ON warning

If emergency stop switch (1) is depressed, the whole
work equipment stops, the horn sounds, and the
items shown at right are displayed.
Engine stop switch ON warning

If engine stop switch (2) is depressed, the whole
work equipment stops, the engine stops, the horn
sounds, and the items shown at right are displayed.
10-150 BR380JG-1
Operation section
1. Crusher clearance adjustment switch 6. Crusher load setting screen selector switch
2. Crusher manual rotation switch 7. Operation switch
3. Conveyor manual rotation switch 8. Buzzer cancel switch
4. Crusher speed setting screen selector switch 9. Maintenance switch
5. Feeder speed setting screen selector switch 10. Display brightness and contrast adjustment switch
BR380JG-1 10-151
• Crusher clearance adjustment switch

This switch is used to adjust the crusher clear-
ance manually.
This switch is effective when the manual adjust-
ment mode (M mode) is selected in the inspec-
tion mode.
• Crusher manual rotation switch

This switch is used to rotate the crusher manu-
ally.
This switch is effective when the crusher stops
in the work/inspection mode.
• Conveyor manual rotation switch

This switch is used to rotate the conveyor manu-
ally.
This switch is effective in the inspection mode.
• Crusher speed setting screen selector switch

This switch is used to set the crusher speed.
If this switch is depressed, the speed setting
screen appears and you can set the crusher
speed.
• Operation switch
This switch is used to use various setting func-
tions.
(For details, see the section of each function.)
• Buzzer cancel switch

When the machine detects abnormality and the
buzzer of the multi monitor sounds, stop the
buzzer with this switch. The buzzer sounds
when any of the following is detected.
• Abnormal coolant level
• Abnormal engine oil pressure
• Overheating of engine coolant
• Abnormality in fuel control dial potentiometer
• Disconnection or short circuit in pump PC-
EPC valve
• Disconnection or short circuit in governor
motor phase A or B
• Maintenance switch
This switch is used to check the maintenance
items.
a For the maintenance items, see MAINTE-
NANCE FUNCTION.
• Display brightness and contrast adjustment

switch
This switch is used to adjust the brightness and
contrast of the display.
10-152 BR380JG-1
Display and function of screen
Travel mode/Work mode

• The monitor screen is set in the travel mode, work mode, or inspection mode with mode selector switch (1)
on the control panel.
Travel mode
• If travel mode A is selected with mode selector
switch (1) on the main panel and speed selector
switch (2) on the upper control panel is changed,
Lo (Low-speed travel) or Hi (Hi-speed travel) is
displayed.
BR380JG-1 10-153
Work mode
• If work mode B is selected with the mode selec-
tor switch (1), you can check the operating con-
dition of each work equipment and find out the
work equipment receiving an overload or abnor-
mal load.
2. Side conveyor condition lamp

3. Feeder condition lamp
4. Crusher condition lamp
5. Magnetic separator condition lamp
6. Conveyor condition lamp
7. Vibratory screen condition lamp
8. Secondary conveyor condition lamp
• If an abnormal load is applied and a red lamp

lights up (See the table on the next page), de-
press return switch (9) or restart the abnormally
loaded work equipment, and the lamp is reset.
10-154 BR380JG-1
Conditions for lighting work equipment lamp
Secondary Vibratory
Magnetic Side conveyor
Conveyor Crusher Feeder conveyor screen
separator (If equipped)
(If equipped) (If equipped)
White lamp White lamp White lamp
Stop Transparent Transparent Transparent Transparent
lights up lights up lights up
White lamp White lamp White lamp
Forward drive Transparent Transparent Transparent Transparent
lights up lights up lights up
White lamp
Reverse drive — — — — — —
lights up
Red lamp
Overload — — — — — —
flashes (*1)
Red lamp
Red lamp Red lamp Red lamp Red lamp Red lamp
Abnormal load lights up —
lights up lights up lights up lights up lights up
(*2, 3)
Stopped under Green lamp
— — — — — —
overload flashes
*1. An overload on the crusher means that an excessive pressure load is applied to the crusher.
*2. An abnormal load on the crusher means that the crusher lock cylinder slips in the clearance increasing
direction or the swing tooth moves into the maximum crusher clearance range.
*3. A red lamp lighting because of an abnormal load is reset when "return" switch (9) is depressed or the
abnormally loaded work equipment is restarted.
BR380JG-1 10-155
Inspection mode
• If work mode B is selected with the mode selec-
tor switch (1), you can check the operating con-
dition of each work equipment and find out the
work equipment receiving an overload or abnor-
mal load.
• The inspection mode has the manual (M), semi-
automatic (S), and automatic (A) modes, each
which is selected by operating crusher clearance
adjustment mode selector switch (2).
1. Manual (M)
• While clearance closing switch (3) of the
monitor is depressed, clearance closing
monitor (8) flashes and actual crusher clear-
ance value (10) changes.
• While clearance opening switch (4) of the
monitor is depressed, clearance opening
monitor (9) flashes and actual crusher clear-
ance value (10) changes.
a If actual crusher clearance value (10) is
smaller than 50 mm or larger than 150 mm,
it lights up red.
10-156 BR380JG-1
2. Semiautomatic (S)
1) Just after this screen appears, the cursor is
at clearance set settle monitor (11).
2) Depress UP switch (5) or DOWN switch (6)
of the monitor to bring the cursor to crusher
clearance set value monitor (12).
3) Depress settle switch (7), and clearance set
value (12) lights up.
of the monitor to bring the cursor to the
clearance set settle monitor and depress the
settle switch (7).
5) Clearance set value (12) flashes and the
clearance is increased or decreased as
explained below.
• When clearance set value (12) is +:
The clearance is increased by the value
of (12) from current actual crusher clear-
ance (10).
• When clearance set value (12) is –:
The clearance is decreased by the value
of (12) from current actual crusher clear-
ance (11).
6) While the crusher clearance is increasing,
(9) flashes. While the former is decreasing,
(8) flashes.
a The input value to crusher clearance set
value (12) is so limited that the actual
crusher clearance will be in the effective
using range of 50 – 150 mm. When
crusher clearance set value (12) is in-
creased or decreased and settle switch
(7) is depressed, if the actual crusher
clearance is out of the above range, the
crusher clearance set value is returned
to the former value.
BR380JG-1 10-157
3. Automatic (A)
1) Just after this screen appears, the cursor is
at clearance set settle monitor (11).
of the monitor to bring the cursor to crusher
clearance set value monitor (12).
3) Depress settle switch (7), and clearance set
value (12) lights up.
of the monitor to bring the cursor to the
clearance set settle monitor and depress the
settle switch (7).
5) Clearance set value (12) flashes and the
clearance is increased or decreased as
explained below.
i) The crusher clearance is decreased
until the swing tooth touches the fixed
tooth.
ii) The crusher clearance is increased to
crusher clearance set value (12).
iii) When actual crusher clearance (10)
becomes larger than crusher clearance
set value (12), the automatic clearance
adjustment is finished.
6) While the crusher clearance is increasing,
(9) flashes. While the former is decreasing,
(8) flashes.
a The input range of crusher clearance set
value (12) is 50 – 150 mm. When settle
switch (7) is depressed, if the input value
is out of the above range, it is returned to
the former value.
10-158 BR380JG-1
Crusher mode setting function

• This function is used to set the crusher speed.
• This function is used while the ordinary screen
(travel mode, work mode, or inspection mode) is
displayed.
How to use
1) Depress crusher speed set switch (1) of the
monitor to display the adjustment screen.
2) Depress the operation switch (2) to select the
crusher speed.
Operation switch Operation
Bar graph extends to right.
Bar graph retract to left.
3) After selecting the level, depress input check

switch (3). The selected crusher speed level is
settled and the ordinary screen appears. At the
same time, the crusher speed level changes.
a The crusher speed does not change until the
input check switch is depressed. If return switch
(4) is depressed to return to the ordinary screen
without depressing the input check switch, the
original setting is maintained.
Feeder speed setting function

• This function is used to set the feeder speed.
The material is sent to the crusher at a proper
speed by selecting the feeder speed according to
the contents of the work.
displayed.
How to use
1) Depress feeder speed set switch (1) of the mon-
itor to display the adjustment screen.
feeder speed.

switch (3). The selected feeder speed level is
same time, the feeder speed changes.
a The feeder speed does not change until the
input check switch is depressed. If return switch
(4) is depressed to return to the ordinary screen
without depressing the input check switch, the
original setting is maintained.
BR380JG-1 10-159
Crusher load setting function

• This function is used to set the crusher load. The
material is crushed properly, regardless of its
type, by adjusting the crusher pressure switch in
proportion to the load level.
displayed.
How to use
1) Depress crusher load set switch (1) of the moni-
tor to display the adjustment screen.
crusher load.

switch (3). The selected crusher load level is
same time, the crusher load changes.
a The crusher load does not change until the input
check switch is depressed. If return switch (4) is
depressed to return to the ordinary screen with-
out depressing the input check switch, the origi-
nal setting is maintained.
10-160 BR380JG-1
Maintenance function
When each of the 10 maintenance items approaches
the time of maintenance such as replacement,
inspection, addition, etc., if maintenance switch (1) is
depressed, the caution lamp (yellow or red) lights up
on the monitor display for 30 seconds after the key is
turned ON to urge the operator to carry out the main-
tenance.
a Maintenance items
No. Item Replacement period (h)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic oil filter 1,000
05 Hydraulic tank breather 500
06 Corrosion resistor 1,000
07 Damper case oil 1,000
08 Final drive case oil 2,000
27 Feeder vibrator oil 1,000
28 Crusher motor case oil 1,000
10 Hydraulic oil 5,000
a The above replacement period is set for each

item and the remaining time before the mainte-
nance is reduced as the machine is operated.
The contents of the displayed caution depends
on the remaining time as shown below.
Display Condition
Remaining time before mainte-
None nance of every item is longer than
30 hours.
Forecast Remaining time before mainte-
(Black symbol on nance of 1 or more items is shorter
yellow background) than 30 hours.
Warning Remaining time before mainte-
(White symbol on nance of 1 or more items is shorter
red background) than 0 hour.
BR380JG-1 10-161
Method of checking condition of maintenance items
a Perform the following while the operator screen

is displayed.
1. Depress maintenance switch (1) to display the
maintenance table screen.
a On this screen, the maintenance items are
shown by symbols in a table.
2. Select the No. of the item to be maintained with

operation switch (2) or input it through the
numeral keys.
a The cursor moves and the selected part is in-
verted.
a Similarly to the "relationship between the re-
maining time and display of caution" on the
previous page, the items of remaining time
shorter than 30 hours are indicated yellow
and those of remaining time shorter than 0
hour are indicated red.
Maintenance operation
1. After selecting, depress input check switch (3),
and the maintenance reset screen appears.
2. Check the contents of the maintenance reset

screen. If there is no problem, depress input
check switch (3) to display the check screen.
If you made a mistake in selecting the item, etc.,
depress return switch (4) to return to the mainte-
nance table screen.
3. Check the contents of the check screen. If there

is no problem, depress input check switch (3) to
reset the maintenance time.
After resetting is completed, the maintenance
table screen appears again. When returning to
the maintenance table screen to check the
remaining time or when you selected a wrong
item, depress return switch (4).
a On the check screen, the symbol and set
time of the maintenance item are displayed
in large size.
a If the maintenance time of an item is reset,
the background of the symbol becomes the
same as the background of the screen to
show that the maintenance time has been
reset.
10-162 BR380JG-1
Brightness, contrast adjustment function
This function is used to adjust the brightness and

contrast of the display.
Adjustment method
a Operate as follows when on the operator
screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
a Relationship between menu symbol and con-
tent.
No. Symbol Content

01 Return mark Return
02 Contrast
03 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 - 02) to select either
contrast or brightness.
After completing the selection, press input con-
firmation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-key
pad to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
Control switch Actuation

Flow level bar graph extends to
the right
Flow level bar graph retracts to

the left
BR380JG-1 10-163
Password function
• If a password is set in advance, the engine does
not start unless the password is input.
• When setting or changing the password, move to
the set screen from the ordinary screen. This
work cannot be carried out until 10 minutes pass
after the starting switch is turned ON and the
monitor screen changes to the ordinary screen.
Setting and changing method

1. Turn the starting switch ON. While depressing
operation switch (2), depress 7, 2, 9, 7, 2, and 9
keys on the numeral key pad in order, and the
screen to input an 8-digit number appears.
2. While the screen is waiting for an input, input the

8-digit number "19210513" with the numeral
keys. After the last digit (3) is input, the screen
to check valid/invalid of the password appears.
10-164 BR380JG-1
3. Depress operation switch (1) or (2) to set valid/

invalid of the password.
In the figure at right, operation switch (1) is
depressed to set "valid".
If invalid is selected and input check switch (3) is

depressed, the password function becomes
invalid and ordinary screen (4) appears.
If valid is selected and input check switch (3) is
depressed, the password function becomes
valid and the screen to input a 4-digit number
appears.
4. On the input screen (where symbols of a lock

and a key are displayed), input a 4-digit number
and depress input check switch (3).
After the input check switch is depressed, the
system urges you to input the same 4-digit num-
ber again for reconfirmation. Input the same 4-
digit number and depress input check switch (3)
to settle it.
When inputting the number first time, "1" is dis-
played at the right top of the screen. When
inputting the number second time, "2" is dis-
played.
After the input number is settled, the ordinary
screen appears.
a If the number input first time is different from
that input second time, the password is not
settled but the screen to input the number
first time appears again.
BR380JG-1 10-165
Function of checking service meter

• When the starting switch is turned OFF, if return
switch (1) and operation switch (2) of the monitor
are depressed and held simultaneously, the
service meter is indicated on the display.
• If the switches are released, the service meter
disappears. It takes 3 - 5 seconds to display the
service meter after depressing the switches.
Function of displaying user code

• If there is any trouble in operation of the ma-
chine, the user code is displayed on the monitor
to urge the operator to take remedy.
• The ordinary screen (Travel, work, inspection)
changes to the screen shown at right and the
user code is indicated in the part of the hydraulic
oil temperature gauge.
• If there are multiple troubles, the user codes are

displayed alternately at intervals of 3 seconds.
10-166 BR380JG-1
• While the user code is displayed, if the input

check switch is depressed, the service code and
failure code are displayed.
• If there are multiple service codes/failure codes

which cause the service codes, all of them are
displayed at intervals of 3 seconds.
Even if there is a service code/failure code
which does not cause any user code, it is not
displayed by this function.
• If a phone number is set by using the phone

number input function of the service menu, it and
a phone symbol can be displayed instead of the
service code/failure code.
For the method of inputting and setting a phone
number, see TESTING AND ADJUSTING, Spe-
cial functions of monitor panel.
BR380JG-1 10-167
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the panel directry. Either side of a sensor of contact type is always
connected to the chassis ground.
Sensor name Type of sensor When normal When abnormal

Engine oil level Contact ON (Closed) OFF (Open)
Engine oil pressure Contact OFF (Open) ON (Closed)
Hydraulic oil temperature Resistance — —
Hydraulic oil level Contact ON (Closed) OFF (Open)
Coolant temperature Resistance — —
Coolant level Contact ON (Closed) OFF (Open)
Fuel level Resistance — —
Air cleaner clogging Contact OFF (Closed) ON (Open)
Coolant level sensor
1. Sub tank
2. Float
3. Sensor
4. Connector
10-168 BR380JG-1
Engine oil level sensor, Hydraulic oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Engine oil pressure sensor (For low pressure)
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Coolant temperature sensor, Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
BR380JG-1 10-169
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
10-170 BR380JG-1
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2

STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
k When working with other workers, always use signals and do not let unauthorized people near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
BR380JG-1 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Applicable model BR380JG-1
Engine model SAA6D102E-2
Item Measurement condition Unit Standard value Permissible value
High idling 2,250 ± 70 2,250 ± 70
Engine speeds Low idling rpm 1,000 ± 50 1,000 ± 50
Rated speed 2,050 2,050
At sudden acceleration Bosch Max. 1.0 2.0
Exhaust gas color
At high idle index Max. 0.5 1.5
Valve clearance Intake valves 0.25 —

mm
(normal temperature) Exhaust valves 0.51 —
Difference between
cylinders
Compression
Oil temperature: 40 to 60°C MPa Min. 2.4 Min. 1.0
pressure
{kg/cm2} {24.6} {10.3}
[Engine speed] [rpm] [250] [250]
Water temperature: operating range kPa
Blow-by pressure Max. 0.5 {50} 1.0 {100}
At rated output {mmH2O}
Water temperature: operating range
Oil pressure MPa
At high idling 0.39 – 0.64 {4.0 – 6.5} 0.25 {2.6}
(SAE15W-40 oil) {kg/cm2}
At low idling Min. 0.15 {1.5} 0.09 {0.9}
Oil temperature Whole speed range (inside oil pan) °C 80 – 110 120
°
Fuel injection timing Before top dead center 11.5 ± 1 11.5 ± 1
(degree)
Deflection when pressed with finger
Belt tension mm 8 6 – 10
force of approx 58.8N {6kg}
20-2 BR380JG-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Applicable Model BR380JG-1

Cate- Standard Permissible
Check Item Measurement Condition Unit
gory value value
• Engine coolant temperature:
To be within operating range
revolution
2 pumps
Engine
• Oil temperature: 45 to 55°C

in relief rpm 2,050 ± 100 2,050 ± 100
• Engine running at full throttle
condition
• Travel circuit in relief condition
(locking track shoe)
l a b l a b
Spool stroke
All spools mm 9.5 9.5 9.5 9.5

— —
± 0.5 ± 0.5 ± 0.5 ± 0.5
Travel • Grip the lever at its knob center Max. 95

• Read out the max. value up to the stroke 86 ± 9
control lever Min. 77
Stroke
end mm
Play of • Stop the engine
Control lever
Max. 15 Max. 23
control lever • Remove lever play at the neutral position
• Engine running at full throttle
Operating effort
• Oil temperature: 45 to 55°C

Operating • Hook a push-pull scale to the center of the 32.3 ± 6.9 Max. 51.9
N {kg}
effort in travel control lever knob and take measurement {3.3 ± 0.7} {Max. 5.3}
• Read out the max. value up to the stroke
end
BR380JG-1 20-3

gory value value
• Oil temperature: 45 – 55°C
• Run engine at full throttle 3.9 ± 1.0 3.9 ± 1.0
Unload pressure
• Set all levers in neutral {40 ± 10} {40 ± 10}
• Pump outlet pressure
38.7 ± 1.5 38.7 ± 2.0
Forward
{395 ± 15} {395 ± 20}
Crusher motor
38.7 ± 1.5 38.7 ± 2.0
Reverse
{395 ± 15} {395 ± 20}
Belt conveyor 23.0 ± 1.0 23.0 ± 1.5
motor {235 ± 10} {235 ± 15}
21.0 ± 1.5 21.0 ± 2.0
Feeder motor
{215 ± 15} {215 ± 20}
Release of lock 32.3 ± 1.0 32.3 ± 1.5
cylinder {330 ± 10} {330 ± 15}
Operation of lock
11.8 ± 1.0 11.8 ± 1.5
cylinder (Exten-
{120 ± 10} {120 ± 15}
sion, retraction)
Oil pressure
Conveyor elevator MPa 23.5 ± 1.0 23.5 ± 1.5

cylinder • Oil temperature: 45 – 55°C {kg/cm2} {240 ± 10} {240 ± 15}
• Run engine at full throttle
Side conveyor 26.5 ± 1.0 26.5 ± 1.5
• Pump outlet pressure
elevator cylinder {270 ± 10} {270 ± 15}
• Relieve only circuit to be measured
Side conveyor 14.7 ± 1.0 14.7 ± 1.5
motor {150 ± 10} {150 ± 15}
Magnetic 19.6 ± 1.0 19.6 ± 1.5
separator motor {200 ± 10} {200 ± 15}
39.2 +1.0
–1.5 39.2 +1.0
–2.5
Left travel
{400 +10
–15 } {400 +10
–25 }
39.2 +1.0
–1.5 39.2 +1.0
–2.5
Right travel
{400 +10
–15 } {400 +10
–25 }
Self-reducing 3.04 – 3.43 2.84 – 3.43

pressure valve {31 – 35} {29 – 35}
• Oil temperature: 45 – 55°C Turn all work

3.9 ± 1.0 3.9 ± 1.0
• Rung engine at full throttle equipment
LS differential {40 ± 10} {40 ± 10}
aLS differential pressure = switches OFF
pressure
Pump outlet pressure – LS Run all work 0.98 ± 0.2 0.98 ± 0.2
pressure equipment idle {10 ± 2} {10 ± 2}
20-4 BR380JG-1

gory value value
Hydraulic drift of
mm 0 0
travel
• Stop engine
• Hydraulic oil temperature: 45 – 55°C
• Stop machine on 12° slope with sprocket side
up
• Measure hydraulic drift of travel in 5 minutes
Leakage from
l/mm Max. 13.6 Max. 27.2
travel motor
• Run engine at full throttle
• Lock shoe with lock pin (1) and relieve travel cir-
cuit
Travel
Lo 26.1 – 35.3 25.0 – 37.5
Travel speed • Run engine at full throttle Sec.

• Set primary conveyor in travel posture
• After approach run of at least 10 m on flat Hi 20.9 – 28.2 20.0 – 30.0
ground, measure time required to travel 20
m.
•Run engine at full throttle
•Hydraulic oil temperature: 45 – 55°C
•Set primary conveyor in travel posture
•Travel at Hi
•After approach run of at least 10 m on flat
ground, measure travel deviation in travel of 20
m.
aTest on hard and level ground.
Travel deviation mm Max. 200 Max. 300
aMeasure dimension x.
BR380JG-1 20-5

Cate-
Check Item Measurement Condition Unit Standard value Permissible value
gory
1) Crusher speed Full 297 – 363 Full 280 – 380

(Forward) Low 144 – 196 Low 136 – 204
rpm
2) Crusher speed Full 238 – 322 Full 224 – 336
Work equipment speed
(Reverse) Low 144 – 196 Low 136 – 204

Full 1,000 – 1,100 Full 950 – 1,150
3) Feeder vibration cpm
Low 415 – 635 Low 440 – 660
4) Primary conveyor
102 – 138 96 – 144
belt speed • Run engine at full throttle
• Hydraulic oil temperature:
5) Side conveyor
45 – 55°C m/min 95 – 129 90 – 135
belt speed
6) Magnetic separa-
70 – 100 66 – 108
tor belt speed
20-6 BR380JG-1
Cate-
Discharge amount of main piston pump (each 1 pump)
gory
Piston pump performance
• Pump speed: At 2050 rpm, PC current 310 mA
Test pump dis- Discharge pres- Standard value for Judgement stan-
Check Average pressure
charge pressure sure of other pump discharge amount dard lower limit Q
point (MPa {kg/cm2})
(MPa {kg/cm2}) (MPa {kg/cm2}) Q (l/min.) (l/min.)
As P1 + P2
P1 P2 See graph See graph
desired 2
aAs far as possible, bring pump discharge pressures; P1 and P2 as close as possible to the average pressure
when measuring. The error is large near the point where the graph curves, so avoid measuring at this point.
aWhen measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement and use them as a base for calculating the pump discharge amount at the specified speed.
BR380JG-1 20-7
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING ........................................................... 20-102
INSPECTION AND ADJUSTMENT OF ENGINE RPM............................................................................... 20-104
MEASURING EXHAUST GAS COLOR ...................................................................................................... 20-106
ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-107
MEASURING COMPRESSION PRESSURE.............................................................................................. 20-109
MEASURING BLOW-BY PRESSURE ........................................................................................................ 20- 110
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20- 111
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 113
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 114
DIODE INSPECTION PROCEDURE.......................................................................................................... 20- 115
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 116
TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT AND TRAVEL CIRCUITS ........ 20- 117
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF-PRESSURE).. 20-121
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE........................................ 20-122
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE ........................................ 20-125
MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-129
MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-131
MEASURING OIL LEAKAGE...................................................................................................................... 20-132
BLEEDING AIR FROM EACH PART.......................................................................................................... 20-133
TESTING TRAVEL DEVIATION ................................................................................................................. 20-135
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20-136
SPECIAL FUNCTIONS OF MONITOR PANEL .......................................................................................... 20-137
TESTING AND ADJUSTING JAW CRUSHER............................................................................................ 20-164
TESTING AND ADJUSTING CRUSHER DRIVE BELT TENSION ............................................................. 20-172
TESTING AND ADJUSTING PRIMARY BELT CONVEYOR ...................................................................... 20-173
TESTING AND ADJUSTING MAGNETIC SEPARATOR............................................................................ 20-174
LIST OF COMPANIES WHICH HANDLES RADIO CONTROLLERS ........................................................ 20-176
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM................................. 20-177
BR380JG-1 20-101
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Test, measurement Sym-

Part No. Part name Q’ty Remarks
item bol
1 799-203-8001 Multi-tachometer 1 Digital display L : 60 – 2,000 rpm
Engine speed A
2 795-790-2500 Adapter 1 H : 60 – 19,999 rpm
1 799-201-9000 Handy smoke checker 1

Discoloration 0 – 70% (with standard color)
Exhaust gas color B
2
Commercially
Smoke meter 1 (Discoloration x 1/10 C Bosch index)
available
1 795-799-1131 Gear 1 For 102 series engine
Engine valve
C Commercially
clearance 2 Feeler gauge 1 (Intake : 0.25 mm, Exhaust : 0.51 mm)
available
Compression 1 795-502-1205 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}

D
pressure 2 795-502-1700 Adapter 6 For 102 series engine
1 799-201-1504 Blow-by checker 1
Blow-by pressure E
2 795-790-1950 Tool (Nozzle) 1 For 102 series engine
1 795-799-1131 Gear 1
Fuel injection timing F 2 795-799-1900 Pin assembly 1
3 795-799-1950 Lock pin 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Engine oil pressure G Hydraulic tester
790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(digital type)
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
{25, 60, 400, 600 kg/cm2}
Hydraulic oil pressure 1
of work equipment, Hydraulic tester
J 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
swing and travel (digital type)
circuit 799-101-5220 Nipple 2 10 x 1.25 mm
2
07002-11023 O-ring 2
{25, 60, 400, 600 kg/cm2}
Control circuit oil 1
K Hydraulic tester
pressure 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(digital type)
2 799-401-3100 Adapter 1
{25, 60, 400, 600 kg/cm2}
1
Pump PC control Hydraulic tester
L 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
circuit oil pressure (digital type)
799-101-5220 Nipple 4 10 x 1.25 mm
2
07002-11023 O-ring 4
20-102 BR380JG-1
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Test, measurement Sym-

Part No. Part name Q’ty Remarks
item bol
{25, 60, 400, 600 kg/cm2}
1
Hydraulic tester
Pump LS control 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
M (digital type)
circuit oil pressure
2 799-401-3100 Adapter 1
Differential pressure
3 799-401-2701 1
gauge
{25, 60, 400, 600 kg/cm2}
Solenoid valve output 1
N Hydraulic tester
pressure 790-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(digital type)
2 799-401-3100 Adapter 1
{25, 60, 400, 600 kg/cm2}
1
PPC valve output Hydraulic tester
P 799-261-1203 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
pressure (digital type)
2 799-101-5230 Nipple 2 Size: 14 x 1.5 mm
3 07002-11423 O-ring 2
Commercially
Oil leakage Q Cylinder 1
available
Coolant temperature,
— 799-101-1502 Digital thermometer 1 – 99.9 – 1,299°C
oil temperature
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Operating force —
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift — Scale 1
available
Work equipment Commercially
— Stopwatch 1
speed available
Commercially
Voltage, resistance — Tester 1
available
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, CONNECTOR
LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.
BR380JG-1 20-103
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
INSPECTION AND ADJUSTMENT OF ENGINE RPM

a Engine inspection and maintenance tools 2. Fit adapter A2, and connect pickup set [1] of
multi-tachometer A1.
Mark Part No. Part Name
1 799-203-8001 Multi-tachometer
A
2 795-790-2500 Adapter
a Engine RPM may be detected using a monitor-

ing function in the monitor panel (special func-
tion furnished to the monitor panel).
3. Measure the engine RPM after setting each

measurement condition.
1) RPM at low idling:
i) Set the fuel dial at low idling (MIN)
ii) Select the working mode and turn the all
work equipment switches OFF.
2) RPM at high idling:
i) Set the fuel dial at high idling (MAX).
k
ii) Select the working mode and turn the all
Be careful not to touch the strongly heated por- work equipment switches OFF.
tion of the engine by accident while installing a 3) RPM when 2 pump relief
measurement equipment. i) Set the fuel dial at high idling (MAX)
ii) Operate the travel lever and measure the
Inspection speed when the travel circuits (right and
1. Open up the engine hood and take off fan guard left) are relieved.
and cover (1).
a Use a filter wrench to take off the cover.
4. After finishing measurement, remove the meas-

uring instruments and return the removed parts.
20-104 BR380JG-1
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM
Adjusting
1. Adjusting low idling speed
a If the low idling speed is out of the standard
range, adjust it with the adjustment function
of the monitor panel.
a For the adjustment procedure, see SPECIAL
FUNCTION OF MONITOR PANEL.
2. Adjusting governor spring

a If the high idling speed is out of the standard
range or the engine speed is unstable (the
engine hunts), adjust the installed dimension
of the governor spring with the adjustment
function of the monitor panel.
a For the adjustment procedure, see SPECIAL
FUNCTION OF MONITOR PANEL.
BR380JG-1 20-105
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR

a Measuring instruments for exhaust gas color

1 799-201-9000 Handy smoke checker
B Commercially
2 Smoke meter
available
k When installing and removing the measuring in-

struments, take care not to touch a hot part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, use
smoke meter B2.
2) Connect the probe hose, receptacle of the
1. Measuring with handy smoke checker B1 accelerator switch, and air hose to smoke
1) Stick a sheet of filter paper to smoke meter B2.
checker B1. a Limit the supplied air pressure to 1.5
2) Insert the exhaust gas intake pipe in the MPa {15 kg/cm2}.
exhaust pipe. 3) Connect the power cable to a receptacle of
3) Run the engine and raise the engine coolant AC 100 V.
temperature to the operating range. a Before connecting the cable, check that
4) Accelerate the engine suddenly or run it at the power switch of the smoke meter is
high idling and operate the handle of smoke turned OFF.
checker B1 so that the filter paper will 4) Loosen the cap nut of the suction pump and
absorb the exhaust gas. fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
B2.
5) Remove the filter paper and compare it with

the attached scale.
2. Measuring with smoke meter B2

1) Insert probe [1] of smoke meter B2 in the 6) Run the engine and raise the engine coolant
outlet of the exhaust pipe and fix it to the temperature to the operating range.
exhaust pipe with a clip. 7) Accelerate the engine suddenly or run it at
high idling and press the accelerator pedal
of smoke meter B2 and collect the exhaust
gas into the filter paper.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the fil-
ter paper holder and read the indicated value.
9) After finishing measurement, remove the
mea su r ing i ns tr um ent an d re tur n th e
removed parts.
20-106 BR380JG-1
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

a Adjusting instruments for valve clearance 4. Rotate the crankshaft forward with gear C1 to
bring the stamped "1.6TOP" line a of the crank
Mark Part No. Part Name pulley to pointer (3) and set the No. 1 cylinder to
1 795-799-1131 Gear the compression top dead center.
a When the No. 1 cylinder is at the compres-
C Commercially
2 Filler gauge sion top dead center, the rocker arm of the
available
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
1. Open the engine hood and remove frame (8) cannot be moved, the No. 1 cylinder is not at
and fan guard (9). the compression top dead center. In this
case, rotate the crankshaft one more turn.
2. Remove all cylinder head covers (1).
3. Remove cap (2) and install gear C1.
BR380JG-1 20-107
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
5. While the No. 1 cylinder is at the compression 6. Rotate the crankshaft forward with gear C1 to
top dead center, adjust the valve clearances bring the stamped "1.6TOP" line a of the crank
marked with q in the valve arrangement dia- pulley to pointer (3) and set the No. 6 cylinder to
gram according to the following procedure. the compression top dead center.
a Valve arrangement diagram
7. While the No. 6 cylinder is at the compression
top dead center, adjust the valve clearances
marked with Q in the valve arrangement dia-
gram.
a Measure the clearances according to the
procedure of step 5.
8. After finishing measurement, return the removed
3 Cylinder head cover mounting bolt:

parts.
24 ± 4 Nm {2.45 ± 0.41 kgm}
1) Insert filler gauge C2 in clearance b

between rocker arm (4) and valve stem (5)
and adjust the valve clearance with adjust-
ing screw (6).
a With the filler gauge inserted, turn the
adjustment screw to a degree that you
can move the filler gauge lightly.
2) Fix adjustment screw (6) and tighten locknut
3 Locknut:
(7).
24 ± 4 Nm {2.45 ± 0.41 kgm}

a After tightening the locknut, check the
valve clearance again.
a After adjusting the clearances of all the
valves marked with q, go to the following
procedure.
20-108 BR380JG-1
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pres-
sure

1 795-502-1205 Compression gauge
D
2 795-502-1700 Adapter
k When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
1. Adjust the valve clearance. For details, see

6. Remove governor spring (2).
Adjusting valve clearance.
a See ADJUSTING VALVE CLEARANCE.
7. Put the governor lever (3) of the fuel injection
pump to the stopper on the STOP side and fix it.
k If the governor lever is not fixed, the engine
2. Prepare for measuring the engine speed.
a See TESTING AND ADJUSTING ENGINE
may start when it is cranked. Accordingly,
SPEED.
be sure to fix the governor lever to the
STOP side.
3. Warm up the engine until the engine oil temper-
ature is 40 – 60°C.
4. Remove nozzle holder (1) of the cylinder to be

measured.
8. Crank the engine with the starting motor and

measure the compression pressure.
a Read the compression gauge when its point-
er is stabilized.
a When measuring the compression pressure,
5. Install adapter D2 to the nozzle holder mounting
measure the engine speed, too, and check
part and connect gauge assembly [1] of com-
that it is in the measurement condition range.
3 Adapter: 60 ± 9 Nm {6.12 ± 0.92 kgm}
pression gauge D1.
2 Nozzle holder:
3 Nozzle holder:
Anti-seizure material (MOLYCOAT 1000)
60 ± 9 Nm {6.12 ± 0.92 kgm}
BR380JG-1 20-109
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

a Measuring instruments for blow-by pressure 4. Run the engine at high idling, relieve the travel
circuit, and measure the blow-by pressure.
Mark Part No. Part Name a Read the blow-by pressure gauge when its
1 799-201-1504 Blow-by kit pointer is stabilized.
E
2 795-790-1950 Tool (Nozzle)
1. Install tool E2 to blow-by hose (1) and connect

the gauge of blow-by kit E1.

2. Start the engine and lock the travel mechanism.

k Put pin [2] between the sprocket and track
frame to lock the travel mechanism secure-
ly.
3. Start the engine and raise the engine coolant

temperature and hydraulic oil temperature to the
operating range.
20-110 BR380JG-1
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

a Fuel injection timing inspection and adjustment 4. Fix the fuel injection pump drive gear to match
tools injection timing by pushing drive gear timing pin
(3) in the direction of the front cover.
Mark Part No. Part Name a Injection timing requires adjustment of high
1 795-799-1131 Gear precision. Be sure to fix the drive gear with
timing pin (3) so as to match injection timing.
F 2 795-799-1900 Pin assembly
a Push-in depth: 8 mm
3 795-799-1950 Lock Pin a If timing pin (3) cannot be pushed in, turn the
crankshaft a bit fore or aft with gear F1.
Inspection a If it is found difficult to confirm the push-in
1. Open up the engine hood, and then detach the depth with timing pin (3) as installed in the
fan guard. engine, metallic pin ass'y F2 may well be
. used instead.
2. Take off cover (1) and fit gear F1.
5. Disconnect plug (4) of the fuel injection pump.

3. Turn the crankshaft clockwise with gear F1, then
match 1.6 TOP notch a of the crank pulley with 6. Reverse and push in timing pin (5) of the fuel
pointer (2), and bring up No.1 cylinder to the top injection pump, and confirm its cut-out portion
dead center. matches with protruding portion b inside the
a Take off the cylinder head cover for No.1 cyl- pump.
inder, and confirm that its rocker arm can be a If timing pin (5) can be pushed in smoothly,
manually moved as much as the valve clear- then injection timing is correct.
ance. If it cannot be moved, that means that a If timing pin (5) cannot be pushed in smooth-
No.1 cylinder is not yet at the top dead cent- ly, injection timing is incorrect and requires
er. In that case, rotate it by one more turn. adjustment.
a If it is found difficult to confirm the push-in
depth with timing pin (5) as installed in the
engine, metallic pin ass'y F3 may well be
used instead.
BR380JG-1 20-111
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
7. Detach the measurement tools after the meas- 3. Reverse and push in timing pin (5) of the fuel
urement, and make sure that the machine is injection pump, then match the pin cut-out por-
3 Cylinder head cover securing bolt:

back to normal condition. tion and protruding portion b inside the fuel
injection pump by turning the shaft.
24 ± 4 Nm {2.45 ± 0.45 kgm} a After fuel timing has been set, fix it by fitting
k Do not forget to bring driving gear timing pin plug (4).
(3) and injection pump timing pin (5) back to
the pre-inspection condition.
a In case the adjustment follows, leave gear
F1 and timing pin (3) as they are.
Adjustment
a If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
a If timing pin (3) was pulled back after the in-
spection had been completed, push it in
again following the foregoing inspection pro-
cedures.
4. Mount the fuel injection pump.
a For mounting the pump, refer to the same
section mentioned in Item 2 above.
5. Detach the measurement tools after the adjust-

ment, and make sure that the machine is back
to normal condition.
k Before starting the engine again, check that
driving gear timing pin (3) and fuel injection
pump timing pin (5) have been brought back
to the pre-adjustment condition.
2. Dismantle the fuel injection pump.

a For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".
20-112 BR380JG-1
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE
MEASUREMENT OF ENGINE OIL PRESSURE

a Engine oil pressure measurement tools 3. Start the engine and keep it running until the
engine coolant temperature rises to the operat-
Mark Part No. Part Name ing range.
799-101-5002 Hydraulic Tester
1 4. Measure engine oil pressure at low idling as well
790-261-1203 Digital type hydraulic tester as at high idling.
G
Hydraulic Tester
2 799-401-2320
(1.0 MPa {10 kg/cm2})
1. Take off engine oil pressure measurement plug

(1) on top of the engine filter.
5. Detach the measurement tools after the meas-

urement, and make sure that the machine is
back to normal condition.
2. Install fitting of the hydraulic tester G1, and

connect it to hydraulic tester G2.
BR380JG-1 20-113
TESTING AND ADJUSTING ADJUSTMENT OF ENGINE SPEED SENSOR
ADJUSTMENT OF ENGINE SPEED SENSOR

a Detach engine speed sensor (1) before the
adjustment, then check that there is no metal
dust stuck or damage at the tip and fit it again.
1. Screw in sensor (1) until its tip comes to contact
3 Threaded portion:
with the tip of flywheel ring gear teeth (2).
Gasket sealant (LG-6)
2. Screw back sensor (1) from that position by the

prescribed angle.
a Screw-back angle: 1 ± 1/6 turn
a Adjust clearance a between the sensor tip
and gear tooth tip to be 1.25 – 1.75 mm.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}

3. Fasten sensor (1) with nut (3).
4. After the adjustment, confirm that correct engine

speed is displayed in the monitor panel, using
the special monitoring function.
a For monitoring engine speed, refer to the
section, "SPECIAL FUNCTION OF MONI-
TOR PANEL".
20-114 BR380JG-1
TESTING AND ADJUSTING DIODE INSPECTION PROCEDURE
DIODE INSPECTION PROCEDURE

a Check an assembled type diode (8 pins) and Note: If it is a silicon diode, a value between
single diode (2 pins) in the following manner. 0.46 V and 0.60 V is shown.
a The continuity direction of an assembled type
diode is as illustrated below.
a The continuity direction of a single diode is
marked on its surface.
2. When using an analog type circuit tester

a Switch to the diode range, if it is provided,
just as in the case of a digital type circuit test-
er.
1) Switch to the resistance range.
2) Check the movement of the tester pointer
when making the following connections.
i) Apply the red probe (+) to the anode
side (P) and black probe (–) to the cath-
ode side (N) of the circuit tester.
ii) Apply the red probe (+) to the cathode
side (N) and the black probe (–) to the
anode side (P) of the circuit tester.
3) Judge with movement of the circuit tester
pointer whether the diode is good or no
good.
• The circuit tester pointer does not move
1. When using digital circuit tester in the i) connection, but it does in ii) con-
1) Switch to the diode range and check a value nection: Normal (but a swing range of
in the display. the circuit tester pointer – resistance val-
a With an ordinary circuit tester, voltage of ue – will vary depending on a type of
the internal battery is shown. testers as well as a selected measure-
2) Apply the red probe (+) to the anode side ment range)
(P) and the black probe (–) to the cathode • The circuit tester pointer moves in both
side (N) of the diode and confirm the indi- cases of the connections i) and ii):
cated value. Defective (short-circuited internally)
3) Judge with the indicated value whether the • The circuit tester pointer does not make
diode is good or no good. any movement in either case of the con-
• No change in the indicated value: Not nections i) and ii):
continued (defective) Defective (short-circuited internally)
• Change in the indicated value: Contin-
ued (normal) (Note)
BR380JG-1 20-115
TESTING AND ADJUSTING EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL

SYSTEM
a If a failure occurs on any of the engine control 3. Remove bolt (4), connect governor spring (3)
devices like fuel dial, governor, pump controller and fix it at the original position.
or governor motor potentiometer, and the engine a Tilt the governor motor lever to the fuel injec-
gets out of control, first fix the engine rpm and tion pump side, but stop short of the gover-
take the following steps to avoid the immediate nor spring.
danger. a The governor lever of the fuel injection pump
a The suggested steps are provisional ones. Iden- is fixed at a near-idling position.
tify the cause for the failure and carry out repairs
promptly thereafter.
1. Disconnect E11 connector (1) of the governor

motor from E12 connector (2) of the governor
potentiometer.
k If the governor motor connector is left con-
nected, the governor motor will be suddenly
activated while the engine is running, caus-
ing a mechanical damage. Be sure to dis-
connect it.
4. Start the engine again and travel the machine to

a safe place.
5. Disconnect governor spring (3) and stop the

engine.
k Operation of stopping the engine is to be
carried out while the engine is running at
high speed. Be careful not to touch the parts
of high temperature or get caught in rotating
parts.
a If the governor spring is tilted all the way to
2. Detach governor spring (3) on the governor the fuel injection pump, the pump stops with
motor side. no more injection.
a Hold the governor spring until the engine
comes to a complete stop. Otherwise the
fuel injection pump automatically returns to
the low idling position, and the engine does
not stop.
20-116 BR380JG-1
TESTING AND ADJUSTING OIL PRESSURES IN
TESTING AND ADJUSTING WORK EQUIPMENT AND TRAVEL CIRCUITS
TESTING AND ADJUSTING OIL PRESSURES IN WORK

EQUIPMENT AND TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pres- Measuring
sures in work equipment and travel circuits 1. Preparation work
k Stop the engine, loosen the oil filler cap of the
Mark Part No. Part Name hydraulic tank gradually to release the residual
799-101-5002 Hydraulic tester pressure from the hydraulic tank, and set the
1 safety lock lever in the LOCK position.
790-261-1203 Digital hydraulic tester 1) Remove oil pressure pickup plugs (1) and
J
799-101-5220 Nipple (10 x 1.25 mm) (2).
2 • Plug (1): For front pump circuit
07002-11023 O-ring
• Plug (2): For rear pump circuit
a The oil pressures in the work equipment and

travel circuits (pump discharge pressures) can
be checked with the monitoring function of the
monitor panel (the special function of the moni-
tor panel), too.
2) Install nipple J2 and connect it to the oil

pressure gauge of hydraulic tester J1.
a Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}
BR380JG-1 20-117
3) Start the engine and raise the hydraulic oil 4. Measuring main relief pressure
temperature to the operating range. 1) Run the engine at high idling.
2) Relieve each actuator and measure the oil
pressure.
a The set pressures of the safety valves of the
actuators other than the travel motor are low-
er than the set pressure of the main relief
valve. Accordingly, the relief pressure of
each safety valve is measured.
a As the relief pressure of the crusher motor,
measure the oil pressure when the crusher
motor is started.
a When measuring the relief pressure of each
motor drive circuit of the grizzly feeder, side
conveyor, and magnetic separator, block the
piping of the forward rotation return circuit.
2. Combination of pump, actuator, and valve
a When the oil from the pumps is divided, the 5. Measuring travel relief pressure
front pump and rear pump act independently 1) Start the engine and lock the travel mecha-
nism.
k Put pin [2] between the sprocket and
on each actuator. Note that different actua-
tors relieve different valves.
track frame to lock the travel mecha-
Pump Actuator Valve relieved nism securely.
(Unload) F unload valve
Magnetic separator Safety valve
Side conveyor Safety valve
Primary conveyor
Safety valve
elevator
Side conveyor
Front Safety valve
elevator
Lock cylinder exten-
Safety valve
sion and retraction
Primary conveyor Safety valve
Left travel F main relief valve
Feeder Safety valve
2) While running the engine at high idling,
Crusher motor relieve the travel circuit and measure the oil
Crusher
safety valve pressure.
Rear Right travel R main relief valve a The relief pressure of the main relief valve is
indicated.
Lock cylinder reset Safety valve
(Unload) R unload valve
3. Measuring unload pressure

1) Start the engine.
2) While running the engine at high idling, turn
the work equipment switch OFF, set the
travel lever in neutral, and measure the oil
pressure.
a The unload pressure of the unload valve is
indicated.
20-118 BR380JG-1
Adjusting 2. Safety valves for work equipment

a The unload valve is not adjustable. • (7): Motor for magnetic separator
1. Main relief valves (Travel) • (8): For side conveyor motor
• (3): For front pump • (10): For feeder motor
• (4): For rear pump • (11): For resetting lock cylinder
1) While fixing adjustment screw (5), loosen 1) Loosen locknut (12) and turn adjustment nut
locknut (6). (13) to adjust the pressure.
a If the adjustment screw is a If the adjustment screw is
• turned to the right, the pressure ris- • turned to the right, the pressure ris-
es. es.
• turned to the left, the pressure low- • turned to the left, the pressure low-
ers. ers.
a Quantity of adjustment per turn of adjust- a Quantity of adjustment per turn of adjust-
ment screw: ment screw:
3 Locknut: 3 Locknut: 39 – 49 Nm {4 – 5 kgm}

Approx. 12.6 MPa {128 kg/cm2} Approx. 25.3 MPa {258 kg/cm2}
29.4 – 39.2 Nm {3 – 4 kgm}
• (9): Accessory valve

2) After finishing adjustment, check the oil • The solenoid selector valve drives actu-
pressure again according to the procedure ators of 3 kinds.
described above. a Adjusting relief pressure (High pressure
setting side)
• Primary conveyor motor
• Conveyor elevator cylinder
BR380JG-1 20-119
• The high relief pressure is the pressure a Adjusting relief pressure (Low pressure
applied when the 2nd-stage relief valve setting side)
is turned OFF and the pilot pressure is • Lock cylinder (Extension and retrac-
not applied to the selector port. tion)
i) Disconnect 2-stage selector pilot hose • The low relief pressure is the pressure
(14). applied when the 2nd-stage relief valve
is turned ON and the pilot pressure is ap-
plied to the selector port.
i) Disconnect 2-stage selector pilot hose
(14).
ii) While fixing holder (15), loosen locknut

(16).
a If the holder is
• turned to the right, the pressure
rises. ii) While fixing holder (17), loosen locknut
• turned to the left, the pressure (18).
lowers. a If the holder is
a Quantity of adjustment per turn of • turned to the right, the pressure
holder: rises.
3 Locknut:
Approx. 25.3 MPa {258 kg/cm2} • turned to the left, the pressure
lowers.
93 – 123 Nm {9.5 – 12.5 kgm} a Quantity of adjustment per turn of
holder:
3 Locknut:
Approx. 25.3 MPa {258 kg/cm2}
78 – 93 Nm {8 – 9.5 kgm}
iii) Connect pilot hose (14).

iv) After finishing adjustment, check the oil
pressure again according to the proce-
dure described above.
a If the high pressure setting side is adjust-
ed, the low pressure setting side chang-
es. Accordingly, adjust the low pressure
setting side, too.
20-120 BR380JG-1
TESTING AND ADJUSTING TESTING CONTROL CIRCUIT OIL PRESSURE
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE

REDUCED BY SELF-PRESSURE)
a Measuring instruments for control circuit basic 3. Install nipple [2] and oil pressure gauge [1] of
pressure hydraulic tester K1.
a Use the oil pressure gauge of 5.9 MPa {60
Mark Part No. Part Name kg/cm2}.
799-101-5002 Hydraulic tester
1
K 799-261-1203 Digital hydraulic tester
2 799-401-3100 Adapter (#02)

hydraulic tank gradually to release the residual
pressure from the hydraulic tank, and set the
safety lock lever in the LOCK position.
1. Disconnect inlet hose (1) of the 5-spool solenoid

valve.
4. Start the engine and raise the hydraulic oil tem-

perature to the operating range.
5. While running the engine at high idling, turn all

the operation switches OFF and measure the oil
pressure.

a The relief valve for the control circuit basic pres-
sure is not adjustable.
2. Connect adapter K2 to hose (1) and install the

hose again.
BR380JG-1 20-121
TESTING AND ADJUSTING TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL

PRESSURE
a Testing and adjusting instruments for pump PC
control circuit oil pressure

1
790-261-1203 Digital hydraulic tester
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measuring
a Before measuring the pump PC control circuit oil
pressure, check that the work equipment and
travel circuit oil pressure and the control circuit 2) Install nipple L2 and connect it to oil pres-
basic pressure are normal. sure gauge [1] of hydraulic tester L1.
k Stop the engine, loosen the oil filler cap of the a Use the oil pressure gauge of 58.8 MPa
hydraulic tank gradually to release the residual {600 kg/cm2}.
1. Measuring PC valve output pressure (servo

piston inlet pressure)
a Measure the PC valve output pressure (ser-
vo piston inlet pressure) and pump dis-
c ha r ge pr e s s ur e si m ul ta ne ou sl y a nd
compare them.
1) Remove oil pressure pickup plugs (1), (2),
(3), and (4).
• (1): For front pump discharge pressure
• (2): For rear pump discharge pressure
• (3): For front pump PC valve output
pressure
• (4): For rear pump PC valve output pres-
sure
20-122 BR380JG-1
3) Start the engine and raise the hydraulic oil 2. Measuring PC-EPC valve output pressure
temperature to the operating range. 1) Remove oil pressure pickup plug (5).
4) While running the engine at high idling, 2) Install nipple L2 and connect it to oil pres-
relieve the travel circuit and measure the sure gauge [1] of hydraulic tester L1.
pump discharge pressure and PC valve out- a Use the oil pressure gauge of 5.9 MPa
put pressure (servo piston inlet pressure) {60 kg/cm2}.
simultaneously.
a Method of judgment:
If the pump discharge pressure and PC
valve output pressure (servo piston out-
put pressure) are in the following ratio,
they are normal.
Measured oil Ratio of oil

pressure pressure
Pump discharge pressure 1
PC valve output pressure Approx. 3/5
a If the PC valve or the servo piston is ab-

normal, the PC valve output pressure
3) Start the engine and raise the hydraulic oil
(servo piston output pressure) is "the
temperature to the operating range.
same as the pump discharge pressure"
4) While running the engine at high idling and
or "almost 0".
low idling, turn all the work equipment
switches OFF and measure the oil pressure.
a If the PC-EPC valve pressure changes
as shown below, it is normal.
All work
Oil pressure
Engine equipment
(MPa {kg/cm2})
switches
Low idling 2.9 {30}
OFF
High idling 0 {0}
BR380JG-1 20-123
Adjusting 2. After finishing adjustment, check that the PC

a If either of the following phenomena occurs and valve output pressure (servo piston inlet pres-
the PC valves seem to be defective, adjust PC sure) is normal according to the procedure
valves (6) and (7) according to the procedure described above.
shown below.
• As the working load increases, the engine
speed lowers remarkably.
• The engine speed is normal but the work
equipment speed is low.
1. Loosen locknut (8) and turn adjustment screw

(9) to adjust the PC valve.
a If the adjustment screw is
• turned to the right, the pump absorption
torque increases.
• turned to the left, the pump absorption
torque decreases.
a The adjustable range of the adjustment
screw is as follows.
• Left turning: Max. 1 turn
3 Locknut:
• Right turning: Max. 1/2 turn (Max. 180°)
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
20-124 BR380JG-1
TESTING AND ADJUSTING TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL

PRESSURE
a Testing and adjusting instruments for pump LS
control circuit oil pressure

1
M 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 799-401-1340 Differential pressure gauge
Measuring
a Before measuring the pump LS control circuit oil
2) Install nipple M2 and connect it to oil pres-
pressure, check that the work equipment and
sure gauge [1] of hydraulic tester M1.
travel circuit oil pressure and the control circuit
basic pressure are normal.
{600 kg/cm2}.
hydraulic tank gradually to release the residual
1. Measuring LS valve output pressure (servo

piston inlet pressure)
a Measure the LS valve output pressure (ser-
vo piston inlet pressure) and pump dis-
c h ar g e p r es s ur e s im ul t ane ou s ly a nd
compare them.
(3), and (4).
• (3): For front pump LS valve output pres-
sure
• (4): For rear pump LS valve output pres-
sure
BR380JG-1 20-125
3) Start the engine and raise the hydraulic oil 2. Measuring LS differential pressure
temperature to the operating range. a As the LS differential pressure, measure
pump discharge pressure and LS pressure
(actuator load pressure) simultaneously and
calculate the difference between them.
(3), and (4).
• (3): For front pump LS pressure
• (4): For rear pump LS pressure
4) While running the engine at high idling

under the conditions in Table 1, measure the
pump discharge pressure and LS valve out-
put pressure (servo piston inlet pressure)
simultaneously.
a Method of judgment:
If the pump discharge pressure and LS
valve output pressure (servo piston out-
put pressure) are in the following ratio,
they are normal.
Table 1
Ratio of oil
Remarks
pressure
Measured oil All work
pressure All work
equipment
equipment
switches ON
switches OFF
(With no load)
Pump
discharge 1
pressure Almost same
LS valve out-
put pressure
Approx. 3/5 2) Install nipple M2 and connect it to oil pres-
sure gauge [1] of hydraulic tester M1 or dif-
ferential pressure gauge M3.
a When using differential pressure gauge:
measuring instruments and return the
Connect the pump discharge pressure
removed parts.
side to the high pressure side and con-
nect the LS pressure side to the low
pressure side.
Since the differential pressure gauge
needs a 12-V power source, connect it
to a battery.
a When using oil pressure gauge:
Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
Since the differential pressure is about
3.9 MPa {40 kg/cm2} at maximum, mea-
sure it by installing the same gauge to
the pickup plugs alternately.
20-126 BR380JG-1
3. Measuring LS-EPC valve output pressure

1) Remove oil pressure pickup plug (5).
2) Install nipple M2 and connect it to the oil

pressure gauge of hydraulic tester M1.
{60 kg/cm2}.
3) Raise the hydraulic oil temperature to the

operating range.
4) While running the engine at high idling
under the conditions in Table 2, measure the
pump discharge pressure and LS pressure
(actuator load pressure) simultaneously.
a Calculation of LS differential pressure:
LS differential pressure = Pump dis-
charge pressure – LS pressure 3) Start the engine and raise the hydraulic oil
a If the LS differential pressure is as fol- temperature to the operating range.
lows, it is normal. 4) While running the engine at high idling, turn
the all work equipment switches OFF and
Table 2 measure the oil pressure.
a If the LS-EPC valve output pressure is
All work equipment LS differential pressure
as follows, it is normal.
switches (MPa {kg/cm2})
OFF 3.9 ± 1.0 {40 ± 10} All work equipment Oil pressure
switches (MPa {kg/cm2})
ON (No load) 0.98 ± 0.1 {10 ± 1.0}
OFF Approx. 2.9 {Approx. 30}

removed parts.
removed parts.
BR380JG-1 20-127
Adjusting
a If the LS differential pressure is abnormal, adjust
LS valves (6) and (7) according to the following
procedure.
1. Loosen locknut (8) and turn adjustment screw

(9) to adjust the LS valve.
a If the adjustment screw is
• turned to the right, the differential pres-
sure rises.
• turned to the left, the differential pres-
sure lowers.
a Quantity of adjustment (LS differential pres-
sure) per turn of adjustment screw: Approx.
3 Locknut: 49 – 64 Nm {5 – 7 kgm}
1.3 MPa {13.3 kg/cm2}
2. After finishing adjustment, check that the LS dif-

ferential pressure is normal according to the pro-
cedure described above.
20-128 BR380JG-1
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE

a Measuring instruments for solenoid valve output
pressure

1
N 790-261-1203 Digital hydraulic tester
2 799-401-3100 Adapter (#02)
a Before measuring the solenoid valve output

pressure, check that the control circuit basic
pressure is normal.
hydraulic tank gradually to release the residual a The hoses to be measured are installed to
pressure from the hydraulic tank, and set the the right side of the main valve.
2. Install adapter N2 and connect the disconnected
1. Disconnect the outlet hose of the solenoid valve hose again.
to be measured.
3. Install nipple [1] of hydraulic tester N1 and con-
No. Solenoid valve to be measured
nect it to oil pressure gauge [2].
1 Travel junction/2-stage relief solenoid valve a Use the oil pressure gauge of 5.9 MPa {60
2 Magnetic separator solenoid valve kg/cm2}.
3 Side conveyor solenoid valve
4 Lock cylinder reset solenoid valve
5 Travel lock solenoid valve
6 Accessory EPC solenoid valve
7 Feeder forward EPC solenoid valve
8 Crusher forward EPC solenoid valve
9 Crusher reverse EPC solenoid valve
Radio control left travel forward solenoid valve
10
(if equipped)
Radio control left travel reverse solenoid valve
11
(if equipped)
Radio control right travel forward solenoid 4. Start the engine and raise the hydraulic oil tem-
12
valve (if equipped) perature to the operating range.
Radio control right travel reverse solenoid
13 5. While running the engine at full throttle, operate
valve (if equipped)
the control levers and switches to turn the sole-
noid valve ON or OFF and measure the oil pres-
sure.
a For the condition for turning the solenoid
valve ON or OFF, see the operation table of
each solenoid valve.
a The operating condition of the solenoid valve
can be checked with the monitoring function
of the monitor panel (Special function of ma-
chine monitor).
BR380JG-1 20-129
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
a If the output pressure is as shown in the fol-

lowing table, the solenoid valve is normal.
Output pressure
Solenoid valve
(MPa {kg/m2})
OFF (De-energized) 0 {0}
ON (Energized) 3 {30}

Operation table of travel junction/2-stage relief Operation table of accessory EPC valve
solenoid valve
Operating condition Operation
Operating condition Operation ON ON
When travel steering signal is Primary conveyor signal
ON OFF OFF
In travel ON
mode When travel steering signal is
OFF
OFF Operation table of crusher forward EPC valve
When crusher clearance Operating condition Operation
ON
In testing reducing switch is ON
Crusher forward signal ON ON
mode When crusher clearance
OFF (Crusher speed: MAX) OFF OFF
reducing switch is OFF
Operation table of side conveyor solenoid valve Operation table of radio control travel (Right,
left, forward, and reverse) solenoid valve
Operating condition Operation (if equipped)
ON ON
Side conveyor signal Operating condition Operation
OFF OFF
ON ON
Radio control travel signal
OFF OFF
Operation table of travel lock solenoid valve
Operating condition Operation Operation table of feeder forward EPC valve

In travel mode ON
Out of travel mode OFF
Feeder forward signal ON ON
(Feeder speed: MAX) OFF OFF
Operation table of magnetic separator solenoid
valve
Operation table of crusher reverse EPC valve
ON ON
Magnetic separator signal Crusher reverse signal ON ON
OFF OFF
(Crusher speed: MAX) OFF OFF
Operation table of lock cylinder reset solenoid

valve

ON ON
Lock cylinder reset signal
OFF OFF
20-130 BR380JG-1
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output 4. Start the engine and raise the hydraulic oil tem-
pressure perature to the operating range.

1
P
2 799-101-5230 Nipple (14 x 1.5 mm)
3 07002-11423 O-ring
a Before measuring the PPC valve output pres-

sure, check that the control circuit basic pres-
sure is normal.
1. Open cover (1).

5. While running the engine at high idling, set the
control lever of the circuit to be measured in the
neutral position and stroke end and measure the
oil pressure in each position.
a If the PPC valve output pressure is as shown
in the following table, it is normal.
Lever position Output pressure (MPa {kg/m2})

Neutral 0 {0}
Stroke end 3 {30}

2. Remove PPC oil pressure switches (2) and (3)
of the circuits to be measured.
• Switch (2): Travel signal (Black)
• Switch (3): Steering signal (Red)
3. Install nipple P2 and connect oil pressure gauge

[1] of hydraulic tester P1.
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
BR380JG-1 20-131
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

Measuring oil leakage from travel motor
1) Remove the travel motor cover.
2) Start the engine and lock the travel mecha-
nism.
k Put pin [1] between the sprocket and
track frame to lock the travel mecha-
nism securely.
3) Disconnect drain hose (1) of the travel

motor and fit a plug to it.
4) Start the engine, drive the machine at high
idling to relieve the travel circuit, and meas-
ure the oil leakage.
k Wrong operation of a lever can cause
an accident. Accordingly, make signs
and checks securely.
a After the travel circuit is relieved for 30
seconds, measure the oil leakage for 1
minute.
a Measure the oil leakage several times,
after moving the motor a little each time
(changing the distance between the
valve plate and cylinder and that be-
tween the cylinder and piston).

removed parts.
20-132 BR380JG-1
BLEEDING AIR FROM EACH PART
1. Bleeding air from pump

1) Loosen air bleeder (1) and check that oil
flows out of the bleeder.
3 Bleeder:
2) After the oil flows out, tighten bleeder (1).
7.8 – 9.8 Nm {0.8 – 1 kgm}
3 Bleeder:
6) Tighten air bleeder (1).
7.8 – 9.8 Nm {0.8 – 1 kgm}

a Precaution for starting engine
When starting the engine for the first time
after the above work, keep its speed at low
idling for about 10 minutes.
a If the oil does not flow out of the air bleeder: a If the warm-up operation is started because
3) Leave bleeder (1) loosened, disconnect of low coolant temperature, reset it with the
drain hose (2), and remove elbow (3). fuel control dial.
4) Add oil through the elbow mounting hole
until it flows out of the bleeder (1).
5) Install elbow (3) and connect drain hose (2).
BR380JG-1 20-133
2. Bleeding air from grizzly feeder motor 4. Bleeding air from travel motor
1) Run the engine at low idling, loosen drain 1) Run the engine at low idling, loosen air
hose (1), and check that oil flows out of the bleeder (1), and check that oil flows out of
drain port. the bleeder.
2) When oil containing no bubbles flows out,
3 Bleeder:
tighten bleeder (1).
27.5 – 35.3 Nm {2.8 – 3.6 kgm}
2) If the oil does not flow out, stop the engine,

disconnect the drain hose, and fill the motor
case with oil.
3) After bleeding air, tighten the drain hose.
4) Run the engine at low idling to rotate the 5. Bleeding air from conveyor motor
motor slowly. 1) Run the engine at low idling, loosen drain
hose (1), and check that oil flows out of the
3. Bleeding air from crusher motor drain hose.
1) Run the engine at low idling, loosen drain
hose (1), and check that oil flows out of the
drain port.
2) If the oil does not flow out, stop the engine,

9JH05861
and fill the motor case with hydraulic oil.
2) If the oil does not flow out, stop the engine, 4) Run the engine at low idling to rotate the
disconnect the drain hose, and fill the motor motor slowly.
case with oil.
4) Run the engine at low idling to rotate the
motor slowly.
20-134 BR380JG-1
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

a When traveling on flat ground
1. Set the machine in the travel posture.
a To set the machine in the travel posture,
raise the primary belt conveyor and hitch
mount hook (1) in fixing position for travel a
securely.
2. Make run up for 10 m, and then measure the

travel deviation in 20 m.
a Run the engine at full throttle for measure-
ment.
a Install an oil pressure gauge and measure
the pump discharge pressure during the
measurement of the travel deviation.
BR380JG-1 20-135
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION

Inspection Adjustment
1. Travel the machine forward by the length of a If the track shoe tension is not proper, adjust it in
track on ground, keeping the engine at low the following manner.
idling, and stop the machine slowly.
1. When the tension is too strong
2. Place straight bar [1] on the track shoe between Discharge grease by loosening valve (1).
the idler and the 1st carrier roller. k Do not loosen valve (1) by more than one
a L beam is recommended for bar [1], because turn, because grease will spurt out due to its
of its deflection-free nature. internal high pressure.
3. Measure max. clearance a between bar [1] and 2. When the tension is too weak
the track shoe. Add grease through valve (1).
• Max. standard clearance a: 10 – 30 mm a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
20-136 BR380JG-1
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
SPECIAL FUNCTIONS OF MONITOR PANEL
[1]: Numeral input switch 1 [6]: Numeral input switch 6 [ ]: Return switch
[2]: Numeral input switch 2 [7]: Numeral input switch 7 [ ]: Move-up switch
[3]: Numeral input switch 3 [8]: Numeral input switch 8 [ ]: Move-down switch
[4]: Numeral input switch 4 [9]: Numeral input switch 9 [ ]: Input check switch
[5]: Numeral input switch 5 [0]: Numeral input switch 0
BR380JG-1 20-137
Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of information
on the multi-display unit.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu

The items in this menu are displayed normally. The operator can display and set them by operating
switches.
2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches.
No. Operator menu No. Service menu

1 Function of inputting and setting password 19 Function of monitoring [01]
2 Screen to display KOMATSU logo Function of abnor- Electric system
20
3 Function of check before starting mality record [02] Mechanical system
4 Function of displaying maintenance items 21 Function of maintenance record [03]

5 Function of displaying caution items 22 Function of maintenance mode change [04]
6 Function of travel mode 23 Function of phone No. entry [05]
7 Function of working mode Function of setting Language
24 initial values and
8 Function of testing mode default [06] Unit
9 Function of setting feeder speed Adjustment of governor lever

10 Function of setting crusher speed stroke
11 Function of setting crusher load Pump absorption torque

Function of adjusting brightness and contrast of Function of Low idling speed
12 25
display adjustment [07]
Initialization of clearance
13 Function of checking maintenance information potentiometer
14 Function of displaying service meter Adjustment of feeder speed
15 Function of displaying cautions Adjustment of crusher speed
16 Function of displaying user code 26 Function of crusher clearance history [08]
17 Function of displaying error code and failure code 27 Function of lock cylinder slip history [09]
18 Function of monitoring emergency stop
20-138 BR380JG-1
Operation and display of operator menu (Outline)

a Only outline of the operator menu is described in
this section. For details of contents and opera-
tion of each menu, see OPERATION MANUAL
or the volume of STRUCTURE AND FUNC-
TION.
1. Function of inputting and setting password

When the starting switch is turned ON, the
screen to input a password is displayed.
a This screen is displayed only when the pass-
word function is set.
2. Screen to display KOMATSU logo

When a password is input (if it is set) or when
the starting switch is turned ON, the KOMATSU
logo is displayed for 2 seconds.
3. Function of check before starting

After the KOMATSU logo is displayed, the
screen for check before starting is displayed for
2 seconds.
4. Function of displaying maintenance items

After the screen for check before starting is dis-
played, if any oil or filter is near or has passed
the set maintenance time, the maintenance
mark is displayed for 30 seconds.
a This screen is displayed only when the main-
tenance function is set.
BR380JG-1 20-139
5. Function of displaying caution items

After the screen for check before starting is dis-
played, if any check item is abnormal, the corre-
sponding symbol mark is displayed.
6. Function of travel mode

If the travel mode is selected with the mode
selector switch of the main control box, the Hi or
Lo speed is displayed according to the setting of
the travel speed selector switch of the upper
control box.
7. Function of working mode

If the working mode is selected with the mode
selector switch of the main control box, the oper-
ator can check the operating condition of each
work equipment unit and specify the work equip-
ment that is overloaded or loaded abnormally.
• If the hydraulic oil temperature is abnormally
high, the travel mode is selected forcibly.
8. Function of testing mode

If the testing mode is selected with the mode
selector switch of the main control box, the
screen changes according to the position of
Manual (M), Semiauto (S), or Auto (A) selected
with the crusher clearance adjustment mode
selector switch of the main control box, then the
operator can adjust the crusher clearance in
each mode.
• If the hydraulic oil temperature is abnormally
high, the travel mode is selected forcibly.
20-140 BR380JG-1
9. Function of setting feeder speed

The operator can adjust the feeder speed with
the feeder speed setting switch of the machine
monitor.
A: Feeding speed is 0
B: Feeding speed is maximum
10. Function of setting crusher speed

The operator can adjust the crusher speed with
the crusher speed setting switch of the machine
monitor.
A: Speed is minimum
B: Speed is maximum
11. Function of setting crusher load

The operator can adjust the crusher load with
the crusher load setting switch of the machine
monitor.
A: Load is set to minimum.
B: Load is set to maximum.
12. Function of adjusting brightness and con-

trast of display
The operator can adjust the brightness and con-
trast of the display with the screen adjustment
switches.
BR380JG-1 20-141
13. Function of checking maintenance informa-

tion
The operator can check the detailed information
about the maintenance items (set time and
elapsed time) and reset them after checking with
the maintenance switches.
a The maintenance function is set and reset
and the maintenance time is set with the
service menu.
9JH05849
14. Function of displaying service meter

When the starting switch is turned OFF, the
operator can display only the service meter by
operating the following switches.
• Operation of switches: [ ] + [ ] (Operate
these switches simultaneously)
15. Function of displaying cautions

If there is any abnormal one in the caution
items, the corresponding symbol mark is dis-
played in large size for 2 seconds, and then it is
displayed in small size until the abnormal item is
repaired.
16. Function of displaying user code

If the machine has any failure, the correspond-
ing user code is displayed to urge the operator
to take a proper remedy, depending on the
degree of the failure.
a If any switch is operated while the user code
is displayed, the service code and failure
code screen appears (See 17).
20-142 BR380JG-1
a User codes and instructions given to operator
User code Failed system Instructions given to operator

E02 PC-EPC valve system The pump cannot be controlled. Have the machine inspected immediately.
The governor cannot be controlled.
Operate the governor lever manually. When fixing it to the FULL position, use the
E05 Governor system
fixing bolt installed to the bracket.
In this case, have the machine inspected immediately.
BR380JG-1 20-143
17. Function of displaying error code and failure

code
While a user code is displayed (A), if switch (1)
is depressed, the error code and failure code,
phone mark (if registered), and phone No. (if
registered) are displayed in order.
a The following are displayed in order repeat-

edly.
1) Error code and failure code (B)
2) Phone mark (C)
3) Phone No. (D)
If switch (1) is depressed again, the user code

display screen appears again.
a The phone mark and phone No. are dis-

played only when the phone No. is regis-
tered in the monitor panel. The phone No. is
registered, changed, or deleted with the
service menu.
a For details of the displayed error code and
failure code, see the error codes and failure
codes table.
9JH05463
9JH05464
20-144 BR380JG-1
Error codes and failure codes table
User Error code Failure code Record

code Code Contents Code Component Trouble division
Disconnection in primary belt conveyor forward
— E201 7RFHKA Disconnection
solenoid Primary belt conveyor
Short circuit in primary belt conveyor forward sole- forward solenoid
— E202 7RFHKB Short circuit
noid
— E203 Disconnection in crusher forward EPC valve 7RF2KA Crusher forward EPC Disconnection
— E204 Short circuit in crusher forward EPC valve 7RF2KB valve Short circuit
— E205 Disconnection in crusher reverse EPC valve 7RF3KA Crusher reverse EPC Disconnection
— E206 Short circuit in crusher reverse EPC valve 7RF3KB valve Short circuit
— E207 Disconnection in feeder forward EPC valve 7RF4KA Feeder forward EPC Disconnection
— E208 Short circuit in feeder forward EPC valve 7RF4KB valve Short circuit
Electrical intake air
— E211 Short circuit in electrical intake air heater relay 7RDMKB Short circuit
heater relay
Disconnection in pressure abnormality processing Pressure abnormality
— E212 7RFMKA Disconnection
relay processing relay
— E213 Disconnection in accessory drive EPC valve 7RFLKA Accessory drive EPC Disconnection
— E214 Short circuit in accessory drive EPC valve 7RFLKB valve Short circuit
Disconnec-
Engine throttle and tion, short cir-
— E217 Abnormality in model code input DA2SKQ
pump controller S-NET cuit, abnormal
communication input
— E218 Disconnection in S-NET signal DA2SKA Disconnection
— E222 Short circuit in LS-EPC solenoid DXE0KB LS-EPC solenoid Short circuit
— E223 Disconnection in LS-EPC solenoid DXE0KA valve Disconnection
F pump pressure sen- Electri-
— E224 Abnormality in F pump pressure sensor DHPAMA Malfunction
sor cal
R pump pressure sen- system
— E225 Abnormality in R pump pressure sensor DHPBMA Malfunction
sor
Engine throttle and
Lowering of
— E226 Abnormality in pressure sensor power supply DA25KP pump controller power
output voltage
supply output
— E227 Abnormality in engine speed sensor DLE2MA Engine speed sensor Malfunction
E02 E232 Short circuit in PC-EPC solenoid DXA0KB Short circuit
TVC solenoid valve
E02 E233 Disconnection in PC-EPC solenoid DXA0KA Disconnection
— E234 Short circuit in rotary lamp SSR DUB0KB Rotary lamp SSR Short circuit
— E235 Short circuit in horn relay D162KB Horn relay Short circuit
Short circuit in pressure abnormality processing Pressure abnormality
— E240 7RFMKB Short circuit
relay processing relay
Disconnection in primary belt conveyor reverse
— E241 7RD2KA Disconnection
solenoid Primary belt conveyor
Short circuit in primary belt conveyor reverse sole- reverse solenoid
— E242 7RD2KB Short circuit
noid
— E243 Disconnection in lock cylinder reset solenoid 7RFNKA Lock cylinder reset Disconnection
— E244 Short circuit in lock cylinder reset solenoid 7RFNKB solenoid valve Short circuit
Lock cylinder exten-
— E246 Short circuit in lock cylinder extension relay 7RFPKB Short circuit
sion solenoid valve
— E247 Disconnection in lock cylinder retraction solenoid 7RFKKA Lock cylinder retrac- Disconnection
— E248 Short circuit in lock cylinder retraction solenoid 7RFKKB tion solenoid valve Short circuit
— E249 Disconnection in magnetic separator relay 7RDNKA Magnetic separator Disconnection
— E250 Short circuit in magnetic separator relay 7RDNKB relay Short circuit
BR380JG-1 20-145
User Error code Failure code Record

code Code Contents Code Component Trouble division
— E301 Disconnection in engine stop switch DDA6KA Engine stop switch Disconnection
Primary belt conveyor-
— E302 Short circuit in primary belt conveyor-ON switch 7RC1KB Short circuit
ON switch
Primary belt conveyor-
— E303 Disconnection in primary belt conveyor-OFF switch 7RC2KA Disconnection
OFF switch
— E304 Short circuit in crusher-ON switch 7RE1KB Crusher-ON switch Short circuit
— E305 Disconnection in crusher-OFF switch 7RE2KA Crusher-OFF switch Disconnection
Governor potentiome-
— E306 Abnormality in governor potentiometer DK54KZ Malfunction
ter sensor
E05 E308 Abnormality in fuel control dial DK10KZ Throttle angle sensor Malfunction
— E315 Short circuit in battery relay output D110KB Battery relay Short circuit
Uncontrolla-
— E316 Stepping out of governor motor DY10K4
bility
Governor motor
E05 E317 Disconnection in governor motor phases A and B DY10KA Disconnection
E05 E318 Short circuit in governor motor phases A and B DY10KB Short circuit
— E320 Short circuit in feeder-ON switch 7RC5KB Feeder-ON switch Short circuit
— E321 Disconnection in feeder-OFF switch 7REPKA Feeder-OFF switch Disconnection Electri-
— E322 Short circuit in conveyor raise switch 7REJKB Conveyor raise switch Short circuit cal
— E323 Short circuit in conveyor lower switch 7REKKB Conveyor lower switch Short circuit system
Crusher manual for-
— E324 Short circuit in crusher manual forward switch 7RE3KB Short circuit
ward switch
Crusher manual
— E325 Short circuit in crusher manual reverse switch 7RE4KB Short circuit
reverse switch
Crusher clearance
— E326 Short circuit in crusher clearance increase switch 7RELKB Short circuit
increase switch
Crusher clearance
— E327 Short circuit in crusher clearance decrease switch 7REMKB Short circuit
decrease switch
Clearance sensing
— E331 Abnormality in clearance sensing potentiometer 7RENKZ Malfunction
potentiometer
One-touch starting
— E332 Short circuit in one-touch starting switch 7RESKB Short circuit
switch
— E333 Disconnection in one-touch stop switch 7RETKA One-touch stop switch Disconnection
Magnetic separator-
— E334 Short circuit in magnetic separator-ON switch 7RE8KB Short circuit
ON switch
Magnetic separator-
— E335 Disconnection in magnetic separator-OFF switch 7RE9KA Disconnection
OFF switch
— — Engine high idling speed out of standard A000N1 Overrun
Engine Low idling out
— — Engine low idling speed out of standard A000N2
of standard
— — Clogging of air cleaner AA10NX Air cleaner element Clogging
Defective
— — Abnormal lowering of charging voltage AB00KE Alternator
charge
Mecha-
Lowering of
— — Abnormal lowering of engine oil pressure B@BAZG nical
oil pressure
Engine oil system
Lowering of
— — Abnormal lowering of engine oil level B@BAZK
level
— — Overheating of engine coolant B@BCNS Overheating
Lowering of
— — Lowering of radiator coolant level B@BCZK Coolant
level
— — Overheating of hydraulic oil B@HANS Overheating
20-146 BR380JG-1
a The items in this table are arranged in the order of the error codes.
a The error codes having no numbers in the user code column and the failure codes having no numbers in
the user code column and error code column are not displayed on the normal screen, even if abnormality
related to them occurs. They are simply recorded in the failure record of the service menu (Electrical sys-
tem or mechanical system).
a The record division column shows in which division each failure is classified, the electrical system or
mechanical system, when it is recorded in the failure record.
a Letter "E" at the head of each error code indicates the following condition.
• With E: The failure has not been repaired yet.
• Without E: The failure has been repaired.
18. Function of monitoring emergency stop

1) Warning for turning emergency stop switch
ON
When an emergency stop switch installed
around the machine is depressed;
• The whole work equipment stops and
the horn sounds.
2) Warning for turning engine stop switch ON

When the engine stop switch installed to the
upper operation box is depressed;
• The whole work equipment and engine
stop and the horn sounds.
BR380JG-1 20-147
Operation and Display of Service Menu
Way of switching to Service Menu

a When using Service Menu, change the display
to Service Menu display through the following
special operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
a Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] o [2] o [3]
(Enter a figure, depressing [ ])
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 AAAAA/ Default
07 Adjustment
08 Crusher Clearance Record
09 Lock Cylinder Slip Record
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
i) Depress [ ] switch. (This method may be
used for terminating any display)
ii) If "Return" switch is shown, depress it.
iii) If "Return" menu is shown, call that menu
and depress [ ] switch.
20-148 BR380JG-1
19. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item
Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
a A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
a In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 999 and depress [ ]
switch.
a The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
a Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communication
speed. If truly real time monitoring is required,
reduce the selected items to the minimum.
a For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function
If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
BR380JG-1 20-149
Monitoring items table
Code Unit (Default: ISO)

Monitoring item Remarks
No. ISO meter inch
000 Return (Not displayed) Finish menu
Display exe-
999 Execution of display (Not displayed)
cution menu
002 Controller model code Numerals
003 Controller model code Numerals
010 Engine speed r/min rpm rpm
2
011 F pump pressure MPa kg/cm psi
2
012 R pump pressure MPa kg/cm psi
013 PC-EPC solenoid mA mA mA
015 LS-EPC solenoid mA mA mA
016 2nd throttle command r/min rpm rpm
030 Fuel control dial voltage V V V
031 Governor potentiometer voltage V V V
032 Source voltage V V V
033 Governor motor phase A current mA mA mA
034 Governor motor phase B current mA mA mA
035 Battery relay output voltage V V V
037 Controller output Battery relay drive ON/OFF
041 Engine coolant temperature °C °C F
042 Fuel sensor voltage V V V
043 Charging voltage V V V
044 Hydraulic oil temperature °C °C F
Key switch ON/OFF
Start ON/OFF
Monitor
045 Preheat ON/OFF
input 1
Light ON/OFF
Radiator coolant level ON/OFF
Air cleaner ON/OFF
Engine oil pressure ON/OFF
Monitor
046 Engine oil level ON/OFF
input 2
Spare ON/OFF
Charging voltage ABN/NOR
200 Program version (Monitor) Numerals
201 Program version (Controller) Numerals
247 Feeder forward EPC valve mA mA mA
Conveyor-ON switch ON when grounded, OFF when opened
Conveyor-OFF switch ON when opened, OFF when grounded
Switch Crusher-ON switch ON when grounded, OFF when opened

250
input 0 Crusher-OFF switch ON when opened, OFF when grounded
Feeder-ON switch ON when grounded, OFF when opened
Feeder-OFF switch ON when opened, OFF when grounded
20-150 BR380JG-1
Code Unit (Default: ISO)

Monitoring item Remarks
No. ISO meter inch
Side conveyor extension switch ON when grounded, OFF when opened
Side conveyor retraction switch ON when grounded, OFF when opened
Switch Crusher manual forward switch ON when grounded, OFF when opened
251
input 1 Crusher manual reverse switch ON when grounded, OFF when opened
Clearance increase switch ON when grounded, OFF when opened
Clearance decrease switch ON when grounded, OFF when opened
Mode selector work switch ON when connected to +24 V, OFF when opened
Mode selector travel switch ON when connected to +24 V, OFF when opened
Crusher forward/reverse selector
Switch ON when grounded, OFF when opened
252 switch
input 2
Model selection 1 ON when grounded, OFF when opened
Switch Emergency stop switch ON when grounded, OFF when opened

253
input 3 Engine stop switch ON when grounded, OFF when opened
Conveyor pressure switch ON when grounded, OFF when opened
Side conveyor pressure switch ON when grounded, OFF when opened
Magnetic separator pressure switch ON when grounded, OFF when opened
Switch
254 Secondary belt conveyor pressure
input 4 ON when grounded, OFF when opened
switch
Vibratory screen pressure switch ON when grounded, OFF when opened
Over-feed sensor ON when grounded, OFF when opened
Conveyor forward solenoid ON/OFF
Sole- Conveyor reverse solenoid ON/OFF

255
noid Lock cylinder reset solenoid ON/OFF
Lock cylinder retraction solenoid ON/OFF
Horn relay ON/OFF
Rotary lamp relay ON/OFF
256 Relay Pressure abnormality processing
ON/OFF
relay
Lock cylinder extension relay ON/OFF
257 Accessory EPC valve mA mA mA
259 Crusher forward EPC valve mA mA mA
260 Crusher reverse EPC valve mA mA mA
261 Clearance potentiometer V V V
262 Clearance potentiometer angle rad ° °
263 Final 0 clearance potentiometer voltage V V V
a You can select 1 of the 3 units of "ISO", "meter", and "inch".

Change the unit with "Unit" of "Initial value setting" function of the service menu.
a "ABN" and "NOR" in the unit column denote the following conditions.
ABN: Abnormal, NOR: Normal
BR380JG-1 20-151
20. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu

Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
Service Code
Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
Time elapsed since the occurrence of
the first failure
Contents of failure
a Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
Record No.
Contents of Abnormality
Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
Total number of occurrence
Service meter reading at the initial
occurrence
a Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.
20-152 BR380JG-1
5) Resetting Electrical Systems

a Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
a For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,

call the resetting display in the display of
Electrical Systems.
• Switch operation: [ ] + [1] o [2] o
[3]
a This is the same switch operation in
changing the display to Service
Menu.
ii) Operate the switch, following the instruc-

tions shown in the resetting display.
a When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
a When resetting all the information, a
display of any information will do.
BR380JG-1 20-153
21. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
Name of oils and filters
Times of replacement to date
Service meter reading at the latest
replacement
20-154 BR380JG-1
22. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item

00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 Damper Oil Service Int.
09 Final Drive Oil Exch. Int.
10 Feeder Vibrator Oil Exch. Int.
11 Crusher Motor Case Oil Exch. Int.
12 Hydraulic Oil Exch. Int.
13 Use Default Values
a 01 and 13 menus are provided for set-

ting the whole maintenance mode, while
those from 02 through 12 are for setting
individual items.
3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)
BR380JG-1 20-155
4) Set contents of individual items

Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
On: Maintenance display function with
this instruction becomes effectual.
Off: Maintenance display with this
instruction becomes ineffectual.
a The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
20-156 BR380JG-1
23. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
a If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
a Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone Num-
ber Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
a Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
a When entering a wrong number, de-
press [q] switch, then the cursor goes
back by one digit.
a When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
BR380JG-1 20-157
24. Function for AAAAA/Default [06]

It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Display language in Service Menu
• Display unit in the monitoring function
Select 06 "AAAAA /Default menu" in the
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
No. AAAAA/Default submenu

00 Return (termination of AAAAA/Default)
01 AA/Language
02 Unit
3) Function for AA/Language

In Service Menu, the language in use can
be changed between Japanese and
English.
a English is used as the language for de-
fault setting in the monitor panel.
a If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
4) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
a Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
20-158 BR380JG-1
25. Function for Adjustment [07]

The monitor panel has a function of making vari-
ous adjustments of the machine.
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.
2) Selection of submenu
Select an item to change from the submenu
No. Adjustment submenu

00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Feeder speed adjustment
05 Crusher speed adjustment
06 Clearance potentiometer initialization
3) Function for Governor Motor Adjustment

a When adjusting the securing position of
governor actuator, fuel injection pump
and governor spring, call this display and
carry out the work in the following man-
ner.
i) Set the fuel dial at MAX.
a In this condition, the governor actua-
tor lever shifts to the full throttle.
Hold this display while in adjust-
ment.
ii) Loosen nuts (2) and (3) of governor
spring (1).
a Nut (2) is of inverse thread (left).
iii) Turn rod (5) so that governor lever (4) of
the fuel injection pump contacts the full
stopper.
iv) Screw in rod (5) by 1 turn from this posi-
tion to reduce distance a between the pin
of governor spring (1).
a Distance a between the pins is re-
duced by 2.0 mm.
3 Nut:
v) Tighten nuts (2) and (3).
11.8 – 19.6 Nm {1.2 – 2.0 kgm}

vi) Confirm that governor spring stretches
by 4.0 mm, when the fuel dial is returned
to the MIN position and operated to the
MAX side again.
BR380JG-1 20-159
4) Function for Pump Absorption Torque

adjustment
The pump absorption torque can be
adjusted within the range shown in the table
below.
Adjustment value Torque adjustment value
220 +4.0 kgm
221 +3.0 kgm
222 +2.0 kgm
223 +1.0 kgm
224 0.0 kgm
225 –1.0 kgm
226 –2.0 kgm
227 –3.0 kgm
228 –4.0 kgm
5) Function for Low Idle Speed adjustment

The engine rotation at low idling can be
adjusted within the range shown in the table
below.
Adjustment value Low idling rotation
320 1,000 rpm
321 1,100 rpm
322 1,200 rpm
323 1,300 rpm
6) Function for feeder speed adjustment

The maximum and minimum feeder speed
can be adjusted within the range shown in
the table below by adjusting the feeder EPC
current.
Item Input range
Max. speed 750 – 910 mA
Min. speed 250 – 650 mA
i) Move the cursor to the current to adjust

with [ ] switch and [ ] switch and
depress [ ] switch.
ii) The adjusted current flashes and the
value input window is displayed.
iii) Input a value with the numeral keys and
depress [ ] switch.
a If a value out of the proper range is input,
the value before inputting is displayed
again.
20-160 BR380JG-1
7) Function for crusher speed adjustment

• Maximum speed adjustment
Adjust the LS-EPC current.
• Minimum speed adjustment
Adjust the crusher forward/reverse EPC
current.
Item Input range
Max. speed
0 – 1000 mA
(LS-EPC solenoid current)
Min. speed Forward 250 – 650 mA

(EPC current) Reverse 250 – 650 mA
i) Move the cursor to the current to adjust

with [ ] switch and [ ] switch and
depress [ ] switch.
ii) The adjusted current flashes and the
value input window is displayed.
iii) Input a value with the numeral keys and
depress [ ] switch.
a If a value out of the proper range is input,
the value before inputting is displayed
again.
a If the LS-EPC solenoid current is adjust-
ed, the minimum crusher speed and
maximum and minimum feeder speeds,
as well as the maximum crusher speed,
change. When adjusting the crusher and
feeder speeds, adjust the maximum
crusher speed first, then adjust the other
speeds.
8) Function for clearance potentiometer initiali-

zation
When the tooth plate is replaced, initialize
the clearance potentiometer.
i) Check that the display is in the ordinary
display mode.
ii) Set mode selector switch (1) of the main
control box in the testing mode position.
iii) Set clearance adjustment selector switch
(2) of the main control box in the manual
mode position.
iv) Rotate the crusher with crusher manual
forward switch (3) and reverse switch (4)
of the machine monitor to bring mark (B)
of the flywheel to the center of adjust-
ment range (A).
v) Depress crusher clearance closing
switch (5) of the machine monitor to
press the swing jaw of the crusher
against the fixed jaw (and the monitor
buzzer sounds).
BR380JG-1 20-161
vi) Select the service menu to display the

clearance potentiometer initialization
screen.
vii) Depress "1" (SET) on the clearance
potentiometer initialization screen.
26. Function for crusher clearance [08]

The monitor panel records the information about
the crusher clearance setting.
• The monitor panel records the information
up to 10 times. After recording 10 times, the
monitor panel discards the data in order from
the oldest one and keeps the newest ones.
• When the mode selector switch is changed
from the "testing mode" to "another mode", if
the crusher clearance saved previous time is
different from the current crusher clearance,
the monitor panel saves the current crusher
clearance.
Select 08 Crusher Clearance History in the
[ ] switch.
2) Information shown in display

i) Crusher clearance
ii) Service meter reading at which crusher
clearance was saved
20-162 BR380JG-1
27. Function for lock cylinder slip history [09]

The monitor panel records the information about
the past slip of the crusher lock cylinder (service
meter reading).
• The monitor panel records the slips up to 10
times. After recording 10 times, the monitor
panel discards the data in order from the old-
est one and keeps the newest ones.
• The total number of the recorded slips above
10 is counted and recorded up to 999.
Select 09 Lock Cylinder Slip History in the
[ ] switch.
2) Deletion of data
[ ] + [1] o [2] o [3]
(While pressing [ ], input numbers]
BR380JG-1 20-163
TESTING AND ADJUSTING TESTING AND ADJUSTING JAW CRUSHER
TESTING AND ADJUSTING JAW CRUSHER
(A) Clearance of discharge setting (C) Fixed jaw

(B) Lock cylinder (D) Swing jaw
1. Testing and adjusting clearance of discharge

setting
k Apply the safety lock of the travel lever.
k Put a warning board to the starting switch of the
control box to notify that the clearance is under
adjustment.
Testing
Clearance of discharge setting (A) (on the opening
side) means the distance between the tip of the fixed
jaw tooth and the root of the swing jaw tooth when
the outlet of the crusher is opened widest.
Measure the clearance of discharge setting at 3
places of both ends and the center and use the
shortest distance as the representative value.
20-164 BR380JG-1
Adjusting Adjusting clearance in A (Automatic) mode

The clearance can be adjusted by the following 3 1) Start the engine.
methods with the machine monitor.
A (Automatic): Input a set value to the clear-

ance set monitor, and the clear-
ance is adjusted automatically.
S (Semiautomatic): Input a value to be added to or
subtracted from the current
clearance to the clearance set
monitor, and the clearance is
adjusted automatically.
(If a + (positive) value is input,
the clearance is increased. If a
– (negative) value is input, the
clearance is decreased.)
M (Manual): Adjust the clearance manually 2) Set the fuel control dial (1) in low idling posi-
with the panel switches. tion (a).
a Before adjusting the clearance of discharge set-

ting, set the marked point of the flywheel (B
(painted red)) to the center of the adjustment
range (A) by inching operation.
3) Set mode selector switch (2) in the "Testing

(c)" position.
• The machine monitor changes to the or-
dinary testing screen.
BR380JG-1 20-165
4) Set clearance adjustment selector switch (3)

in position A (Automatic).
a Once a value is set, it is displayed when the

clearance is adjusted next time. When you
use that value as it is, you do not need to in-
5) Check that clearance adjustment monitor put it again.
(D) of the machine monitor is in mode A a When canceling setting of the desired OSS
(Automatic) and input desired OSS clear- clearance, depress return switch (7), and the
ance (A) to the machine monitor according former set value is displayed.
to the following procedure. 6) Execution of adjustment of clearance
• OSS: The state when the discharge set- i) Move the cursor in the screen to posi-
ting is opened widest. tion (C) with move-up switch (4) and
i) Move the cursor in the screen to posi- move-down switch (5).
tion (A) with move-up switch (4) and ii) Depress input check switch (6) to finish
move-down switch (5). preparation, and lamp "|" of (C) flashes.
iii) Depress input check switch (6) again to
execute adjustment, and lamp "|" lights
up and automatic clearance adjustment
is executed.
ii) Depress input check switch (6). Then,

(A) flashes and value input window (B) is
displayed at the left top of the screen.
iii) Increase or decrease the displayed value
to the desired value with the move-up
switch (4) or move-down switch (5).
The clearance can be adjusted by 1 mm
in the range between 50 mm and 150
mm.
If move-up switch (4) or move-down
switch is held, the set value continues
changing by 10 mm.
iv) Input the desired OSS clearance and
depress input check switch (6) to settle it.
20-166 BR380JG-1
7) Lamp "|" of (C) goes off and the adjustment iv) When the crusher clearance reaches the
of the clearance is finished. desired OSS clearance set value (H), the
• In the automatic adjustment mode, the ad- automatic clearance adjustment is fin-
justment is executed in the following order. ished.
i) The swing jaw moves toward the fixed
jaw to eliminate the crusher clearance.
A t thi s tim e, mac hi ne mon ito r (E )
flashes.
k The value of the clearance of discharge set-

ting displayed on the monitor panel and the
clearance of discharge setting adjusted in
mode A (Automatic) may be different be-
ii) If the swing jaw touches the fixed jaw, the cause of wear and mounting condition of the
buzzer in the machine monitor sounds tooth plates. If certain accuracy is neces-
and crusher actual clearance monitor sary, measure the clearance and adjust it in
value (F) becomes 0. mode S (Semiautomatic) or M (Manual).
iii) The swing jaw moves in the direction to

increase the crusher clearance. While
the clearance is being increased, part
(G) of the machine monitor flashes.
BR380JG-1 20-167
Adjusting clearance in mode S (Semiautomatic)

1) Measure the current clearance of discharge
setting and calculate the difference between
it and the target clearance.

in position S (Semiautomatic).
6) Check that clearance adjustment monitor

(D) of the machine monitor is in mode S
(Semiautomatic) and input value (A) to be
3) Set the fuel control dial (1) in low idling posi- changed from the current clearance to the
tion (a). machine monitor according to the following
procedure.
i) Move the cursor in the screen to posi-
tion (A) with move-up switch (4) and
move-down switch (5).

(c)" position. The machine monitor changes
to the ordinary testing screen.
ii) Depress input check switch (6). Then,

(A) flashes and value input window (B) is
displayed at the left top of the screen.
20-168 BR380JG-1
iii) Increase or decrease the displayed value Adjusting clearance in mode M (Manual)
to the desired value with the move-up 1) Measure the current clearance of discharge
switch (4) or move-down switch (5). setting and calculate the difference between
The total of the current clearance and it and the target clearance.
the set value can be adjusted by 1 mm
in the range between 50 mm and 150
mm.
Display of + : Adjustment to increase
clearance
Display of – : Adjustment to decrease
clearance
If move-up switch (4) or move-down
switch (5) is held, the set value contin-
ues changing by 10 mm.
iv) Input the set value and depress input
check switch (6) to settle it.
7) Execution of adjustment of clearance

i) Move the cursor in the screen to posi-
tion (C) with move-up switch (4) and
move-down switch (5). 3) Set the fuel control dial (1) in low idling posi-
ii) Depress input check switch (6) to finish tion (a).
preparation, and lamp "|" of (C) flashes.
iii) Depress input check switch (6) again to
execute adjustment, and lamp "|" lights
up.
8) Lamp "|" of (C) goes off and the adjustment
of the clearance is finished.

(c)" position. The machine monitor changes
to the ordinary testing screen.
BR380JG-1 20-169
a As the machine is operated, the teeth are

worn and the value of clearance monitor (A)
becomes different from the actual clearance.
In this case, hold crusher clearance de-
crease switch (4) to touch the swing jaw to
the fixed jaw and correct the value. If the
jaws are kept in contact with each other, the
buzzer sounds and the correction is complet-
ed. Then, check that the value of (A) is cor-
rected.
2. Check for wear

1) Fixed jaw and swing jaw
• Hatched part: Simulated worn range
If the lower teeth of the fixed jaw and swing
in position M (Manual).
jaw are worn to the wear limit, turn over or
replace the tooth plates.
• Wear limit A of fixed jaw: 55 mm (Thick-
ness from mounting face)
• Wear limit B of swing jaw: 60 mm (Thick-
ness from mounting face)
6) Check that clearance adjustment monitor

(D) of the machine monitor is in mode M
(Manual).
7) Using crusher clearance decrease switch
(4) and crusher clearance increase switch
(5), adjust the value of crusher actual clear-
2) Cheek plate
ance monitor (A) to the target value.
When the remaining thickness on the upper
(4) Crusher clearance decrease switch
side of the cheek plate becomes about 15
While this switch is pressed, the clear-
mm (Wear: 10 mm) and that on the lower
ance is decreased continuously.
side becomes about 10 mm (Wear: 15 mm),
(5) Crusher clearance increase switch
replace the cheek plate.
While this switch is pressed, the clear-
ance is increased continuously.
20-170 BR380JG-1
3) Protector 6) Toggle plate

When the remaining thickness of the protec- When the toggle plate is worn by about 5
tor becomes about 10 mm (Wear: 10 mm), mm, replace it. When it is worn unevenly as
replace the protector. (When the protector shown in the figure, replace it, too.
is worn unevenly, replace it, too.)
(A) Wear: 10 mm
(B) Thickness of protector: 19 mm
• When replacing toggle plate (6), replace

its dust cover, too.
• When toggle plate (6) rolls on toggle
4) Swing jaw wedge seat (5), it makes sounds, which have no
When remaining width (A) on the lower side effects on the machine. If toggle plate
of the wedge becomes about 79 mm (Wear makes hitting sounds, however, check to
(B): 10 mm), replace the wedge. (When the see if set length C of tension spring (7) is
wedge is worn unevenly, replace it, too.) in the standard range.
• Set length C: 260 mm
5) Toggle seat
When the toggle seat is worn by about 5
mm, replace it.
(A) Wear: 5 mm
(B) 50 mm
(C) 30 mm
BR380JG-1 20-171
TESTING AND ADJUSTING TESTING AND ADJUSTING CRUSHER DRIVE BELT TENSION
TESTING AND ADJUSTING CRUSHER DRIVE BELT TENSION

a Measuring instrument for belt tension 3. Adjusting belt tension
Loosen locknut (3) and rotate turnbuckle (2) to
Mark Part No. Part Name adjust the belt tension.
R 8242-70-5F40 Tension meter
4. After adjusting the belt tension to the standard
value with turnbuckle (2), tighten locknut (3).
1. Remove the bolts of crusher inspection cover (1)
on the left side of the operator's seat and open
the cover.
2. Testing belt tension
Tension load P per V-belt: N {kg}

Deflection
a:mm When belt is new After test
or replaced operation
15 68.6 {7.0} 53.9 {5.5}
• The test operation means to start and stop the

crusher 2 – 5 times.
20-172 BR380JG-1
TESTING AND ADJUSTING TESTING AND ADJUSTING PRIMARY BELT CONVEYOR
TESTING AND ADJUSTING PRIMARY BELT CONVEYOR

k Before checking and cleaning the conveyor and 3. Adjusting scraper
around it, be sure to stop the conveyor so that 1) Drive pulley side
you will not be rolled in a rotary part. Fit the tip of belt cleaner (6) to belt (7) with
adjustment bolt (8). (Standard clearance: 0
1. Testing and adjusting winding of belt mm)
k When turning the adjustment bolt, stop the
engine.
If the belts winds, turn adjustment bolt (1) to
adjust the tension of the right and left sides.
When turning the adjustment bolt, remove lock
plate (2). After adjusting, be sure to return the
lock plate.
Install the belt cleaner at right angles to the

belt surface.
2. Adjusting conveyor side rubber

When conveyor side rubber (3) is worn and
there is clearance between it and belt (4),
loosen adjustment screw (5) and adjust the
position of the conveyor side rubber. (Standard
clearance: 0 mm (Fitted))
2) Driven pulley side

If scraper rubber (9) is worn, loosen mount-
ing bolts (10) and replace scraper rubber
(9). (Make the scraper rubber touch the belt
evenly over the belt width.)
BR380JG-1 20-173
TESTING AND ADJUSTING TESTING AND ADJUSTING MAGNETIC SEPARATOR
TESTING AND ADJUSTING MAGNETIC SEPARATOR

k Do not carry a precision instrument such as a 1) When belt deviates or winds
wristwatch, an instrument, etc. with you near the Adjust the position of the take-up unit. The
magnetic separator. If you approach the mag- take-up unit consists of the base plate, pil-
netic separator, taking a piece of steel with you, low block, and push bolt. Loosen the base
the steel is attracted by the magnetic separator, plate fixing bolt and adjust the push bolt.
and that is very dangerous. After adjusting, tighten the fixing bolt again.
k A person who uses a pacemaker must not ap- When the belt is positioned properly, there is
proach the magnetic separator, since the pace- a clearance of at least 10 mm from the
maker can malfunction near the magnetic inside of the flange on each pulley side.
separator.
k Do not approach the magnetic separator, carry-
ing a credit card, etc. with you, since the data in
the card can be broken.
k During the test operation, be sure to run the mo-
tor at low speed and see if the belt winds.
k If a piece of steel is attracted by the magnetic
separator, it is accelerated and discharged by
the steel discharge belt and it becomes danger-
ous. Accordingly, install a safety cover to the
discharge section to prevent pieces of steel
from scattering.
The discharge belt of this machine has the same

structure as a common belt conveyor. Check the fol- 2) When belt tension is not proper
lowing points before starting the operation and dur- Adjust the belt tension, similarly to the devi-
ing the daily inspection. ation, so that the clearance between the
• Is the belt shifted to either side or does it wind? underside of the magnet and the belt will be
• Is the belt tension proper? 30 - 40 mm.
• Is there foreign matter on the back side of the
belt?
• Is the belt surface scratched or peeled?
• Is the belt scraper damaged?
• Are the fittings or bolts at the belt end joints dam-
aged or removed?
If abnormality is detected by the inspection, take the
following remedies.
3) When there is foreign matter on reverse

side of belt
When there is foreign matter on the reverse
side of the belt, remove it immediately since
it can damage the belt and pulleys.
20-174 BR380JG-1
TESTING AND ADJUSTING TESTING AND ADJUSTING MAGNETIC SEPARATOR
4) When belt or another part is damaged

When the belt or another part is damaged,
replace it immediately.
5) Adjustment of conveyor clearance

• Set the belt conveyor and magnet in par-
allel.
• Standard clearance between belt of belt
conveyor and magnet a: 350 mm
Change the clearance properly accord-
ing to the clearance of discharge setting
and operating condition.
BR380JG-1 20-175
TESTING AND ADJUSTING LIST OF COMPANIES WHICH HANDLES RADIO CONTROLLERS
LIST OF COMPANIES WHICH HANDLES RADIO CONTROLLERS

Area Company name Address
Yamada Bldg., Honjo 2-3-12, Matsumoto-shi,
Nagano-ken
Japan (Japan and Asia) Hetronic Japan
Tel: 0263-38-7403
Fax: 0263-38-7404
Abalbert-Stifter-Sir. 2
D-84085 Langquaid, Germany
Europe (all European countries) Hetronic Steuesysteme GmbH
Tel: +49 9452-1890
Fax: +49 9452-189-20
P.O.Box 619 Unit 4/11 Durie Road
Cardiff NSW 2285, Newcastle, Australia
Australia (Australia) Hetronic Australia
Tel: +61 249-537931
Fax: +61 249-537932
4300 Highline Blvd. Building A
Oklahoma City, OK 73108 USA
USA (North & South America) Hetronic USA Inc.
Tel: +1 405-946-3574
Fax: +1 405-946-3574
Mosta Technopark, Factory F15B
MT-MST02 Mosta, Malta
Mediteranean and Middle East Hetronic Malta Ltd.
Tel: +356-436214
Fax: +356-435057
20-176 BR380JG-1
PREPARATION WORK FOR TROUBLESHOOT-
TESTING AND ADJUSTING ING FOR ELECTRICAL SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR

ELECTRICAL SYSTEM
a When carrying out troubleshooting for an elec- 2. Engine throttle and pump controller
tric circuit related to the monitor panel, engine Insert or connect test T-adapters to connectors
throttle and pump controller, expose the related C1, C2, and C3 of engine throttle and pump
connectors according to the following proce- controller (3).
dure. a Since the connectors are fixed with screws,
a Since the monitor panel, engine throttle and loosen those screws before disconnecting
pump controller are installed inside main panel the connectors.
(1), remove the 6 main panel mounting screws a When returning the connectors, tighten the
3 Screw: 2.82 Nm {0.288 kgm}

and open the main panel first. screws to the specified torque.
1. Monitor panel
Insert or connect test T-adapters to connectors
P1, P2, and P3 of monitor panel (2).
BR380JG-1 20-177
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING ................................................................... 20-215
TYPES AND LOCATIONS OF CONNECTORS.......................................................................................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-248
T-BRANCH BOX AND T-BRANCH TABLE ................................................................................................. 20-268
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND
FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED............................................................ 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-401
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-501
TROUBLESHOOTING OF ENGINE (S-MODE) ......................................................................................... 20-601
BR380JG-1 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait
for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form some
idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4. Confirming the failure.

to disassemble the components. • Confirm the extent of the failure yourself, and
If components are disassembled immediately judge whether to handle it as a real failure or
after a failure occurs: as a problem with the method of operation,
• Parts that have no connection with the failure etc.
or other unnecessary parts will be disassem- a When operating the machine to re-enact
bled. the troubleshooting symptoms, do not
• It will become impossible to find the cause of carry out any investigation or measure-
the failure. ment that may make the problem worse.
It will also cause a waste of man hours, parts, or
oil and grease. At the same time, it will also lose 5. Troubleshooting
the confidence of the user or operator. For this • Use the results of the investigation and in-
reason, when carrying out troubleshooting, it is spection in Steps 2 - 4 to narrow down the
necessary to carry out thorough prior investiga- causes of the failure, then use the trouble-
tion and to carry out troubleshooting in accor- shooting flowchart to locate the position of
dance with the fixed procedure. the failure exactly.
a The basic procedure for troubleshooting
2. Points to ask the user or operator. is as follows.
1) Have any other problems occurred apart 1) Start from the simple points.
from the problem that has been reported? 2) Start from the most likely points.
2) Was there anything strange about the 3) Investigate other related parts or
machine before the failure occurred? information.
3) Did the failure occur suddenly, or were there
problems with the machine condition before 6. Measures to remove root cause of failure.
this? • Even if the failure is repaired, if the root
4) Under what conditions did the failure occur? cause of the failure is not repaired, the same
5) Had any repairs been carried out before the failure will occur again.
failure? When were these repairs carried To prevent this, always investigate why the
out? problem occurred. Then, remove the root
6) Has the same kind of failure occurred before? cause.
3. Check before troubleshooting.

1) Check the oil level.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
5) Other maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
20-202 BR380JG-1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
BR380JG-1 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on 'Handling electric equipment' and 'Handling hydraulic
equipment' (particularly hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connect-
ing one component to another component,
connectors used for connecting and discon-
necting one wire from another wire, and pro-
tector or tubes used for protecting the
wiring.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses
are more likely to be affected by the direct
effects of rain, water, heat, or vibration. Fur-
thermore, during inspection and repair oper-
ations they are frequently removed and
installed again, so they are likely to suffer
deformation or damage. For this reason, it is
necessary to be extremely careful when
handling wiring harnesses.
Main failures occurring in wiring harness

i) Faulty contact of connectors (faulty con-
tact between male and female).
Problems with faulty contact are likely to
occur because the male connector is
not properly inserted into the female
connector, or because one or both of
the connectors is deformed or the posi-
tion is not correctly aligned, or because
there is corrosion or oxidation of the
contact surfaces.
ii) Defective compression or soldering of

connectors
The pins of the male and female con-
nectors are in contact at the com-
pressed terminal or soldered portion,
but there is excessive force on the wir-
ing, and the plating peels to cause
improper connection or breakage.
20-204 BR380JG-1
iii) Disconnections in wiring

If the wiring is held and tugged and the
connectors are pulled apart, or compo-
nents are lifted with a crane with the wir-
ing still connected, or a heavy object
hits the wiring, the crimping compres-
sion of the connectors to the wire may
be loosened, or the soldering may be
damaged, or the wiring may be broken.
iv) High pressure water entering a connec-

tor
The connector is designed to make it
difficult for water to enter (drip-proof
structure), but if high-pressure water is
sprayed directly on the connector, water
may enter the connector depending on
the direction of the water jet. The con-
nector is designed to prevent water from
entering, but if water does enter, it is dif-
ficult for it to be drained. Therefore, if
water should get into the connector, the
pins will be short-circuited by the water,
so if any water gets in, immediately dry
the connector or take other appropriate
action before passing electricity through
it.
v) Oil, grease or dirt stuck to connector

If oil or grease are stuck to the connec-
tor and an oil film is formed on the mat-
ing surface between the male and
female pins, the oil will not let the elec-
tricity pass, and this will cause a defec-
tive contact.
If there is oil or grease or dirt stuck to
the connector, wipe it off with a dry cloth
or blow dry with air, and spray it with a
contact restorer.
a When wiping the mating portion of
the connector, be careful not to use
excessive force or deform the pins.
a If there is water or oil present, it will
increase the contamination of the
points, so clean with air until all wa-
ter and oil has been removed.
BR380JG-1 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
i) Hold the connectors when disconnect-
ing. When disconnecting the connec-
tors, hold the connectors and not the
wires. For connectors held by a screw,
loosen the screw fully, then hold the
male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never try to pull apart with one hand.
ii) When removing from clips

When removing the connectors from the
clips, pull the connector in a parallel
direction to the clip.
a If the connector is twisted to the left
and right or up and down, the hous-
ing may break.
iii) Action to take after removing connec-

tors.
After removing any connector, cover it
with a vinyl bag to prevent any dust, dirt,
oil, or water from getting in the connec-
tor portion.
a If the machine is left for a long time,
it is particularly easy for improper
contact to occur, so always cover
the connector.
20-206 BR380JG-1
• Connecting connectors
i) Check the connector visually.
1) Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
2) Check that there is no deformation,
faulty contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt stuck
to the connector, wipe it off with a
dry cloth. If any water has gotten in-
side the connector, warm the inside
of the wiring with a dryer, but be
careful not to make it too hot as this
will cause short circuits.
a If there is any damage or breakage,
replace the connector.
ii) Assemble the connector securely.

Align the position of the connector cor-
rectly, then insert it securely.
For connectors with a lock stopper:
Push in the connector until the stopper
clicks into position.
iii) Correct any protrusion of the boot and

any misalignment of the wiring harness.
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if
the wiring harness is misaligned, or the
clamp is out of position, adjust it to its
correct position.
a When blowing with dry air, there is
danger that the oil in the air may
cause improper contact, so clean
with properly filtered air.
iv) If the connector clamp has been

removed, be sure to return it to its origi-
nal position. Check also that there are
no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type
connectors have 2 latches respectively,
push them in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizonal) : a, b, d
• Incomplete locking state (Diagonal) : c
BR380JG-1 20-207
• Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do not
use high pressure water or steam directly on
the wiring harness.
If water gets directly on the connector, do as

follows:
i) Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with air,
there is the risk that oil in the air may
cause a faulty contact, so avoid
blowing with air.
ii) Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used,
but be careful not to make the con-
nector or related parts too hot, as
this will cause deformation or dam-
age to the connector.
iii) Carry out a continuity test on the con-

nector.
After drying, leave the wiring harness
disconnected and carry out a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connec-
tor, spray it with contact restorer and
reassemble.
20-208 BR380JG-1
3) Handling control box

i) The control box contains a microcom-
puter and electronic control circuits.
This controls all of the electronic circuits
on the machine, so be extremely careful
when handling the control box.
ii) Do not open the cover of the control box
unless necessary.
iii) Do not place objects on top of the con-

trol box.
iv) Cover the control connectors with tape
or a vinyl bag.
Never touch the connector contacts with
your hand.
v) Do not leave the control box in a place
where it is exposed to rain.
vi) Do not place the control box on oil,

water, or soil, or in any hot place, even
for a short time.
(Place it on a suitable dry stand)
vii) Precautions when carrying out arc weld-
ing
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the control box. Fit
an arc welding ground close to the weld-
ing point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in the circuit.
BR380JG-1 20-209
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of
hydraulic equipment, the most common cause
of failure is dirt (foreign material) in the hydraulic
circuit. When adding hydraulic oil, or when dis-
assembling or assembling hydraulic equipment,
it is necessary to be particularly careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters,
or repairing the machine in rain or high
winds, or places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is car-
ried out on hydraulic equipment in the field,
there is danger of dust entering the equip-
ment. It is also difficult to confirm the perfor-
mance after repairs, so it is desirable to use
unit exchange. Disassembly and mainte-
nance of hydraulic equipment should be car-
ried out in a specially prepared dust proof
workshop, and the performance should be
confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed,
the openings should be sealed with caps,
tape, or vinyl bags to prevent any dirt or dust
from entering. Never leave any openings
opened or blocked with a rag, this could
cause particles or dirt to get into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper
environmental regulation for any disposal of
oil.
4) Do not let any dirt, or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in
when refilling with hydraulic oil. Always keep
the oil filler and the area around it clean, and
also use clean pumps and oil containers. If
an oil cleaning device is used, it is possible
to filter out the dirt that has collected during
storage, so this is an even more effective
method.
20-210 BR380JG-1
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it
flows easily. In addition, the sludge can also
be dr ained out easily from the circuit
together with the oil, so it is best to change
the oil when it is still warm. When changing
the oil, as much as possible of the old
hydraulic oil must be drained out. (Do not
drain the oil from the hydraulic tank; but
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6) Flushing operations
After disassembling and assembling the
equipment, or changing the oil, use flushing
oil to remove the contaminants, sludge, and
old oil from the hydraulic circuit.
Normally, flushing is carried out twice: pri-
mary flushing is carried out with flushing oil,
and secondary flushing is carried out with
the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running
the machine, carry out oil cleaning to
remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to
remove the ultra fine (about 3µ) particles
that the filter built into the hydraulic equip-
ment cannot remove, so it is an extremely
effective device.
BR380JG-1 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

1. Chasis
Judgement
Item Action
Value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricat- 4. Check hydraulic oil strainer — Clean, drain
ing oil,
coolant 5. Check engine oil level (oil pan oil level) — Add oil
6. Check coolant level — Add water
7. Check dust indicator for clogging — Clean or replace
8. Check hydraulic filtering — Replace
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
equipment
3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
Hydraulic, 1. Check for abnormal noise, smell — Repair
mechani-
2. Check for oil leakage — Repair
cal
equipment 3. Carry out air bleeding — Bleed air
1. Check battery voltage (Engine stopped) 20 – 30 V Replace
2. Check battery electrolyte level — Add or replace
3. Check for discolored, burnt, exposed wiring — Replace
4. Check for missing wiring clamps, hanging wire — Repair
5. Check for water leaking on wiring (Pay particular attention to Disconnect
Electrical —
water leaking on connectors or terminals) connector and dry
equipment
6. Check for blown, corroded fuses — Replace
After running for
7. Check alternator voltage (Engine running at 1/2 throttle or
several minutes: Replace
above)
27.5 – 29.5 V
8. Check operating sound of battery relay (When starting switch is
—
turned ON, OFF)
20-212 BR380JG-1
2. Inspection items related to crusher

Inspection interval
No. Inspection item Every Every Every Method Standard value Remedy against trouble
day week month
Abnormal vibration of Visual Stop and inspect. Retighten tooth
1 Q —
chassis inspection plate mounting bolts.
2 Abnormal sound Q Listening — Stop and inspect.
Check for abnormal supply.
Flow of processed Visual Restrict supply rate and adjust
3 Q —
material inspection quantity supplied to grizzly
feeder.
Outside tem- If temperature is abnormally
Abnormal heating of
4 Q Feeling perature + high, stop and inspect. Adjust oil
bearing
40°C leakage properly.
Abnormal sound from If there is abnormality, stop and
5 Q Listening Not detected
bearing inspect. Repair or replace.
Looseness of Must not be
6 Q Spanner Retighten.
foundation bolt loosened.
Visual
7 Wear of fixed jaw Q — Turn over or replace.
inspection
Visual
8 Wear of swing jaw Q — Turn over or replace.
inspection
Visual
9 Wear of cheek plate Q — Replace
inspection
Visual
10 Wear of protector Q — Replace
inspection
11 Supply of grease Q Grease gun — Refilling
BR380JG-1 20-213
3. Belt conveyor
Problems with the conveyor caused by the method of daily handling and improper maintenance are frequently
problems that could have been prevented . Simple check will extend the life of the conveyor and enable it to
show its ability to the full.
20-214 BR380JG-1
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
Code display
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
(Engine) Troubleshooting of engine assembly (refer to the shop manual for engine in 102 series)
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
BR380JG-1 20-215
Phenomena considered to be failures and troubleshooting Nos.

Troubleshooting
No. Phenomena considered to be failures Indication
E-mode H-mode (Engine)
of code
Phenomena related to user code, error code, or failure code
1 User code is displayed on monitor panel
Accord-
When failure history is checked, error code is displayed in electrical
2 ing to
system
indicated
When failure history is checked, error code is displayed in mechanical code
3
system
Phenomena related to engine
4 Engine does not start easily (It always takes time to start) S-1
5 Engine does not crank E-1 S-2 (1)
Engine does
6 Engine cranks but exhaust smoke does not come out S-2 (2)
not start
7 Exhaust smoke comes out but engine does not start S-2 (3)
8 Engine speed does not rise sharply (Follow-up performance is low) S-3
9 Engine stops during operation E-2 H-2 S-4
10 Engine rotation is unstable (Engine hunts) E-3 S-5
11 Output is insufficient (Power is low) H-1 S-6
12 Exhaust gas color is bad (Incomplete combustion) S-7
13 Oil is consumed much or exhaust gas color is bad S-8
14 Oil becomes dirty quickly S-9
15 Fuel is consumed much S-10
16 Coolant contains oil, blows back, or reduces S-11
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Abnormal sound comes out S-15
19 Vibration is excessive S-16
20 Engine does not stop E-4
21 All work equipment stops suddenly E-5
22 Automatic warm-up function does not work E-6
23 The engine preheater does not operate E-7
Phenomena related to work equipment, swing, and travel
24 Speed or power of whole work equipment and travel is low H-1 S-6
25 Engine speed lowers extremely or engine stalls H-2 S-4
26 Work equipment and travel systems do not work H-3
27 Abnormal sound comes out from around hydraulic pump H-4
28 Fine control performance or response is low H-5
Phenomena related to work equipment
29 Conveyor does not operate H-6
30 Speed or power of conveyor is low H-7
31 Crusher does not operate H-8
32 Speed or power of crusher is low H-9
33 Feeder does not operate H-10
34 Feeder does not feed smoothly (Vibration frequency is low) H-11
35 Magnetic separator does not operate H-12
20-216 BR380JG-1
Troubleshooting
No. Phenomena considered to be failures Indication
E-mode H-mode (Engine)
of code
36 Speed of magnetic separator belt is low H-13
37 Side conveyor does not operate H-14
38 Speed or power of side conveyor is low H-15
39 Primary conveyor and side conveyor do not move up and down H-16
40 Feeder cannot be turned ON and OFF by radio control E-19
41 Crusher cannot be turned ON and OFF by radio control E-20
42 Rotating direction cannot be changed by radio control E-17
Phenomena related to travel
43 Machine deviates during travel H-17
44 Travel speed is low H-18
45 Machine is not steered well or steering power is low H-19
46 Travel motor does not work (only 1 side) H-20
When travel switch of radio controller is depressed, machine does not
47 E-18 H-21
travel
Phenomena related to monitor panel (Operator menu: Ordinary screen)
48 Red mark of emergency stop is indicated just after engine is started E-8
49 No items are displayed on monitor panel E-9
50 Some items are not displayed on monitor panel E-10
51 Radiator coolant level monitor lights red during check before starting B@BCZK
52 Engine oil level monitor lights red during check before starting B@BAZK
53 Maintenance hour monitor lights red during check before starting Refer to Operation & Maintenance Manual
54 Battery charge level monitor lights red while engine is running AB00K
55 Fuel level monitor lights red while engine is running E-11
56 Air cleaner clogging monitor lights red while engine is running AA10NX
57 Engine coolant temperature monitor lights red while engine is running B@BCNS
58 Hydraulic oil temperature monitor lights red while engine is running B@HANS
59 Engine coolant temperature gauge does not display normally E-12
60 Fuel level gauge does not display normally E-13
61 Hydraulic oil temperature gauge does not display normally E-14
62 Travel, work, and inspection modes do not change E-15
63 Crusher clearance adjustment mode does not change E-16
64 When switches on monitor are operated, nothing is displayed E-21
Phenomena related to monitor panel (Service menu: Special function screen)
Crusher cannot be operated with crusher manual forward/reverse
65 E-22
switch on monitor
Conveyor cannot be operated with conveyor manual forward/reverse
66 E-23
switch on monitor
Crusher clearance cannot be adjusted with crusher clearance
67 H-22
increase/decrease switch on monitor
BR380JG-1 20-217
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

a The addresses in the following table are the addresses used in the connector arrangement drawings and
each failure mode circuit diagram.
Address
Con- No.
nector Type of Name of device Arrange-
No. pins ment M-circuit G-circuit W-circuit
drawing
Intermediate connector
A1 DT(Gray) 12 B-6, BE-5 K-7
(EPC valve, pressure switch)
A2 DT(Black) 12 Intermediate connector (Solenoid) C-6, BE-5 E-7 E-7 K-7
A3 DT(Black) 12 C-6, BE-5 E-6 E-6 K-6
(Pressure sensor, potentiometer)
A4 DT(Green) 8 C-6, BE-5 E-6 K-6
(Belt conveyor control box)
A5 DT(Green) 12 Intermediate connector D-6, BF-5 E-6 E-6
A6 DT(Brown) 12 Intermediate connector E-6, BF-5 E-5 E-5
A7 DT(Gray) 8 Intermediate connector E-6, BF-5 E-4 E-4 K-5
A8 DT(Black) 8 Intermediate connector F-6, BF-5 E-4 E-4 K-5, S-8
A9 L 2 Intermediate connector (Battery relay) F-6, BG-5 E-3 E-3
A10A DT(Gray) 12 AN-1, BY-1 N-2, V-3
(Belt conveyor control box)
A10B DT(Black) 8 Intermediate connector (Side conveyor) AT-8, BZ-6 N-2, W-3
A11 DT 6 Intermediate connector (Travel box) L-7 G-2 O-2
A12 M 1 Headlamp (Right) K-8 K-9
One-pin
A13 1 Travel alarm T-7
connector
A14 YAZAKI 2 Horn (High tone) U-7 K-9
A15 YAZAKI 2 Horn (Low tone) R-4 K-9
A16 X 2 Feeder lamp (Red) I-8 R-8
A17 M 1 Rear lamp AK-9 K-8
A18 SWP 6 BK-1 K-3, S-3
(Addition of attachment)
A19 DT(Gray) 12 Intermediate connector (Network path) BQ-4
A20 DT(Green) 8 BE-5 K-3, S-9
(Connection of radio controller)
A21 DT 6 BG-5 K-2, S-1
(Addition of attachment)
A22 DT 3 Intermediate connector (Over-feed sensor) BD-5
A23 DT(Black) 12 BD-5 H-1
(Connection of remote controller)
A24 X 4 Model selector BQ-4 C-1
A25 DT 4 B-6 P-5
(Conveyor elevator solenoid)
A26 DT 2 BD-5 K-2, S-4
(Water sprinkler power supply)
One-pin
A27 1 Control box lamp BK-5 B-9
connector
20-218 BR380JG-1
Address
Con- No.
drawing
Cigarette lighter power supply
A28 Connector 1 CB-4 V-5
(If equipped)
A29 KES 1 2 Resistor of rotary lamp BQ-5 G-1
A30 KES 1 2 Resistor of rotary lamp BQ-5 H-1
A31 Connector 1 Cigarette lighter ground (If equipped) CB-4 V-5
A32 X 2 Radio control lamp (If equipped) CC-9 U-7
A33 HAN24E 24 Radio controller (If equipped) CB-1 W-7
A34 DT 4 Centralized connector (Emergency stop) A-6 M-2
A35 M 1 Headlamp (Left) G-7 K-8
Centralized connector
A36 DT 6 A-6 P-2
(Emergency stop switch)
Intermediate connector (Side conveyor
A37 DT 6 BZ-1 W-2
emergency stop switch, if equipped)
Intermediate connector (Side conveyor
A38 DT 6 BV-2 W-1
One-pin
A39 1 Magnetic separator used/unused sensor BJ-3 B-5
connector
A40 DT 2 Additional power supply BD-5 K-2, U-5
Centralized connector (Side conveyor
A41 DT 4 BU-4 V-2
A42 DT(Black) 8 Centralized resistor connector BJ-4 H-1
A50 X 4 Download connector BR-3 D-1
One-pin
A51 1 Box lamp K-8
connector
AV1 DT 2 Solenoid (Straight travel, 2-stage relief) U-6 O-8
AV2 DT 2 Solenoid (Lock cylinder reset) U-6 N-8
AV3 DT 2 Solenoid (Side conveyor) U-6 O-8
AV4 DT 2 Solenoid (Magnetic separator) U-6 O-8
AV5 DT 2 Solenoid (Travel lock) U-5 N-8
B1 IZUMI 6 Switch (Primary conveyor ON) BM-3 B-8
B2 IZUMI 6 Switch (Primary conveyor OFF) BJ-3 C-8
B3 IZUMI 6 Switch (Crusher ON) BL-1 C-8
B4 IZUMI 6 Switch (Crusher OFF) BJ-1 D-8
B5 IZUMI 6 Switch (Feeder ON) BL-1 D-8
B6 IZUMI 6 Switch (Feeder OFF) BK-1 D-8
B7 IZUMI 6 Switch (Side conveyor ON) BJ-3 E-8
B8 IZUMI 6 Switch (Side conveyor OFF) BJ-3 E-8
B9 IZUMI 6 Switch (Magnetic separator ON) BJ-3 F-8
B10 IZUMI 6 Switch (Magnetic separator OFF) BJ-3 F-8
B11 IZUMI 6 Switch (Horn) BM-5
B12 IZUMI 6 Switch (Emergency stop) BM-4 G-8
B13 KES 1 4 Switch (Mode selector) BM-3 G-8
B14 KES 1 4 Switch (Light) BM-4 C-9
BR380JG-1 20-219
Address
Con- No.
drawing
B15 KES 1 4 Switch (Crusher forward/reverse selector) BK-5 H-8
B16 IZUMI 6 Switch (Engine stop) K-8 N-1
B17 IZUMI 6 Switch (Horn) L-7 G-1
B18 IZUMI 6 Switch (Travel Hi/Lo selector) L-7 O-1
B19 IZUMI 6 Switch (Emergency stop, right side) R-3 P-1
B20 IZUMI 6 Switch (Emergency stop, right side) H-7 P-1
B21 IZUMI 6 Switch (Conveyor raise) AM-4 M-1, U-1
B22 IZUMI 6 Switch (Conveyor lower) AM-3 N-1, U-1
B23 IZUMI 6 Switch (Emergency stop) (If equipped) BY-3 X-1
B24 IZUMI 6 Switch (Emergency stop) (If equipped) BW-4 X-1
Switch (Secondary conveyor ON)
B25 IZUMI 6 BJ-2 T-3
(If equipped)
Switch (Secondary conveyor OFF)
(If equipped)
B27 IZUMI 6 Switch (Vibratory screen ON) (If equipped) BJ-2 T-3
B28 — — Fuse box BO-5 E-8 E-8 J-8
Switch (Conveyor raise/lower selector)
B29 IZUMI 6 BU-4 V-1
(If equipped)
B30 IZUMI 6 Switch (Emergency stop) G-3 P-1, T-5
B31 IZUMI 6 Switch (Emergency stop) G-4 Q-1
B32 IZUMI 6 Switch (One-touch start) BK-5 B-1
B33 IZUMI 6 Switch (One-touch stop) BJ-5 B-1
B34 IZUMI 6 Switch (Emergency stop) (If equipped) BU-5 V-1
Switch (Vibratory screen OFF)
(If equipped)
B50 KES 1 6 Switch (Radio control selector) BL-1, CB-4 H-8
B51 DT 2 Switch (Water sprinkler) BM-1 F-1
Clearance adjustment mode selector
B52 KES 1 4 BM-2 H-8
switch
B53 IZUMI 6 Switch (Safety lock) AQ-9 M-1
B54 IZUMI 6 Switch (Emergency stop) AM-3 N-1
C1 DRC26 24 Engine throttle and pump controller BJ-6 A-4 A-5 A-7
C4 DT 3 CAN terminal resistor BR-3 B-1 B-1
D01 SWP 8 Assembled-type diode BJ-4 D-8 D-9
D02 SWP 8 Assembled-type diode BJ-4 B-9
D5 KES 1 2 Diode (If equipped) BU-4
D6 KES 1 2 Diode (Travel lock) BP-5
D7 KES 1 2 Diode (Straight travel, 2-stage relief) BP-5
D10 SWP 8 Assembled-type diode (If equipped) CF-3 V-9
D11 SWP 8 Assembled-type diode (If equipped) CF-4 U-9
20-220 BR380JG-1
Address
Con- No.
drawing
D12 SWP 8 Assembled-type diode (If equipped) CE-4 S-9
D13 KES 1 2 Diode BQ-9 I-1
D14 KES 1 2 Diode (Magnetic separator-ON switch) BM-4 I-1
D15 KES 1 2 Diode BL-5 I-1
D16 KES 1 2 Diode BL-5 C-1
D17 KES 1 2 Diode BL-5 C-1
E1 DT 1 Starting motor (C) AC-6 K-5 K-5
E2 M 2 Fusible link (30 A) A-2 L-2 L-2
E3 DT 2 Switch (Engine oil level) AB-1 K-7
E4 DT 2 Sensor (Engine coolant temperature) AH-6 K-6
E5 Terminal 1 Switch (Engine oil pressure) AE-6 K-7
E6 DT 2 Sensor (Engine speed) AI-6 K-5
E7 L 2 Fusible link (65 A) A-3 L-2 L-2
E8 X 1 Intermediate connector (Alternator L) AB-6 K-4 K-4
E9 X 2 Relay (Starting motor S, R) F-2 J-4 J-4
E10 M 3 Fuel control dial BJ-4 C-9
E11 DT 4 Governor motor AI-6 K-6
E12 DT 3 Potentiometer (Governor) AJ-6 K-6
G01 DRC 40 KOMTRAX controller (If equipped) BR-7
G02 X 1 KOMTRAX test connector (If equipped) BO-7
J2 DT 6 Centralized connector (GND) T-4 H-9 P-9
J3 DT(Black) 8 Centralized connector (Power) T-4 H-9 Q-9
J4 DT(Black) 8 Centralized connector (GND) E-6 I-1 Q-1
J5 DT 6 Centralized connector D-6 G-1 O-1
M2 X 2 Alternator AC-6 L-4 L-4
One-pin
N20 1 Water sprinkler pump (If equipped) BV-4 T-5
connector
One-pin
N21 1 Water sprinkler pump (If equipped) BV-4 T-5
connector
P1 070 12 Monitor panel BM-3 A-7 A-7
P2 040 20 Monitor panel BM-3 A-7 A-7 A-7
P3 040 10 Monitor panel BM-3 A-5 A-6
P4 DT 3 CAN terminal resistor BT-9 B-1 B-1
R1 SHINAGAWA 5 Relay (Starting motor cutout) BP-1 C-1 C-1
R2 SHINAGAWA 5 Relay (Side conveyor interlock) BP-1 C-1
R3 SHINAGAWA 5 Relay (Travel alarm) BP-1 C-1
R4 SHINAGAWA 5 Relay (Horn) BP-1 C-1
R5 SHINAGAWA 5 Relay (Pressure abnormality stop) BP-1 D-1
BR380JG-1 20-221
Address
Con- No.
drawing
R6 SHINAGAWA 5 Relay (Side conveyor) BQ-1 D-1
R7 SHINAGAWA 5 Relay (Magnetic separator) BQ-1 E-1
R8 SHINAGAWA 5 Relay (Straight travel, 2-stage relief) BQ-1 E-1
R9 SHINAGAWA 6 Relay (Secondary conveyor) (If equipped) BR-1 S-3
R10 SHINAGAWA 6 Relay (Vibratory screen) (If equipped) BR-2 S-3
R11 OMRON 8 Relay (Red rotary lamp) BL-1 G-1
R12 SHINAGAWA 5 Relay (Water sprinkler) BQ-1 F-1
R13 SHINAGAWA 6 Relay (Lock cylinder extension) BR-1 G-1
Relay (Water sprinkler pump stop)
R20 SHINAGAWA 5 BU-4 S-5
(If equipped)
RR1 SHINAGAWA 5 Relay (Feeder OFF) (If equipped) CD-1 X-9
RR2 SHINAGAWA 5 Relay (Crusher OFF) (If equipped) CE-1 X-9
RR3 SHINAGAWA 5 Relay (Horn) (If equipped) CE-1 W-9
RR4 SHINAGAWA 5 Relay (Rotary lamp) (If equipped) CE-1 W-9
RR5 SHINAGAWA 5 Relay (Engine stop) (If equipped) CF-1 V-9
RR6 SHINAGAWA 5 Relay (Travel Lo) (If equipped) CF-2 V-9
RR7 SHINAGAWA 5 Relay (Left travel forward) (If equipped) CE-2 U-9
RR8 SHINAGAWA 5 Relay (Left travel reverse) (If equipped) CE-2 T-9
RR9 SHINAGAWA 5 Relay (Right travel forward) (If equipped) CE-2 T-9
RR10 SHINAGAWA 5 Relay (Right travel reverse) (If equipped) CD-2 T-9
S1 MA2 3 Pressure switch (Primary conveyor) V-4 P-9
S2 MA2 3 Pressure switch (Side conveyor) U-2 P-9
S3 MA2 3 Pressure switch (Magnetic separator) U-2 P-9
S4 X 2 Switch (Travel steering oil pressure) L-6 R-8
S5 X 2 Switch (Travel oil pressure) L-6 R-8
S6 MA2 3 Pressure switch (Secondary conveyor) U-3 T-1
S7 MA2 2 Pressure switch (Vibratory screen) U-3 T-1
S10 DT 3 Pressure switch (Rear pump) S-1 K-8
S11 DT 3 Pressure switch (Front pump) S-2 K-8
S12 DT 3 Potentiometer (Crusher clearance sensor) AI-6, AQ-1 Q-8
S13 DT 3 AI-7, AS-1 Q-8
(Crusher clearance sensor)
S14 X 1 Sensor (Fuel level) K-2 K-8
S15 DT 2 Switch (Air cleaner clogging) G-2 K-6
S16 X 2 Switch (Radiator coolant level) N-2 K-6
S17 DT 2 Sensor (Hydraulic oil temperature) AJ-1 K-5
Sensor (Side conveyor storage sensor)
S18 DT 3 BW-1 W-1
(If equipped)
Sensor (Water sprinkler pump float)
S45 DT 2 BV-4 S-5
(If equipped)
T1 Terminal 1 GND (Engine frame) AC-1
T2 Terminal 1 GND (Engine frame) AC-1
20-222 BR380JG-1
Address
Con- No.
drawing
T3 Terminal 1 Starting motor safety relay (B) D-5 K-4 K-4
T4 Terminal 1 Starting motor safety relay (C) C-5 K-3 K-3
T5 Terminal 1 Electrical intake air heater relay (Contact) A-2 K-3
T6 Terminal 1 Electrical intake air heater relay (Contact) A-4 K-3 K-3
T7 Terminal 1 Electrical intake air heater relay (Coil) A-3 K-3 K-3
T8 Terminal 1 Battery relay (E) F-3 K-3 K-2
T9 Terminal 1 Battery relay (M) F-3 K-3 K-2
T10 Terminal 1 Battery relay (BR) F-4 K-2 K-2
T11 Terminal 1 Battery relay (B) E-5 K-2 K-2
T12 Terminal 1 GND (Engine frame) W-1 N-7
T13 Terminal 1 GND (Engine frame) W-1 Q-4
T14 Terminal 1 GND (Engine frame) W-1 R-4
T15 Terminal 1 GND (Engine frame) C-1 R-8
T16 Terminal 1 GND (Engine frame) C-1 H-1 I-1 R-1
T17 Terminal 1 GND (Engine frame) D-1 H-1 I-1
T18 Terminal 1 GND (Engine frame) E-1 H-1 I-1
T19 Terminal 1 GND (Engine frame) (If equipped) X-1 T-1
T21 Terminal 1 GND (Engine frame) (If equipped) BZ-7 W-2
T22 Terminal 1 GN (Box lamp) BP-4 B-9
T23 Terminal 1 GND (Engine frame) V-1
T24 Terminal 1 GN (Box lamp) L-7
T25 Terminal 1 Electrical intake air heater AF-6 K-4
V1 X 2 EPC valve (Crusher reverse) U-5 M-8
V2 X 2 EPC valve (Crusher forward) U-5 M-8
V3 X 2 EPC valve (Feeder forward) U-5 M-8
V4 X 2 EPC valve (Accessory) U-5 N-8
V5 DT 2 EPC solenoid (Pump LS) AI-1 K-7
V6 DT 2 EPC solenoid (Pump PC) AI-1 K-7
Solenoid (Conveyor raise/lower selector)
V15 X 2 BX-9 X-3
(If equipped)
Solenoid (Conveyor raise/lower selector)
V16 X 2 BX-9 X-3
(If equipped)
Solenoid (Secondary conveyor)
V17 X 2 T-4 S-1
(If equipped)
V18 X 2 Solenoid (Vibratory screen) (If equipped) T-4 T-1
V20 X 2 Solenoid (Left travel forward) (If equipped) CA-5 S-7
V21 X 2 Solenoid (Left travel reverse) (If equipped) CA-6 S-6
Solenoid (Right travel forward)
V22 X 2 CA-7 S-6
(If equipped)
Solenoid (Right travel reverse)
V23 X 2 CA-7 S-6
(If equipped)
V7A X 2 Solenoid (Conveyor lower) U-6 Q-5
BR380JG-1 20-223
Address
Con- No.
drawing
V7B X 2 Solenoid (Conveyor raise) X-6 R-5
V8A X 2 Solenoid (Lock retraction) U-5 Q-5
V8B X 2 Solenoid (Lock extension) X-5 R-5
V9A X 2 Solenoid (Conveyor forward) U-5 Q-4
V9B X 2 Solenoid (Conveyor reverse) X-5 R-4
Type of connector Detailed information

D DT-type connector manufactured by NIHON DEUTSCH (08192-XXXXX)
L L-type connector manufactured by YAZAKI (08056-2XXXX)
M M-type connector manufactured by YAZAKI (08056-0XXXX)
SHINAGAWA Connector manufactured by SHINAGAWA JIDOSHA DENSEN
X X-type connector manufactured by YAZAKI (08055-0XXXX)
SWP SWP-type connector manufactured by YAZAKI (08055-1XXXX)
DRC DRC-type connector manufactured by NIHON DEUTSCH
040 040-type connector manufactured by NIHON AMP
070 070-type connector manufactured by NIHON AMP
YAZAKI Connector manufactured by YAZAKI
KES1 KES1-tyep connector (08027-1XXXX)
IZUMI MW9Z-C1-type connector manufactured by IZUMI DENKI
MA2 ECONOSEAL J MARK 2-type connector manufactured by NIHON AMP
OMRON PTF-08A-type connector manufactured by OMRON
HAN 24E Connector manufactured by HARTING
One-pin connector Round pin-type 1-pole connector
Terminal Round terminal or ordinary terminal
20-224 BR380JG-1
Connector arrangement drawing (1/7)
20-226 BR380JG-1
BR380JG-1 20-227
20-228 BR380JG-1
BR380JG-1 20-229
20-230 BR380JG-1
BR380JG-1 20-231
20-232 BR380JG-1
BR380JG-1 20-233
20-234 BR380JG-1
BR380JG-1 20-235
20-236 BR380JG-1
BR380JG-1 20-237
20-238 BR380JG-1
BR380JG-1 20-239
Circuit diagram of monitor panel system (M circuit)
20-240 BR380JG-1
a This circuit diagram is made by excerpting the monitor panel system, engine preheating/starting/charging
system, and night lighting system from the general electric circuit diagram.
BR380JG-1 20-241
Circuit diagram of governor control system of engine throttle and pump controller (G circuit)
20-242 BR380JG-1
a This circuit diagram is made by excerpting the engine throttle and pump controller system (power supply,
governor control, model selection, and communication) from the general electric circuit diagram.
BR380JG-1 20-243
Circuit diagram of work equipment control system of engine throttle and pump controller
(W circuit)
(1/4)
20-244 BR380JG-1
a This circuit diagram is made by excerpting the engine throttle and pump controller system (work equipment
control) from the general electric circuit diagram.
(2/4)
BR380JG-1 20-245
(3/4)
20-246 BR380JG-1
(4/4)
BR380JG-1 20-247
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-248 BR380JG-1
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
BR380JG-1 20-249
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-250 BR380JG-1
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
BR380JG-1 20-251
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-252 BR380JG-1
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
BR380JG-1 20-253
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
17 799-601-2730
21 799-601-2740
Terminal part No.: 79A-222-2770 (Q’ty: 50) Terminal part No.: 79A-222-2760 (Q’ty: 50) —
20-254 BR380JG-1
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
BR380JG-1 20-255
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
20-256 BR380JG-1
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
BR380JG-1 20-257
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
8 —
08027-10820 (Black) 08027-10870 (Black)
20-258 BR380JG-1
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
BR380JG-1 20-259
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-260 BR380JG-1

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
BR380JG-1 20-261

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-262 BR380JG-1

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
BR380JG-1 20-263

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-264 BR380JG-1
DT Series connector
No.of
pins T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
BR380JG-1 20-265
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820T (normal type) Part No.: 08192-1810T (normal type)
08192-2820T (fine wire type) 08192-2810T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920T (normal type) Part No.: 08192-1910T (normal type)
08192-2920T (fine wire type) 08192-2910T (fine wire type)
20-266 BR380JG-1
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
1 —
Part No.: 08192-31200 (Contact Part No.: 08192-31100 (Contact

size#12) size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
BR380JG-1 20-267
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-2600 Measurement box Econo-21P Q Q Q Q Q Q

799-601-3100 Measurement box MS-37P Q
799-601-3200 Measurement box MS-37P Q
799-601-3300 Measurement box Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P Q Q
799-601-3420 BENDIX (MS) 24P Q Q
799-601-3430 BENDIX (MS) 17P Q Q
799-601-3440 BENDIX (MS) 17P Q Q
799-601-3450 BENDIX (MS) 5P Q Q
799-601-3460 BENDIX (MS) 10P Q Q
799-601-3510 BENDIX (MS) 5P Q Q
799-601-3520 BENDIX (MS) 14P Q Q
799-601-3530 BENDIX (MS) 19P Q Q
799-601-2910 BENDIX (MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Additional cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
799-601-7320 SWP 16P Q
799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
20-268 BR380JG-1
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
—
Part No. No. of pins
part name
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
799-601-9240 HD30 18-21 Q Q
799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Measurement box For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DEUTSCH 40P Q
799-601-9360 DEUTSCH 24P Q
799-601-9410 For NE, G sensor 2P Q
799-601-9420 For fuel, boost press. 3P Q
799-601-9430 PVC socket 2P Q
BR380JG-1 20-269
TROUBLESHOOTING WHEN ERROR CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-303

Electrical System Error Code [E201] (Disconnection in primary belt conveyor forward solenoid) .............. 20-305
Electrical System Error Code [E202] (Short circuit in primary belt conveyor forward solenoid).................. 20-306
Electrical System Error Code [E203] (Disconnection in crusher forward EPC valve) ................................. 20-307
Electrical System Error Code [E204] (Short circuit in crusher forward EPC valve)..................................... 20-308
Electrical System Error Code [E205] (Disconnection in crusher reverse EPC valve) ................................. 20-309
Electrical System Error Code [E206] (Short circuit in crusher reverse EPC valve)..................................... 20-310
Electrical System Error Code [E207] (Disconnection in feeder forward EPC valve)................................... 20- 311
Electrical System Error Code [E208] (Short circuit in feeder forward EPC valve) ...................................... 20-312
Electrical System Error Code [E211] (Short circuit in electrical intake air heater relay) .............................. 20-313
Electrical System Error Code [E212] (Disconnection in pressure abnormality processing relay) ............... 20-314
Electrical System Error Code [E213] (Disconnection in accessory drive EPC valve) ................................. 20-315
Electrical System Error Code [E214] (Short circuit in accessory drive EPC valve)..................................... 20-316
Electrical System Error Code [E217] (Disconnection, short circuit, or abnormal input
in model selection circuit)................................................................ 20-317
Electrical System Error Code [E218] (Disconnection in S-NET signal line) ................................................ 20-318
Electrical System Error Code [E222] (Short circuit in LS-EPC solenoid) .................................................... 20-319
Electrical System Error Code [E223] (Disconnection in LS-EPC solenoid) ................................................ 20-320
Electrical System Error Code [E224] (Abnormality in F pump pressure sensor) ........................................ 20-322
Electrical System Error Code [E225] (Abnormality in R pump pressure sensor) ........................................ 20-324
Electrical System Error Code [E226] (Abnormality in pressure sensor power supply) ............................... 20-326
Electrical System Error Code [E227] (Abnormality in engine speed sensor) .............................................. 20-328
Electrical System Error Code [E232] (Short circuit in PC-EPC solenoid) ................................................... 20-329
Electrical System Error Code [E233] (Disconnection in PC-EPC solenoid)................................................ 20-330
Electrical System Error Code [E234] (Short circuit in rotary lamp SSR) ..................................................... 20-331
Electrical System Error Code [E235] (Short circuit in horn relay) ............................................................... 20-332
Electrical System Error Code [E240] (Short circuit in pressure abnormality processing relay)................... 20-333
Electrical System Error Code [E241] (Disconnection in primary belt conveyor reverse solenoid) .............. 20-334
Electrical System Error Code [E242] (Short circuit in primary belt conveyor reverse solenoid).................. 20-335
Electrical System Error Code [E243] (Disconnection in lock cylinder reset solenoid)................................. 20-336
Electrical System Error Code [E244] (Short circuit in lock cylinder reset solenoid) .................................... 20-337
Electrical System Error Code [E246] (Short circuit in lock cylinder extension relay) .................................. 20-338
Electrical System Error Code [E247] (Disconnection in lock cylinder retraction solenoid).......................... 20-339
Electrical System Error Code [E248] (Short circuit in lock cylinder retraction solenoid) ............................. 20-340
Electrical System Error Code [E249] (Disconnection in magnetic separator relay) .................................... 20-341
Electrical System Error Code [E250] (Short circuit in magnetic separator relay)........................................ 20-342
Electrical System Error Code [E301] (Disconnection in engine stop switch) .............................................. 20-343
Electrical System Error Code [E302] (Short circuit in primary belt conveyor-ON switch) ........................... 20-344
Electrical System Error Code [E303] (Disconnection in primary belt conveyor-OFF switch) ...................... 20-345
Electrical System Error Code [E304] (Short circuit in crusher-ON switch).................................................. 20-346
Electrical System Error Code [E305] (Disconnection in crusher-OFF switch) ............................................ 20-348
Electrical System Error Code [E306] (Abnormality in governor potentiometer) .......................................... 20-350
Electrical System Error Code [E308] (Abnormality in fuel control dial) ....................................................... 20-352
BR380JG-1 20-301
TROUBLESHOOTING
Electrical System Error Code [E315] (Short circuit of battery relay output) ................................................ 20-354
Electrical System Error Code [E316] (Stepping out of governor motor)...................................................... 20-356
Electrical System Error Code [E317] (Disconnection in governor motor phases A and B) ......................... 20-358
Electrical System Error Code [E318] (Short circuit in governor motor phases A and B)............................. 20-360
Electrical System Error Code [E320] (Short circuit in feeder-ON switch).................................................... 20-362
Electrical System Error Code [E321] (Disconnection in feeder-OFF switch) .............................................. 20-363
Electrical System Error Code [E322] (Short circuit in conveyor RAISE switch) .......................................... 20-364
Electrical System Error Code [E323] (Short circuit in conveyor lower switch) ............................................ 20-365
Electrical System Error Code [E331] (Abnormality in clearance sensor potentiometer) ............................. 20-366
Electrical System Error Code [E332] (Short circuit in one-touch start switch)............................................. 20-368
Electrical System Error Code [E333] (Disconnection in one-touch stop switch) ......................................... 20-370
Electrical System Error Code [E334] (Short circuit in magnetic separator-ON switch) ............................... 20-372
Electrical System Error Code [E335] (Disconnection in magnetic separator-OFF switch).......................... 20-374
Mechanical System Error Code [A000N1] (Engine high idling speed out of standard) ............................... 20-376
Mechanical System Error Code [A000N2] (Engine low idling speed out of standard) ................................ 20-376
Mechanical System Error Code [AA10NX] (Clogged air cleaner) ............................................................... 20-377
Mechanical System Error Code [AB00KE] (Abnormal lowering of charging voltage) ................................. 20-378
Mechanical System Error Code [B@BAZG] (Abnormal lowering of engine oil pressure) ........................... 20-379
Mechanical System Error Code [B@BAZK] (Abnormal lowering of engine oil level) .................................. 20-380
Mechanical System Error Code [B@BCNS] (Overheating of engine coolant) ............................................ 20-381
Mechanical System Error Code [B@BCZK] (Abnormal lowering of radiator coolant level) ........................ 20-382
Mechanical System Error Code [B@HANS] (Overheating of hydraulic oil) ................................................ 20-383
20-302 BR380JG-1
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

a The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.
User Code Error Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information
Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over
the presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement
<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness oc-
curred.
2 • Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with
standard value in normalcy
the grounding circuit.

Presumed cause and
• Short-circuiting
Cause that presumably
A wiring harness that is not connected with a 24 V electric circuit has a contact with
triggered failure in ques-
the electric circuit.
tion
3
(The assigned No. is for
<Precaution for Troubleshooting>
filing purpose only. It
1) Connector No. display method and handling of T-adapter
does not stand for any
Insert or connect T-adapters in the following manner before starting troubleshoot-
priority)
ing unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., discon-
4 nect the connector and insert the T-adapter into both male and female sides.
• If there is an indication of "male" or "female" in a specific connector No., discon-
nect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5 • Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring
harness.
BR380JG-1 20-303
Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
20-304 BR380JG-1
TROUBLESHOOTING E201
Electrical System Error Code [E201] (Disconnection in primary belt conveyor forward
solenoid)
User Code Error Code Failure Code Disconnection in primary belt conveyor forward sole-
Failure
noid
— E201 7RFHKA phenomenon
(Engine throttle and pump controller system)
• When the signal is not output to the primary belt conveyor forward solenoid circuit, the terminal voltage
Failure content
of the engine throttle and pump controller is above the specified value.
Response from • None in particular.
controller • If the cause of the failure disappears, the system resets itself.
Phenomenon
• The primary belt conveyor does not operate.
occurring on
• When this trouble is detected, the horn sounds (3 times intermittently).
machine
Relative • Since the controller detects disconnection while the solenoid output is turned OFF, be sure to turn the
information solenoid output OFF when checking for reproduction of the failure after repair.
Defective primary belt aPrepare with starting switch OFF, then carry out troubleshooting without turning
conveyor forward starting switch ON.
1
solenoid V9A (male) Resistance
(Internal disconnection) Between (1) and (2) 20 – 60 z
aPrepare with starting switch OFF, then carry out troubleshooting without turning
Disconnection in wiring starting switch ON.

Presumed cause and
harness
Wiring harness between C3 (female) (8) and V9A
2 (Disconnection in wiring Resistance Max. 1 z
(female) (2)
harness or defective
contact in connector) Wiring harness between V9A (female) (1) and chassis
Resistance Max. 1 z
ground
Short circuit with power aPrepare with starting switch OFF, then turn starting switch ON and carry out trou-
source in wiring harness bleshooting.
3
(Contact with 24-V Between wiring harness between C3 (female) (8) and
circuit) Voltage Max. 1 V
V9A (female) (2) and chassis ground
Defective engine throttle starting switch ON.
4
and pump controller C3 (female) Resistance
Between (8) and chassis ground 20 – 60 z
BR380JG-1 20-305
Electrical System Error Code [E202] (Short circuit in primary belt conveyor forward
solenoid)
User Code Error Code Failure Code Short circuit in primary belt conveyor forward sole-
Failure
noid
— E202 7RFHKB phenomenon
• When the signal is output to the primary belt conveyor forward solenoid circuit, an abnormal current
Failure content
flows.
• Turns the output to the primary belt conveyor forward solenoid circuit OFF.
Response from
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller
turned OFF.
Phenomenon
occurring on
machine
Relative
—
information

conveyor forward starting switch ON.
1 solenoid V9A (male) Resistance
(Internal short circuit or

20 – 60 z
Presumed cause and
grounding fault) Between (1) and (2)

Short circuit with chassis aPrepare with starting switch OFF, then carry out troubleshooting without turning
ground in wiring harness starting switch ON.
2
(Contact with ground cir- Between wiring harness between C3 (female) (8) and
cuit) Resistance Min. 1 Mz
aPrepare with starting switch OFF, then turn starting switch ON and carry out trou-
bleshooting.
Defective engine throttle Side conveyor
3 C3 Voltage
and pump controller forward switch
Between (8) and OFF Max. 1 V
chassis ground ON 20 – 30 V
20-306 BR380JG-1
Electrical System Error Code [E203] (Disconnection in crusher forward EPC valve)
User Code Error Code Failure Code Failure Disconnection in crusher forward EPC valve
— E203 7RF2KA phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the crusher forward solenoid circuit, no current flows.
Response from • None in particular (Since no current flows, the solenoid does not operate).
Phenomenon
• The crusher does not operate forward.
occurring on
machine
Relative • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information solenoid output ON when checking for reproduction of the failure after repair.

Defective crusher starting switch ON.
1 forward EPC solenoid
V2 (male) Resistance
(Internal disconnection)
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
Wiring harness between C3 (female) (26) and V2
(female) (2)
contact in connector) Wiring harness between C3 (female) (13), (23) and V2
Resistance Max. 1 z
(female) (1)
3
V2 (female) (2) and chassis ground
4
Between (26) and (13), (23) 7 – 14 z
BR380JG-1 20-307
Electrical System Error Code [E204] (Short circuit in crusher forward EPC valve)
User Code Error Code Failure Code Failure Short circuit in crusher forward EPC valve
— E204 7RF2KB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the crusher forward EPC valve solenoid circuit, an abnormal current flows.
• Turns the output to the crusher forward EPC solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The crusher does not rotate forward.
occurring on
machine
Relative
—
information

forward EPC solenoid V2 (male) Resistance
1

Between (1) and (2) 7 – 14 z
Presumed cause and
grounding fault)
Between (2) and chassis ground Min. 1 Mz
2
(Contact with ground Between wiring harness between C3 (female) (26) and
circuit) Resistance Min. 1 Mz
starting switch ON.
Defective engine throttle C3 (female) Resistance
3
and pump controller
Between (26) and (13), (23) 7 – 14 z
20-308 BR380JG-1
Electrical System Error Code [E205] (Disconnection in crusher reverse EPC valve)
User Code Error Code Failure Code Failure Disconnection in crusher reverse EPC valve
Failure content • When the signal is output to the crusher reverse solenoid circuit, no current flows.
Phenomenon
• The crusher does not operate in reverse.
occurring on
machine

1 reverse EPC solenoid
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
(female) (2)
Resistance Max. 1 z
(female) (1)
3
4
Between (36) and (13), (23) 7 – 14 z
BR380JG-1 20-309
Electrical System Error Code [E206] (Short circuit in crusher reverse EPC valve)
User Code Error Code Failure Code Failure Short circuit in crusher reverse EPC valve
Failure content • When the signal is output to the crusher reverse EPC valve solenoid circuit, an abnormal current flows.
• Turns the output to the crusher reverse EPC solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The crusher does not rotate in reverse.
occurring on
machine
Relative
—
information

reverse EPC solenoid V1 (male) Resistance
1

Between (1) and (2) 7 – 14 z
Presumed cause and
grounding fault)
2
starting switch ON.
3
and pump controller
Between (36) and (13), (23) 7 – 14 z
20-310 BR380JG-1
Electrical System Error Code [E207] (Disconnection in feeder forward EPC valve)
User Code Error Code Failure Code Failure Disconnection in feeder forward EPC valve
Failure content • When the signal is output to the feeder forward solenoid circuit, no current flows.
Phenomenon
• The feeder does not operate forward.
occurring on
machine

Defective feeder forward starting switch ON.
1 EPC solenoid
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
(female) (2)
Resistance Max. 1 z
(female) (1)
3
4
Between (38) and (13), (23) 7 – 14 z
BR380JG-1 20-311
Electrical System Error Code [E208] (Short circuit in feeder forward EPC valve)
User Code Error Code Failure Code Failure Short circuit in feeder forward EPC valve
Failure content • When the signal is output to the feeder forward EPC valve solenoid circuit, an abnormal current flows.
• Turns the output to the feeder forward EPC solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The feeder does not rotate forward.
occurring on
machine
Relative
—
information

Defective feeder forward starting switch ON.
EPC solenoid V3 (male) Resistance
1

Between (1) and (2) 7 – 14 z
Presumed cause and
grounding fault)
2
starting switch ON.
3
and pump controller
Between (38) and (13), (23) 7 – 14 z
20-312 BR380JG-1
Electrical System Error Code [E211] (Short circuit in electrical intake air heater relay)
User Code Error Code Failure Code Failure Short circuit in electrical intake air heater relay
— E211 7RDMKB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the electrical intake air heater relay.
Response from • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller turned OFF.
Phenomenon
occurring on • The automatic preheater does not work.
machine
Relative
—
information

starting switch ON.
Defective electrical
1 Electrical intake air heater relay Resistance
intake air heater relay
Between T7 (relay side) and
25 – 40 z
chassis ground
Presumed cause and
2 Defective diode (D01) bleshooting.
Replace with diode D02. Normal
Short circuit with chassis starting switch ON.
ground in wiring harness Between wiring harness between D01 (female) (4) and
3 Resistance Min. 1 Mz
(Contact with ground relay terminal T7 and chassis ground
circuit) Between wiring harness between C3 (female) (18) and
Resistance Min. 1 Mz
D01 (female) (8) and chassis ground
Defective engine throttle
4 When the result of troubleshooting No. 1 – No. 3 is normal
and pump controller
BR380JG-1 20-313
Electrical System Error Code [E212] (Disconnection in pressure abnormality process-

ing relay)
User Code Error Code Failure Code Disconnection in pressure abnormality processing
Failure
relay
— E212 7RFMKA phenomenon
• When the pressure abnormality processing relay is disconnected grounded (the output is turned OFF),
Failure content
the voltage of 24 V is not generated.
Phenomenon • Even if the side conveyor, magnetic separator, primary belt conveyor, and screen are loaded abnormally,
occurring on they do not stop.
machine • When this trouble is detected, the horn sounds (3 times intermittently).
Relative • This error code detects abnormality on the primary side (coil side) of the pressure abnormality process-
information ing relay but does not detect abnormality on the secondary side (contact side).

If fuse No. (10) is broken, the circuit probably has a grounding fault, etc. (See cause
1 Defective fuse No. (10)
4.)
Defective pressure aPrepare with starting switch OFF, then carry out troubleshooting without turning
abnormality processing starting switch ON.
2
relay R5 (male) Resistance
Disconnection in wiring aPrepare with starting switch OFF, then carry out troubleshooting without turning
Presumed cause and
harness starting switch ON.

3 (Disconnection in wiring Wiring harness between C2 (female) (18) and R5
Resistance Max. 1 z
harness or defective (female) (2)
contact in connector) Wiring harness between R5 (female) (1) and fuse (10). Resistance Max. 1 z
ground in wiring harness Between wiring harness between C2 (female) (18) and
(Contact with ground R5 (female) (2) and chassis ground
circuit) Between wiring harness between R5 (female) (1) and
fuse (10) and chassis ground
5
Between (18) and fuse (10) 100 – 500 z
20-314 BR380JG-1
Electrical System Error Code [E213] (Disconnection in accessory drive EPC valve)
User Code Error Code Failure Code Failure Disconnection in accessory drive EPC valve
— E213 7RFLKA phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the accessory drive solenoid circuit, no current flows.
Phenomenon
• The side conveyor elevating device, lock cylinder, and primary conveyor do not operate.
occurring on
machine

Defective accessory starting switch ON.
1 drive EPC solenoid
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
(female) (2)
Resistance Max. 1 z
(female) (1)
3
4
Between (28) and (13), (23) 7 – 14 z
BR380JG-1 20-315
Electrical System Error Code [E214] (Short circuit in accessory drive EPC valve)
User Code Error Code Failure Code Failure Short circuit in accessory drive EPC valve
— E214 7RFLKB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the accessory drive EPC valve solenoid circuit, an abnormal current flows.
• Turns the output to the accessory drive EPC solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The side conveyor elevator, lock cylinder, and primary belt conveyor do not operate.
occurring on
machine
Relative
—
information

Defective accessory starting switch ON.
drive EPC solenoid V4 (male) Resistance
1

Between (1) and (2) 7 – 14 z
Presumed cause and
grounding fault)
2
starting switch ON.
3
and pump controller
Between (28) and (13), (23) 7 – 14 z
20-316 BR380JG-1
Electrical System Error Code [E217] (Disconnection, short circuit, or abnormal input in
model selection circuit)
User Code Error Code Failure Code Disconnection, short circuit, or abnormal input in
Failure
model selection circuit
— E217 DA2SKQ phenomenon
Failure content • A code signal that indicates a model other than the models registered in the controller is input.
Response from • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
controller turned OFF.
Phenomenon
• When this trouble is detected, the horn sounds (3 times intermittently) (The work equipment can be op-
occurring on
erated).
machine
Relative
—
information

starting switch ON.
1 Between C2 (female) (7) and chassis ground, between

and pump controller
Presumed cause and
C2 (female) (13) and chassis ground, between C2 Resistance Min. 1 Mz

(female) (17) and chassis ground
starting switch ON.
Short circuit with chassis Between wiring harness between C2 (female) (7) and
ground in wiring harness A24 (male) (3) and chassis ground
2
A24 (male) (4) and chassis ground
Between wiring harness between C2 (female) (17) and
A24 (male) (2) and chassis ground
BR380JG-1 20-317
Electrical System Error Code [E218] (Disconnection in S-NET signal line)
User Code Error Code Failure Code Failure Disconnection in S-NET signal line
— E218 DS2SKA phenomenon (Engine throttle and pump controller system)
Failure content • A failure occurred in the S-NET communication between the monitor and controller.
• Controls with the data before occurrence of the failure while the failure is occurring. The crusher clear-
Response from ance increasing/decreasing operation, crusher manual forward/reverse operation, and side conveyor
controller forward/reverse operation which are carried out through the monitor panel are stopped, however.
• If the cause of the failure disappears, the system resets itself.
Phenomenon
occurring on • Operation cannot be carried out through the multi-monitor.
machine
• Error codes are transmitted between the engine throttle and pump controller and monitor panel by the
Relative
CAN communication. On the other hand, operation commands from the monitor panel are transmitted
information
by the S-NET communication.

harness
Wiring harness between P02 (female) (9), (10) and C2
(female) (21)
contact in connector) Wiring harness between P02 (female) (20) and C2
Resistance Max. 1 z
(female) (31)

Presumed cause and
2
(Contact with ground Between wiring harness between P02 (female) (9), (10)
circuit) Resistance Max. 1 Mz
and C2 (female) (21) and chassis ground
3
(Contact with 24-V Between wiring harness between P02 (female) (9), (10)
and C2 (female) (21) and chassis ground
bleshooting.
4 Defective monitor panel
P02 (male) Voltage
Between (9), (10) and (20) 6–9V
Defective engine throttle bleshooting.
5
and pump controller C2 (male) Voltage
Between (21) and (31) 6–9V
20-318 BR380JG-1
Electrical System Error Code [E222] (Short circuit in LS-EPC solenoid)
User Code Error Code Failure Code Failure Short circuit in LS-EPC solenoid
— E222 DXE0KB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the LS-EPC solenoid circuit.
• Turns the output to the LS-EPC solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The travel speed cannot be changed between Hi and Lo or the work equipment speed is low. (The set
occurring on
pressure of the LS valve cannot be controlled.)
machine
Relative
—
information

Defective LS-EPC starting switch ON.
solenoid V5 (male) Resistance
1

Between (1) and (2) 7 – 14 z
Presumed cause and
grounding fault)
2
starting switch ON.
3
and pump controller
Between (6) and (3) 7 – 14 z
BR380JG-1 20-319
Electrical System Error Code [E223] (Disconnection in LS-EPC solenoid)
User Code Error Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (Engine throttle and pump controller system)
Failure content • No current flows in the LS-EPC solenoid circuit.
Phenomenon
• The travel Hi/Lo cannot be changed or the work equipment speed is high.
occurring on
(The set pressure of the LS valve cannot be controlled.)
machine

Defective LS-EPC starting switch ON.
1 solenoid
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
(female) (1)
contact in connector) Wiring harness between C3 (female) (3) and V5
Resistance Max. 1 z
(female) (2)
3
4
Between (6) and (3) 7 – 14 z
20-320 BR380JG-1
Electrical System Error Code [E224] (Abnormality in F pump pressure sensor)
User Code Error Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (Engine throttle and pump controller system)
Failure content • The signal voltage from the F pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • Assumes the F pump pressure to be 0 MPa {0 kg/cm2} for control.
Phenomenon
occurring on • Overloads and abnormal loads on the crusher are not detected.
machine
Relative • If the 5-V circuit (B) of the pressure sensor and the ground circuit (A) are connected inversely, the pres-
information sure sensor will be broken. When checking, take care extremely.

Defective sensor power
1 If error code [E226] is displayed, carry out troubleshooting for it first.
supply system
aPrepare with starting switch OFF, then turn starting switch ON or start engine and
carry out troubleshooting.
S11 Voltage
Defective F pump
Between (B) and (A) Power supply 4.5 – 5.5 V
2 pressure sensor
(Internal disconnection) Between (C) and (A) Signal 0.5 – 4.5 V
The voltage of the pressure sensor is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the failure, and then judge.
starting switch ON.
Disconnection in wiring Wiring harness between C1 (female) (22) and S11

Resistance Max. 1 z
Presumed cause and
harness (female) (B)

3 (Disconnection in wiring
Wiring harness between C1 (female) (10) and S11
harness or defective Resistance Max. 1 z
contact in connector) (female) (A)
Resistance Max. 1 z
(female) (C)
4
S11 (female) (C) and chassis ground
Short circuit with power bleshooting.
source in wiring harness Between wiring harness between C1 (female) (22) and
5 Voltage Max. 1 V
(Contact with 24-V S11 (female) (B) and chassis ground
Voltage Max. 1 V
Defective engine throttle C1 Voltage
6
and pump controller
Between (22) and (10) Power supply 4.5 – 5.5 V
Between (8) and (10) Signal 0.5 – 4.5 V
20-322 BR380JG-1
BR380JG-1 20-323
Electrical System Error Code [E225] (Abnormality in R pump pressure sensor)
User Code Error Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (Engine throttle and pump controller system)
Failure content • The signal voltage from the R pump pressure sensor is below 0.3 V or above 4.42 V.
Response from • Assumes the R pump pressure to be 0 MPa {0 kg/cm2} for control.
Phenomenon
occurring on • Overloads and abnormal loads on the crusher are not detected.
machine
Relative • If the 5-V circuit (B) of the pressure sensor and the ground circuit (A) are connected inversely, the pres-
information sure sensor will be broken. When checking, take care extremely.

supply system
S10 Voltage
Defective R pump
Between (B) and (A) Power supply 4.5 – 5.5 V
2 pressure sensor
(Internal disconnection) Between (C) and (A) Signal 0.5 – 4.5 V
The voltage of the pressure sensor is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the failure, and then judge.
starting switch ON.

Resistance Max. 1 z
Presumed cause and
harness (female) (B)

Resistance Max. 1 z
(female) (C)
4
5 Voltage Max. 1 V
(Contact with 24-V S10 (female) (B) and chassis ground
Voltage Max. 1 V
6
and pump controller
20-324 BR380JG-1
BR380JG-1 20-325
Electrical System Error Code [E226] (Abnormality in pressure sensor power supply)
User Code Error Code Failure Code Failure Abnormality in pressure sensor power supply
— E226 DA25KP phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the power supply (5 V) circuit of the pressure sensor and potentiometer.
• Turns the output to the power supply (5 V) OFF.
Response from
controller
turned OFF.
Phenomenon
occurring on • The signals of the pressure sensor and potentiometer are not input normally.
machine
Relative
—
information

bleshooting.
Fuel control dial Connector E10
Defective pressure Disconnect the devices at
right in order. If the error Governor potentiometer Connector E12
1 sensor or potentiometer
(Internal short circuit) code disappears when a F pump pressure sensor Connector S11
device is disconnected, R pump pressure sensor Connector S10
that device has a defect in
it. Clearance sensor
Connector S12
potentiometer
starting switch ON.
Presumed cause and

E10 (female) (1) and chassis ground [Fuel control dial Resistance Min. 1 Mz
system]
E12 (female) (A) and chassis ground [Governor potenti- Resistance Min. 1 Mz
Short circuit with chassis ometer system]
ground in wiring harness
2 Between wiring harness between C1 (female) (22) and
(Contact with ground
circuit) S11 (female) (B) and chassis ground [F pump pressure Resistance Min. 1 Mz
sensor system]
S10 (female) (B) and chassis ground [R pump pressure Resistance Min. 1 Mz
sensor system]
S12 (female) (C) and chassis ground [Clearance sensor Resistance Min. 1 Mz
potentiometer system]
3
and pump controller C1 Voltage
Between (22) and (10), (21) 4.5 – 5.5 V
20-326 BR380JG-1
BR380JG-1 20-327
Electrical System Error Code [E227] (Abnormality in engine speed sensor)
User Code Error Code Failure Code Failure Abnormality in engine speed sensor
— E227 DLE2MA phenomenon (Engine throttle and pump controller system)
Failure content • Normal pulse signals are not input to the signal circuit of the engine speed sensor.
Response from
controller
Phenomenon
occurring on • The power is a little low (The engine speed cannot be sensed).
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code: 010 Engine speed)

Defective engine speed starting switch ON.
sensor E6 (male) Resistance
1
disconnection) Between (1) and (2) 500 – 1,000 z
Defective adjustment of
2 Refer to TESTING AND ADJUSTING, Adjusting engine speed sensor.
engine speed sensor
Presumed cause and

harness
Wiring harness between C2 (female) (40) and E6
(female) (1)
contact in connector) Wiring harness between C2 (female) (39) and E6
Resistance Max. 1 z
(female) (2)
4
(Contact with 24-V Wiring harness between C2 (female) (40) and E6
(female) (1)
starting switch ON.
5
and pump controller
Between (40) and (39) 500 – 1,000 z
20-328 BR380JG-1
Electrical System Error Code [E232] (Short circuit in PC-EPC solenoid)
User Code Error Code Failure Code Failure Short circuit in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the PC-EPC solenoid circuit.
• Turns the PC-EPC current OFF.
Response from
controller
turned OFF.
Phenomenon
occurring on • When the pump load is increased, the engine speed lowers remarkably and the engine may stall.
machine
Relative
• The PC-EPC current can be checked in the monitoring function.
information
Defective PC-EPC aPrepare with starting switch OFF, then carry out troubleshooting without turning
solenoid starting switch ON.
1
(Internal short circuit or V6 (male) Resistance
Presumed cause and
grounding fault) Between (1) and (2) 7 – 14 z

2
3
Between (16) and (3) 7 – 14 z
BR380JG-1 20-329
Electrical System Error Code [E233] (Disconnection in PC-EPC solenoid)
User Code Error Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (Engine throttle and pump controller system)
Failure content • No current flows in the PC-EPC solenoid circuit.
Phenomenon
occurring on • When the pump load is increased, the engine speed lowers remarkably and the engine may stall.
machine
Relative
• The PC-EPC current can be checked in the monitoring function of the monitor.
information

Defective PC-EPC starting switch ON.
1 solenoid
Between (1) and (2) 7 – 14 z

Presumed cause and
harness
(female) (1)
contact in connector) Wiring harness between C3 (female) (3) and V6
Resistance Max. 1 z
(female) (2)
3
4
Between (16) and (3) 7 – 14 z
20-330 BR380JG-1
Electrical System Error Code [E234] (Short circuit in rotary lamp SSR)
User Code Error Code Failure Code Failure Short circuit in rotary lamp SSR
— E234 DUB0KB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the rotary lamp relay.
• Turns the current to the rotary lamp relay circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The rotary lamp does not light up.
occurring on
machine
Relative • Since short circuit is detected while the rotary lamp output is turned ON, be sure to turn the rotary lamp
information output ON when checking for reproduction of the failure after repair.

aPrepare with starting switch OFF, then disconnect (7) and (8) of R11, start the en-
Defective rotary lamp gine, and overload the crusher.
1 relay (SSR)
Rotary lamp lights up. Relay is abnormal.
(Internal defect)
Presumed cause and
Rotary lamp does not light up. Relay is normal.

Short circuit with power aPrepare with starting switch OFF, then disconnect (7) of A29, A30, and R11, start
source in wiring harness the engine, and overload the crusher.
2
(Contact with 24-V
circuit) Between C2 (female) (9) and chassis ground Voltage Max. 1 V
starting switch ON.
3 Defective resistor
Between A29 (male) (1) and (2) 2 – 2.4 kz
Between A30 (male) (1) and (2) 2 – 2.4 kz
4 When results of 1 – 3 above are normal
and pump controller
BR380JG-1 20-331
Electrical System Error Code [E235] (Short circuit in horn relay)
User Code Error Code Failure Code Failure Short circuit in horn relay
— E235 D162KB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the horn relay.
• Turns the current to the horn relay circuit OFF.
Response from
controller
turned OFF.
Phenomenon
occurring on • When the controller detects abnormality, the horn does not sound.
machine
Relative • Since short circuit is detected while the horn output is turned ON, be sure to turn the horn output ON
information when checking for reproduction of the failure after repair.

starting switch ON.
Defective horn relay aDisconnect R4.
1
(Internal defect)
Presumed cause and
Horn relay R4 (male) Continuity/Resistance

Between (1) and (2) 250 – 350 z
2
R4 (female) (2) and chassis ground
3 aDisconnect C2.
and pump controller
Short C2 (female) (19) with chassis ground Horn Sounds
20-332 BR380JG-1
Electrical System Error Code [E240] (Short circuit in pressure abnormality processing
relay)
User Code Error Code Failure Code Short circuit in pressure abnormality processing
Failure
relay
— E240 7RFMKB phenomenon
• When the pressure abnormality processing relay circuit is connected to the chassis ground (the output
Failure content
is turned ON), an abnormal current flows.
• Turns the output to the pressure abnormality processing relay circuit OFF.
Response from
controller
turned OFF.
Phenomenon • Even if the side conveyor, magnetic separator, primary belt conveyor, and screen are loaded abnormally,
occurring on they do not stop.
Relative • This error code detects abnormality on the primary side (coil side) of the relay but does not detect ab-
information normality on the secondary side (contact side).

Defective magnetic starting switch ON.
1 separator relay
R5 (male) Resistance
Presumed cause and
(Internal short circuit)

Between (1) and (2) 250 – 300 z
2
3
Between (18) and fuse (10) 250 – 300 z
BR380JG-1 20-333
Electrical System Error Code [E241] (Disconnection in primary belt conveyor reverse
solenoid)
User Code Error Code Failure Code Disconnection in primary belt conveyor reverse sole-
Failure
noid
— E241 7RD2KA phenomenon
Failure content • When the signal is output to the primary belt conveyor reverse solenoid circuit, no current flows.
Phenomenon
• The primary conveyor does not operate.
occurring on
machine
conveyor reverse starting switch ON.
1
solenoid V9B (male) Resistance

Presumed cause and
harness
Wiring harness between C3 (female) (7) and V9B
(female) (2)
contact in connector) Wiring harness between V9B (female) (1) and chassis
Resistance Max. 1 z
ground
3
V9B (female) (2) and chassis ground
4
20-334 BR380JG-1
Electrical System Error Code [E242] (Short circuit in primary belt conveyor reverse
solenoid)
User Code Error Code Failure Code Short circuit in primary belt conveyor reverse sole-
Failure
noid
— E242 7RD2KB phenomenon
• When the signal is output to the primary belt conveyor reverse solenoid circuit, an abnormal current
Failure content
flows.
• Turns the output to the primary belt conveyor reverse solenoid circuit OFF.
Response from
controller
turned OFF.
Phenomenon
occurring on
machine
Relative
—
information

conveyor reverse starting switch ON.
1 solenoid V9B (male) Resistance

20 – 60 z
Presumed cause and
grounding fault) Between (1) and (2)

2
V9B (female) (2) and chassis ground
bleshooting.
Defective engine throttle Side conveyor
3 C3 Voltage
and pump controller forward switch
BR380JG-1 20-335
Electrical System Error Code [E243] (Disconnection in lock cylinder reset solenoid)
User Code Error Code Failure Code Failure Disconnection in lock cylinder reset solenoid
— E243 7RFNKA phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the lock cylinder reset solenoid circuit, no current flows.
Phenomenon
• The machine operates while the lock cylinder is in the lock position.
occurring on
machine

Defective lock cylinder starting switch ON.
1 reset solenoid
AV2 (male) Resistance
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
Wiring harness between C3 (female) (17) and AV2
(female) (2)
contact in connector) Wiring harness between AV2 (female) (1) and chassis
Resistance Max. 1 z
ground
3
AV2 (female) (2) and chassis ground
4
20-336 BR380JG-1
Electrical System Error Code [E244] (Short circuit in lock cylinder reset solenoid)
User Code Error Code Failure Code Failure Short circuit in lock cylinder reset solenoid
— E244 7RFNKB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the lock cylinder reset solenoid circuit, an abnormal current flows.
• Turns the output to the lock cylinder reset, extension, and retraction solenoid circuits OFF.
Response from
controller
turned OFF.
Phenomenon
• The crusher clearance cannot be adjusted.
occurring on
machine
Relative
—
information
Defective lock cylinder aPrepare with starting switch OFF, then carry out troubleshooting without turning
reset solenoid starting switch ON.
1
(Internal short circuit or AV2 (male) Resistance

Presumed cause and

2
AV2 (female) (2) and chassis ground
bleshooting.
Defective engine throttle C3 Crusher clearance switch Voltage
3
and pump controller
BR380JG-1 20-337
Electrical System Error Code [E246] (Short circuit in lock cylinder extension relay)
User Code Error Code Failure Code Failure Short circuit in lock cylinder extension relay
— E246 7RFPKB phenomenon (Engine throttle and pump controller system)
Failure content • An abnormal current flows in the lock cylinder extension relay.
• Even if the crusher clearance reducing switch is turned ON, the outputs to the lock cylinder reset and
Response from extension solenoids are turned OFF.
controller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Phenomenon
• The crusher clearance cannot be adjusted.
occurring on
machine
Relative
—
information

1 extension relay

Between (5) and (6) 100 – 500 z
Presumed cause and
2
bleshooting.
Defective engine throttle Crusher clearance
3 C3 Voltage
and pump controller reducing switch
20-338 BR380JG-1
Electrical System Error Code [E247] (Disconnection in lock cylinder retraction sole-
noid)
User Code Error Code Failure Code Failure Disconnection in lock cylinder retraction solenoid
— E247 7RFKKA phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the lock cylinder retraction solenoid circuit, no current flows.
Phenomenon
• The lock cylinder is not retracted.
occurring on
machine

1 retraction solenoid
V8A (male) Resistance
Between (1) and (2) 20 – 60 z

Presumed cause and
harness
Wiring harness between C3 (female) (37) and V8A
(female) (2)
contact in connector) Wiring harness between V8A (female) (1) and chassis
Resistance Max. 1 z
ground
3
4
BR380JG-1 20-339
Electrical System Error Code [E248] (Short circuit in lock cylinder retraction solenoid)
User Code Error Code Failure Code Failure Short circuit in lock cylinder retraction solenoid
— E248 7RFKKB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the lock cylinder retraction solenoid circuit, an abnormal current flows.
• Turns the output to the lock cylinder reset and retraction solenoids OFF, even if the crusher clearance
Response from increase switch is turned ON.
controller • Even if the cause of the failure disappears, the system does not reset itself until the starting switch is
turned OFF.
Phenomenon
• The lock cylinder is not retracted.
occurring on
machine
Relative
—
information
Defective lock cylinder aPrepare with starting switch OFF, then carry out troubleshooting without turning
retraction solenoid starting switch ON.
1
(Internal short circuit or V8A (male) Resistance

Presumed cause and
2
bleshooting.
Defective engine throttle Crusher clearance
3 C3 Voltage
and pump controller increase switch
20-340 BR380JG-1
Electrical System Error Code [E249] (Disconnection in magnetic separator relay)
User Code Error Code Failure Code Failure Disconnection in magnetic separator relay
— E249 7RDNKA phenomenon (Engine throttle and pump controller system)
• When the magnetic separator relay is grounded (the output is turned OFF), the voltage of 24 V is not
Failure content
generated.
Phenomenon
• The magnetic separator does not operate.
occurring on
machine
Relative • This error code detects abnormality on the primary side (coil side) of the magnetic separator relay but
information does not detect abnormality on the secondary side (contact side).

If fuse No. (10) is broken, the circuit probably has a grounding fault, etc.
1 Defective fuse No. (10)
(See cause 4.)
2 separator relay
Between (1) and (2) 100 – 500 z

Presumed cause and
3 (Disconnection in wiring Wiring harness between C2 (female) (8) and R7

Resistance Max. 1 z
harness or defective (female) (2)
contact in connector) Wiring harness between R7 (female) (1) and fuse (10). Resistance Max. 1 z
(Contact with ground R7 (female) (2) and chassis ground
circuit) Between wiring harness between R7 (female) (1) and
fuse (10) and chassis ground
bleshooting.
Defective engine throttle Magnetic separator-ON
5 C2 Voltage
and pump controller switch
Between (8) and OFF 20 – 30 V
chassis ground ON Max. 1 V
BR380JG-1 20-341
Electrical System Error Code [E250] (Short circuit in magnetic separator relay)
User Code Error Code Failure Code Failure Short circuit in magnetic separator relay
— E250 7RDNKB phenomenon (Engine throttle and pump controller system)
• When the magnetic separator relay circuit is connected to the chassis ground (the output is turned ON),
Failure content
an abnormal current flows.
• Turns the output to the magnetic separator relay circuit OFF.
Response from
controller
turned OFF.
Phenomenon
• The magnetic separator does not operate.
occurring on
machine
Relative • This error code detects abnormality on the primary side (coil side) of the magnetic separator relay but
information does not detect abnormality on the secondary side (contact side).

1 separator relay

Between (1) and (2) 100 – 500 z
Presumed cause and
2
bleshooting.
Defective engine throttle Magnetic separator-ON
3 C2 Voltage
and pump controller switch
Between (8) and OFF 20 – 30 V
chassis ground ON Max. 1 V
20-342 BR380JG-1
Electrical System Error Code [E301] (Disconnection in engine stop switch)
User Code Error Code Failure Code Failure Disconnection in engine stop switch
— E301 DDA6KA phenomenon (Engine throttle and pump controller system)
• The engine stop switch input signal circuit is opened (disconnected from the chassis ground) in 1 second
Failure content
after the starting switch is turned ON.
• None in particular (The engine stop switch is kept depressed).
Response from
controller
turned OFF.
Phenomenon
occurring on • When this trouble is detected, the horn sounds (3 times intermittently).
machine
Relative
—
information

starting switch ON.
Defective engine stop B16 (male) Engine stop switch Resistance
1
switch
ON Min. 1 Mz
Between (1) and (3)
Presumed cause and
OFF Max. 1 z
harness
Wiring harness between C2 (female) (3) and B16
(female) (3)
contact in connector) Wiring harness between B16 (female) (1) and chassis
Resistance Max. 1 z
ground
3
Between (3) and chassis ground Max. 1 z
BR380JG-1 20-343
Electrical System Error Code [E302] (Short circuit in primary belt conveyor-ON switch)
User Code Error Code Failure Code Failure Short circuit in primary belt conveyor-ON switch
— E302 7RC1KB phenomenon (Engine throttle and pump controller system)
• The primary belt conveyor-ON switch input signal circuit is closed (connected to the chassis ground) in
Failure content
1 second after the starting switch is turned ON.
• Turns the primary belt conveyor-ON switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the primary belt conveyor-ON switch is depressed, the primary belt conveyor does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective primary belt Primary belt
1 B1 (male) Resistance
conveyor-ON switch conveyor-ON switch
Presumed cause and
ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
2
B1 (female) (2) and chassis ground
3
20-344 BR380JG-1
Electrical System Error Code [E303] (Disconnection in primary belt conveyor-OFF

switch)
User Code Error Code Failure Code Failure Short circuit in primary belt conveyor-OFF switch
— E303 7RC2KA phenomenon (Engine throttle and pump controller system)
• The primary belt conveyor-OFF switch input signal circuit is opened (disconnected from the chassis
Failure content
ground) in 1 second after the starting switch is turned ON.
• Turns the primary belt conveyor-OFF switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the primary belt conveyor-ON switch is depressed, the primary belt conveyor does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective primary belt Primary belt
conveyor-OFF switch conveyor-OFF switch
ON Min. 1 Mz
Presumed cause and
(1) – (3)
OFF Max. 1 z
harness
Resistance Max. 1 z
ground
3
BR380JG-1 20-345
Electrical System Error Code [E304] (Short circuit in crusher-ON switch)
User Code Error Code Failure Code Failure Short circuit in crusher-ON switch
— E304 7RE1KB phenomenon (Engine throttle and pump controller system)
• The crusher-ON switch input signal circuit is closed (connected to the chassis ground) in 1 second after
Failure content
the starting switch is turned ON.
• Turns the crusher-ON switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the crusher-ON switch is depressed, the crusher does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective crusher-ON B3 (male) Crusher-ON switch Resistance
1
switch
ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
Defective radio control starting switch ON.

Presumed cause and
2
selector switch
Between B50 (male) (1) and (6) (Direct position) Resistance Max. 1 z
3
receiver
Between A33 (male) (11) and (3) Resistance Min. 1 Mz
(Contact with ground A33 (female) (11) and chassis ground
5
and pump controller
Between C1 (female) (12) and chassis ground Resistance Min. 1 Mz
20-346 BR380JG-1
BR380JG-1 20-347
Electrical System Error Code [E305] (Disconnection in crusher-OFF switch)
User Code Error Code Failure Code Failure Disconnection in crusher-OFF switch
— E305 7RE2KA phenomenon (Engine throttle and pump controller system)
• The crusher-OFF switch input signal circuit is opened (disconnected from the chassis ground) in 1 sec-
Failure content
ond after the starting switch is turned ON.
• Turns the crusher-OFF switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the crusher-OFF switch is depressed, the crusher does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective crusher-OFF B4 (male) Crusher-OFF switch Resistance
1
switch
ON Min. 1 Mz
Between (1) and (3)
OFF Max. 1 z
Defective crusher-OFF starting switch ON.
2
relay
Between RR2 (male) (3) and (6) Resistance Max. 1 z

Presumed cause and
3
receiver
Between A33 (male) (14) and (3) Resistance Min. 1 Mz
starting switch ON.
Disconnection in wiring Wiring harness between C1 (female) (6) and RR2
harness Resistance Max. 1 z
(female) (6)
Wiring harness between RR2 (female) (3) and B4
contact in connector) (female) (3)
Wiring harness between B4 (female) (1) and chassis
Resistance Max. 1 z
ground
5
and pump controller Wiring harness between C1 (female) (6) and chassis
Resistance Max. 1 z
ground
20-348 BR380JG-1
BR380JG-1 20-349
Electrical System Error Code [E306] (Abnormality in governor potentiometer)
User Code Error Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (Engine throttle and pump controller system)
Failure content • The signal voltage from the governor potentiometer is below 0.4 V or above 4.6 V.
• Calculates the motor position from the voltage just before occurrence of the failure for control.
Response from
controller
turned OFF.
• The high idling speed is abnormal (a little low).
• The low idling speed is abnormal (a little high).
Phenomenon
• The auto-decelerator or automatic warm-up device does not operate.
occurring on
• The engine hunts.
machine
• The engine stalls.
• The engine does not stop.
Relative
—
information

supply system
starting switch ON.
Defective governor E12 (male) Resistance
2 potentiometer
Between (A) and (C) 4.0 – 6.0 kz
(Internal defect)
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
starting switch ON.
Disconnection in wiring Wiring harness between C1 (female) (22) and E12
Resistance Max. 1 z
harness (female) (A)

Presumed cause and
contact in connector) (female) (C)
Resistance Max. 1 z
(female) (B)
4
E12 (female) (B) and chassis ground
5 Voltage Max. 1 V
(Contact with 24-V E12 (female) (A) and chassis ground
Voltage Max. 1 V
E12 (female) (B) and chassis ground
bleshooting.
6
and pump controller
20-350 BR380JG-1
BR380JG-1 20-351
Electrical System Error Code [E308] (Abnormality in fuel control dial)
User Code Error Code Failure Code Failure Abnormality in fuel control dial
E05 E308 DK10KZ phenomenon (Engine throttle and pump controller system)
Failure content • The signal voltage from the fuel control dial is below 0.23 V or above 4.77 V.
Response from • Calculates the fuel control dial position from the voltage just before occurrence of the failure for control.
• If the output was set in the full mode before occurrence of the failure, it is not set in the partial mode.
Phenomenon
• If the output was set in the partial mode before occurrence of the failure, it is not set in the full mode.
occurring on
machine
• The high idling speed is not obtained and the output is insufficient.
Relative
—
information

supply system
starting switch ON.
Defective fuel control dial E10 (male) Resistance

2
(Internal defect) Between (1) and (3) 4.0 – 6.0 kz
Between (2) and (1) 0.25 – 5.0 kz
Between (2) and (3) 0.25 – 5.0 kz
starting switch ON.
Disconnection in wiring Wiring harness between C1 (female) (22) and E10
Resistance Max. 1 z
harness (female) (1)

Presumed cause and
Resistance Max. 1 z
(female) (2)
4
E10 (female) (2) and chassis ground
5 Voltage Max. 1 V
(Contact with 24-V E10 (female) (1) and chassis ground
Voltage Max. 1 V
bleshooting.
6
and pump controller
20-352 BR380JG-1
BR380JG-1 20-353
Electrical System Error Code [E315] (Short circuit of battery relay output)
User Code Error Code Failure Code Failure Short circuit of battery relay output
— E315 D110KB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the battery relay drive circuit, an abnormal current flows.
• Turns the output to the battery relay drive circuit OFF.
Response from
controller
turned OFF.
Phenomenon • The engine does not stop (The controller power source cannot be maintained until the engine is
occurring on stopped).
Relative
—
information

starting switch ON.
Defective battery relay Battery relay (Unit) Resistance
1
(Internal defect)
T10 (BR) – T8 (E) Approx. 100 z
Presumed cause and
Between T10 (BR) and chassis ground Min. 1 Mz

2
(Contact with ground Between wiring harness between C3 (female) (4), D01,
and T10 (BR) and chassis ground
bleshooting.
3 C3 (female) Starting switch Voltage
and pump controller
Between (4) and 20 – 30 V
ON o OFF
chassis ground (4 – 7 sec)
20-354 BR380JG-1
BR380JG-1 20-355
Electrical System Error Code [E316] (Stepping out of governor motor)
User Code Error Code Failure Code Failure Stepping out of governor motor
— E316 DY10K4 phenomenon (Engine throttle and pump controller system)
• The signal input from the governor potentiometer is remarkably different from the value set in the con-
Failure content
troller.
• Repeats the control operation (Steps out).
Response from
controller
turned OFF.
Phenomenon • The engine speed cannot be controlled.
occurring on • The engine hunts.
machine • The engine does not stop.
Relative
—
information

Defective fuel control dial
system
Defective governor
potentiometer system
Presumed cause and
Defective governor motor

system (Disconnection)
system (Short circuit)
5 See TESTING AND ADJUSTING, Special functions of monitor panel.
governor lever
Defective fuel control
6 See 102 Series, Engine, Shop Manual.
system of engine
Troubleshooting cannot be carried out since the defect is in the engine throttle and
7 pump controller.
and pump controller
(If none of causes 1 – 6 is the cause of the failure, the controller must be defective.)
20-356 BR380JG-1
Electrical System Error Code [E317] (Disconnection in governor motor phases A and B)
User Code Error Code Failure Code Failure Disconnection in governor motor phases A and B
E05 E317 DY10KA phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the governor motor, no current flows.
• The engine speed is fixed to low idling.
Phenomenon
occurring on
machine
• The governor motor steps out.
Relative
—
information

starting switch ON.
Defective governor motor E11 (male) Resistance
1
Between (1) and (2) 2.5 – 7.5 z
Between (3) and (4) 2.5 – 7.5 z
starting switch ON.

Presumed cause and

Disconnection in wiring Resistance Max. 1 z
(female) (1)
harness
(female) (2)
Resistance Max. 1 z
(female) (3)
Resistance Max. 1 z
(female) (4)
starting switch ON.
3
and pump controller
Between (5) and (15) 2.5 – 7.5 z
Between (25) and (35) 2.5 – 7.5 z
20-358 BR380JG-1
BR380JG-1 20-359
Electrical System Error Code [E318] (Short circuit in governor motor phases A and B)
User Code Error Code Failure Code Failure Short circuit in governor motor phases A and B
E05 E318 DY10KB phenomenon (Engine throttle and pump controller system)
Failure content • When the signal is output to the governor motor, an abnormal current flows.
• The engine speed cannot be controlled.
Phenomenon
• The engine speed is fixed to low idling.
occurring on
machine
Relative
—
information

starting switch ON.
E11 (male) Resistance
1 (Internal short circuit or Between (1) and (2) 2.5 – 7.5 z
grounding fault) Between (3) and (4) 2.5 – 7.5 z
starting switch ON.

Presumed cause and
Disconnection in wiring Resistance Min. 1 Mz

(female) (1)
harness
2 (Disconnection in wiring Resistance Min. 1 Mz
(female) (2)
(female) (3)
(female) (4)
starting switch ON.
C3 (female) Resistance
Between (5) and (15) 2.5 – 7.5 z
Defective engine throttle Between (25) and (35) 2.5 – 7.5 z
3
and pump controller
20-360 BR380JG-1
BR380JG-1 20-361
Electrical System Error Code [E320] (Short circuit in feeder-ON switch)
User Code Error Code Failure Code Failure Short circuit in feeder-ON switch
— E320 7RC5KB phenomenon (Engine throttle and pump controller system)
• The feeder-ON switch input signal circuit is closed (connected to the chassis ground) in 1 second after
Failure content
the starting switch is turned ON.
• Turns the feeder-ON switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the feeder-ON switch is depressed, the feeder does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective feeder-ON B5 (male) Feeder-ON switch Resistance
1
switch
ON Max. 1 z
Between (1) and (2)
Presumed cause and
OFF Min. 1 Mz
(Contact with ground B5 (female) (2) and chassis ground
circuit) Between wiring harness between C3 (female) (10), A20
(3), and radio control switch and chassis ground
3
20-362 BR380JG-1
Electrical System Error Code [E321] (Disconnection in feeder-OFF switch)
User Code Error Code Failure Code Failure Disconnection in feeder-OFF switch
— E321 7REPKA phenomenon (Engine throttle and pump controller system)
• The feeder-OFF switch input signal circuit is opened (disconnected from the chassis ground) in 1 sec-
Failure content
ond after the starting switch is turned ON.
• Turns the feeder-OFF switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the feeder-ON switch is depressed, the feeder does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective feeder-OFF B6 (male) Feeder-OFF switch Resistance
1
switch
ON Min. 1 Mz
Between (1) and (3)
Presumed cause and
OFF Max. 1 z
harness
Resistance Max. 1 z
ground
3
BR380JG-1 20-363
Electrical System Error Code [E322] (Short circuit in conveyor RAISE switch)
User Code Error Code Failure Code Failure Short circuit in conveyor RAISE switch
— E322 7REJKB phenomenon (Engine throttle and pump controller system)
• The conveyor RAISE switch input signal circuit is closed (connected to the chassis ground) in 1 second
Failure content
• Turns the conveyor RAISE switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the conveyor RAISE switch is depressed, the conveyor does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective conveyor
1 B21 (male) Conveyor RAISE switch Resistance

RAISE switch
Presumed cause and
ON Max. 1 z
Between (4) and (5)
OFF Min. 1 Mz
2
3
20-364 BR380JG-1
Electrical System Error Code [E323] (Short circuit in conveyor lower switch)
User Code Error Code Failure Code Failure Short circuit in conveyor lower switch
— E323 7REKKB phenomenon (Engine throttle and pump controller system)
• The conveyor lower switch input signal circuit is closed (connected to the chassis ground) in 1 second
Failure content
• Turns the conveyor lower switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the conveyor lower switch is depressed, the conveyor does not lower.
occurring on
machine
Relative
—
information

starting switch ON.
Defective conveyor lower
1 B22 (male) Conveyor lower switch Resistance

switch
Presumed cause and
ON Max. 1 z
Between (4) and (5)
OFF Min. 1 Mz
2
3
BR380JG-1 20-365
Electrical System Error Code [E331] (Abnormality in clearance sensor potentiometer)
User Code Error Code Failure Code Failure Abnormality in clearance sensor potentiometer
— E331 7RENKZ phenomenon (Engine throttle and pump controller system)
Failure content • The signal voltage from the clearance sensor potentiometer is below 0.5 V or above 4.5 V.
• Does not display the correct clearance on the multi-monitor (Displays 0 as the clearance).
• Does not save clearance of 0 in the clearance adjustment mode.
Response from
• Does not save the wear limit standard angle.
controller
• Does not judge bear lock cylinder slip.
• The wear limit warning is not given.
Phenomenon
• The clearance cannot be adjusted.
occurring on
• Even if foreign matter is caught in the crusher and the swing jaw is widened, the crusher and feeder do
machine
not stop.
Relative
—
information

starting switch ON.
Defective clearance S12 (male) Resistance
1 sensor potentiometer
Between (A) and (C) 4.0 – 6.0 kz
(Internal defect)
Between (B) and (A) 0.25 – 5.0 kz
Between (B) and (C) 0.25 – 5.0 kz
starting switch ON.
(female) (C)

harness or defective Max. 1 z
Presumed cause and
Resistance
Resistance Max. 1 z
(female) (B)
3
S12 (female) (B) and chassis ground
4 Voltage Max. 1 V
(Contact with 24-V S12 (female) (C) and chassis ground
Voltage Max. 1 V
S12 (female) (B) and chassis ground
bleshooting.
5
and pump controller
20-366 BR380JG-1
BR380JG-1 20-367
Electrical System Error Code [E332] (Short circuit in one-touch start switch)
User Code Error Code Failure Code Failure Short circuit in one-touch start switch
— E332 7RESKB phenomenon (Engine throttle and pump controller system)
• The one-touch start switch input signal circuit is closed (connected to the chassis ground) in 1 second
Failure content
• Turns the one-touch start switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the one-touch start switch is depressed, the work equipment does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective one-touch start B32 (male) One-touch start switch Resistance
1
switch
ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
(Contact with ground D16 (female) (2) and chassis ground
circuit)
Between wiring harness between D16 (female) (1) and

Presumed cause and

3
selector switch
Between B50 (male) (1) and (6) (Direct position) Resistance Max. 1 z
starting switch ON.
4 Defective diode D16 (male) Continuity
Between (1) and (2) Broken
Between (2) and (1) Made
starting switch ON.
A42 (male) Resistance
Between (3) and (6) 2.0 – 2.4 z
6
20-368 BR380JG-1
BR380JG-1 20-369
Electrical System Error Code [E333] (Disconnection in one-touch stop switch)
User Code Error Code Failure Code Failure Disconnection in one-touch stop switch
— E333 7RETKA phenomenon (Engine throttle and pump controller system)
• The one-touch stop switch input signal circuit is opened (disconnected from the chassis ground) in 1
Failure content
second after the starting switch is turned ON.
• Turns the one-touch stop switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the one-touch start switch is depressed, the work equipment does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective one-touch stop B33 (male) One-touch stop switch Resistance
1
switch
ON Min. 1 Mz
Between (1) and (3)
OFF Max. 1 z
starting switch ON.
Disconnection in wiring Between wiring harness between C1 (female) (3) and
D17 (female) (2) and chassis ground
Between wiring harness between D17 (female) (1) and
Presumed cause and

contact in connector) B33 (female) (3) and chassis ground
Resistance Max. 1 z
ground
starting switch ON.
starting switch ON.
Between (2) and (7) 2.0 – 2.4 z
5
20-370 BR380JG-1
BR380JG-1 20-371
Electrical System Error Code [E334] (Short circuit in magnetic separator-ON switch)
User Code Error Code Failure Code Failure Short circuit in magnetic separator-ON switch
— E334 7RE8KB phenomenon (Engine throttle and pump controller system)
• The magnetic separator-ON switch input signal circuit is closed (connected to the chassis ground) in 1
Failure content
second after the starting switch is turned ON.
• Turns the magnetic separator-ON switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the magnetic separator-ON switch is depressed, the magnetic separator does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective magnetic Magnetic separator-ON
separator-ON switch switch
ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
Presumed cause and
(Contact with ground D14 (female) (2) and chassis ground

circuit) Between wiring harness between D14 (female) (1) and
starting switch ON.
starting switch ON.
Between (1) and (8) 2.0 – 2.4 z
5
20-372 BR380JG-1
BR380JG-1 20-373
Electrical System Error Code [E335] (Disconnection in magnetic separator-OFF

switch)
User Code Error Code Failure Code Failure Disconnection in magnetic separator-OFF switch
— E335 7RE9KA phenomenon (Engine throttle and pump controller system)
• The magnetic separator-OFF switch input signal circuit is opened (disconnected from the chassis
Failure content
ground) in 1 second after the starting switch is turned ON.
• Turns the magnetic separator-OFF switch input OFF.
Response from
controller
turned OFF.
Phenomenon
• When the magnetic separator-ON switch is depressed, the magnetic separator does not operate.
occurring on
machine
Relative
—
information

starting switch ON.
Defective magnetic B10 (male) One-touch stop switch Resistance
1
separator-OFF switch
ON Min. 1 Mz
Between (1) and (3)
OFF Max. 1 z
starting switch ON.
Disconnection in wiring Wiring harness between C1 (female) (14) and D15
(female) (2)
Wiring harness between D15 (female) (1) and B10
Presumed cause and

Resistance Max. 1 z
ground
starting switch ON.
starting switch ON.
Between (4) and (5) 2.0 – 2.4 z
5
20-374 BR380JG-1
BR380JG-1 20-375
TROUBLESHOOTING A000N1, A000N2
Mechanical System Error Code [A000N1] (Engine high idling speed out of standard)
User Code Error Code Failure Code Failure Engine high idling speed out of standard
— — A000N1 phenomenon (Mechanical system)
Failure content • Engine speed above 2,350 rpm is sensed for 10 seconds continuously while the engine is running.
Phenomenon
occurring on • If the machine is operated as it is, the engine may be damaged.
machine
information (Code 010: Engine speed)

Presumed cause and
Defective mechanical Check for external and internal factors that have heightened the engine high idling
1
system of engine speed, and then carry out troubleshooting for the mechanical system of the engine.
2 pump controller.
and pump controller
(If there is not any visible trouble in the machine, the controller may be used as it is.)
Mechanical System Error Code [A000N2] (Engine low idling speed out of standard)
User Code Error Code Failure Code Failure Engine low idling speed out of standard
— — A000N2 phenomenon (Mechanical system)
Failure content • Engine speed below 500 rpm is sensed for 10 seconds continuously while the engine is running.
Phenomenon
machine
information (Code 010: Engine speed)

Presumed cause and
Defective mechanical Check for external and internal factors that have lowered the engine low idling speed,
1
system of engine and then carry out troubleshooting for the mechanical system of the engine.
2 pump controller.
and pump controller
(If there is not any visible trouble in the machine, the controller may be used as it is.)
20-376 BR380JG-1
TROUBLESHOOTING AA10NX
Mechanical System Error Code [AA10NX] (Clogged air cleaner)
User Code Error Code Failure Code Failure Clogged air cleaner
— — AA10NX phenomenon (Mechanical system)
• While the engine is running, the signal circuit of the air cleaner clogging switch is opened (disconnected
Failure content
from the chassis ground).
Response from
• None in particular.
monitor panel
Phenomenon
machine
• If the air cleaner clogging monitor on the monitor panel lights red while the engine is running, this failure
Relative code is recorded.
information • Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.
(Code 046: Monitor input 2)

Clogged air cleaner
1 Check the air cleaner. If it is clogged, clean or replace it.
(When system is normal)
starting switch ON.
Defective air cleaner
S15 (male) Air cleaner Resistance
2 clogging switch
Presumed cause and
(Internal disconnection) Normal Max. 1 z

Between (1) and (2)
Clogged Min. 1 Mz
harness
Wiring harness between P2 (female) (5) and S15
(female) (1)
contact in connector) Wiring harness between S15 (female) (2) and chassis
Resistance Max. 1 z
ground
aPrepare with starting switch OFF, then start engine and carry out troubleshooting.
P2 Air cleaner Voltage
Between (5) and Normal Max. 1 V
chassis ground Clogged 20 – 30 V
BR380JG-1 20-377
TROUBLESHOOTING AB00KE
Mechanical System Error Code [AB00KE] (Abnormal lowering of charging voltage)
User Code Error Code Failure Code Failure Abnormal lowering of charging voltage
— — AB00KE phenomenon (Mechanical system)
Failure content • While the engine is running, the generation signal is not input from the alternator.
Response from
monitor panel
Phenomenon
occurring on • If the machine is operated as it is, the battery may not be charged.
machine
• If the charge level monitor on the monitor panel lights red while the engine is running, this failure code
Relative is recorded.
information • Input from the alternator (ON or OFF) can be checked in the monitoring function.
(Code 043: Charging voltage)

Defective alternator M2 (male) Engine speed Voltage
1
(Insufficient generation) Between (1) and
Medium or higher 27.5 – 29.5 V
chassis ground
Presumed cause and

Wiring harness between P2 (female) (11) and M2
3
(Contact with ground Between wiring harness between P2 (female) (11) and
M2 (female) (1) and chassis ground
P2 Engine speed Voltage
Between (11) and
Medium or higher 27.5 – 29.5 V
chassis ground
20-378 BR380JG-1
TROUBLESHOOTING B@BAZG
Mechanical System Error Code [B@BAZG] (Abnormal lowering of engine oil pressure)
User Code Error Code Failure Code Failure Abnormal lowering of engine oil pressure
— — B@BAZG phenomenon (Mechanical system)
• While the engine is running, the signal circuit of the engine oil pressure switch is closed (connected to
Failure content
the chassis ground).
Response from
monitor panel
Phenomenon
occurring on • If the machine is operated as it is, the engine may be seized.
machine
• If the engine oil pressure monitor on the monitor panel lights red while the engine is running, this failure
Relative code is recorded.
information • Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.

Lowering of engine oil
Check the engine oil pressure. If it is abnormal, find the cause and check the engine
1 pressure
for damage, then repair.
Defective engine oil

Presumed cause and
E5 (Unit) Engine oil pressure Resistance

2 pressure switch
(Internal short circuit) Between terminal and Normal Min. 1 Mz
chassis ground Low Max. 1 z
3
E5 (terminal) and chassis ground
P2 Engine oil pressure Voltage
Between (7) and Normal 20 – 30 V
chassis ground Low Max. 1 V
BR380JG-1 20-379
TROUBLESHOOTING B@BAZK
Mechanical System Error Code [B@BAZK] (Abnormal lowering of engine oil level)
User Code Error Code Failure Code Failure Abnormal lowering of engine oil level
— — B@BAZK phenomenon (Mechanical system)
• While the engine is stopped (with the starting switch in the ON position), the signal circuit of the engine
Failure content
oil level switch is opened (disconnected from the chassis ground).
Response from
monitor panel
Phenomenon
machine
• If the engine oil level monitor on the monitor panel lights red while the engine is stopped (with the starting
Relative switch in the ON position), this failure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.

Lowering of engine oil
Check the oil level in the engine oil pan. If it is low, add oil. (If this trouble occurs
1 level
frequently, find the cause.)
starting switch ON.
Defective engine oil level
2 switch E3 (male) Engine oil level Resistance

Presumed cause and
(Internal disconnection) Between (1) and Normal Max. 1 z

chassis ground Low Min. 1 Mz
Between wiring harness between P2 (female) (8) and
contact in connector) E3 (female) (1) and chassis ground
bleshooting.
4 Defective monitor panel P2 Engine oil level Voltage
chassis ground Low 20 – 30 V
20-380 BR380JG-1
TROUBLESHOOTING B@BCNS
Mechanical System Error Code [B@BCNS] (Overheating of engine coolant)
User Code Error Code Failure Code Failure Overheating of engine coolant
— — B@BCNS phenomenon (Mechanical system)
Failure content • While the engine is running, the signal of the engine coolant temperature sensor exceeds 102°C
Response from
monitor panel
Phenomenon
machine
• If the engine coolant temperature gauge on the monitor panel enters the red range while the engine is
Relative running, this failure code is recorded.
information • Input from the engine coolant temperature sensor (temperature) can be checked in the monitoring func-
tion. (Code 041: Engine coolant temperature)

Overheating of engine The engine may have overheated. Find the cause and check the engine for damage,
1
(When system is normal) then repair.
starting switch ON.
Defective engine coolant Engine coolant
E4 (male) Resistance
2 temperature sensor temperature
(Internal short circuit) Between (1) and (2) 90 – 3.5 kz

Presumed cause and
Between (1) and 10 – 100°C

Min. 1 Mz
chassis ground
3
starting switch ON.
Engine coolant
P2 Resistance
4 Defective monitor panel temperature
Between (1) and (13) 90 – 3.5 kz
Min. 1 Mz
chassis ground
BR380JG-1 20-381
TROUBLESHOOTING B@BCZK
Mechanical System Error Code [B@BCZK] (Abnormal lowering of radiator coolant

level)
User Code Error Code Failure Code Failure Abnormal lowering of radiator coolant level
— — B@BCZK phenomenon (Mechanical system)
• While the engine is running, the signal circuit of the radiator coolant level switch is opened (disconnected
Failure content
from the chassis ground).
Response from
monitor panel
Phenomenon
occurring on • If the machine is operated as it is, the engine may overheat.
machine
• If the radiator coolant level monitor on the monitor panel lights red while the engine is stopped (with the
Relative starting switch in the ON position), this failure code is recorded.
information • Input from the radiator coolant level switch (ON or OFF) can be checked in the monitoring function.

Lowering of radiator
Check the water level in the radiator sub tank. If it is low, add water.
1 coolant level
(If this trouble occurs frequently, find the cause.)
starting switch ON.
Defective radiator
S16 (male) Radiator coolant level Resistance
2 coolant level switch

Presumed cause and
(Internal disconnection) Normal Max. 1 z

Between (1) and (2)
Low Min. 1 Mz
harness
Between wiring harness between P2 (female) (3) and
S16 (female) (1) and chassis ground
contact in connector) Between wiring harness between S16 (female) (2) and
Resistance Max. 1 z
chassis ground
bleshooting.
4 Defective monitor panel P2 Air cleaner Voltage
chassis ground Low 20 – 30 V
20-382 BR380JG-1
TROUBLESHOOTING B@HANS
Mechanical System Error Code [B@HANS] (Overheating of hydraulic oil)
User Code Error Code Failure Code Failure Overheating of hydraulic oil
— — B@HANS phenomenon (Mechanical system)
Failure content • While the engine is running, the signal of the hydraulic oil temperature sensor exceeds 102°C.
Response from
monitor panel
Phenomenon
occurring on • If the machine is operated as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature gauge on the monitor panel lights red while the engine is running, this
Relative failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring function.
(Code 044: Hydraulic oil temperature)

Overheating of
The hydraulic oil may have overheated. Find the cause and check the engine for
1 hydraulic oil
damage, then repair.
starting switch ON.
Defective hydraulic oil S17 (male) Hydraulic oil temperature Resistance
2 temperature sensor
Between (1) and (2) 90 – 3.5 kz
Presumed cause and

Min. 1 Mz
chassis ground
3
starting switch ON.
Engine coolant
P2 Resistance
4 Defective monitor panel temperature
Between (12) and (13) 90 – 3.5 kz
Min. 1 Mz
chassis ground
BR380JG-1 20-383
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

E-1 The engine does not start (The engine does not crank). .................................................................. 20-404
E-2 The engine stops while it is running.................................................................................................. 20-407
E-3 The engine rotation is unstable (The engine hunts).......................................................................... 20-408
E-4 The engine does not stop. ................................................................................................................ 20-410
E-5 The whole work equipment stops suddenly. ..................................................................................... 20-412
E-6 The automatic warm-up function does not work. .............................................................................. 20-413
E-7 The engine preheater does not operate. .......................................................................................... 20-414
E-8 The red mark of emergency stop is indicated just after the engine is started................................... 20-416
E-9 The monitor panel does not display any item. .................................................................................. 20-418
E-10 Some items are not displayed on the monitor panel......................................................................... 20-419
E-11 The fuel level monitor lights red while the engine is running. ........................................................... 20-420
E-12 The engine coolant temperature gauge does not display normally .................................................. 20-421
E-13 The fuel level gauge does not display normally. ............................................................................... 20-422
E-14 The hydraulic oil temperature gauge does not display normally....................................................... 20-423
E-15 The travel, work, and inspection modes do not change. .................................................................. 20-424
E-16 The crusher clearance adjustment mode does not change. ............................................................. 20-426
E-17 The crusher rotation direction does not change................................................................................ 20-428
E-18 Travel cannot be controlled by radio control. .................................................................................... 20-429
E-19 The feeder cannot be turned ON and OFF by radio control. ............................................................ 20-432
E-20 The crusher cannot be turned ON and OFF by radio control. .......................................................... 20-434
E-21 The monitor switches do not work. ................................................................................................... 20-436
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch
on the monitor. .................................................................................................................................. 20-437
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch
on the monitor. .................................................................................................................................. 20-438
BR380JG-1 20-401

Phenomenon
occurring on Phenomena occuring on machine
machine
Relative
Information on occurred failures and troubleshooting
information

<Content Included>
the presumed cause
1
<Phenomenon of Wiring Harness Failure>

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness oc-
curred.
2 • Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact with
the grounding circuit.

Presumed cause and
• Short-circuiting
Cause that presumably
A wiring harness that is not connected with a 24 V electric circuit has a contact with
the electric circuit.
tion
3
(The assigned No. is for
<Precaution for Troubleshooting>
1) Connector No. display method and handling of T-adapter
Insert or connect T-adapters in the following manner before starting troubleshoot-
priority)
ing unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., discon-
4 nect the connector and insert the T-adapter into both male and female sides.
• If there is an indication of "male" or "female" in a specific connector No., discon-
nect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5 • Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring
harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
20-402 BR380JG-1
TROUBLESHOOTING E-1
E-1 The engine does not start (The engine does not crank).
Phenomenon
occurring on • The engine does not start (The engine does not crank).
machine
Relative • The engine starting circuit is equipped with the start lock mechanism which is operated with a password
information through the monitor panel.

Insufficient battery Battery voltage Electrolyte specific gravity
1
capacity Min. 24 V Min. 1.26
If the fuse or block fuse is broken, the circuit probably has a grounding fault, etc.
Defective fuse No. 1 or
2 If the monitor panel does not light up, check the power cable between the battery and
block fuse E2
fuse, too.
starting switch ON.
Defective starting switch Starting switch Position Resistance
3
OFF Min. 1 Mz
Between terminals B and C
START Max. 1 z
starting switch ON.
Defective starting motor
cutout relay R1 R1 (male) Resistance
4
(Internal disconnection or Between (1) and (2) 250 – 350 z
short circuit) Between (3) and (5) Min. 1 Mz
Between (3) and (6) Max. 1 z
Presumed cause and
(If the power cable, grounding, generation signal, and starting input are normal but
the starting output is abnormal, the starting motor relay is defective.)
Safety relay Starting switch Voltage
Power cable: Terminal B –
20 – 30 V
Chassis ground
Defective safety relay
Grounding: Terminal E –
5 (Internal disconnection or Connected
Chassis ground
short circuit)
Generation signal: Termi-
START Max. 1 V
nal R – Chassis ground
Starting input: Terminal C –
20 – 30 V
Chassis ground
Starting output: Terminal S
20 – 30 V
– Chassis ground
(If the power cable and starting input are normal but the starting motor does not run,
the starting motor is defective.)
Defective starting motor Starting motor Starting switch Voltage
6 (Internal disconnection or
breakage) Power cable: Terminal B –
20 – 30 V
Chassis ground
START
Starting input: Terminal C –
20 – 30 V
Chassis ground
Defective alternator carry out troubleshooting.
7
(Internal short circuit) M2 (male) Voltage
Between (1) and chassis ground Max. 1 V
20-404 BR380JG-1
TROUBLESHOOTING E-1

aPrepare with starting switch OFF, then turn starting switch ON and carry out trouble-
Defective battery relay shooting.
(Disconnection or Battery relay Starting switch Voltage
8
defective tightening of Between battery relay OFF 0V
terminal) terminal M and chassis
ground ON 20 – 30 V
starting switch ON.
Between starting switch terminal B and E2 (female) (2) Resistance Max. 1 z
Between starting switch terminal C and R1 (female) (6) Resistance Max. 1 z
Disconnection in wiring Between R1 (female) (3) and safety relay terminal S Resistance Max. 1 z
harness Between safety relay terminal C and starting motor ter-
minal C
Between starting switch terminal BR and battery relay

contact in connector) Resistance Max. 1 z
Presumed cause and
terminal BR
Between starting switch terminal B and battery relay ter-
Resistance Max. 1 z
minal B
Between battery relay terminal M and starting motor ter-
Resistance Max. 1 z
minal B
starting switch ON.
Between wiring harness between fuse (1) outlet and
starting switch terminal B and chassis ground
Short circuit with chassis Between wiring harness between battery relay terminal
ground in wiring harness B and fuse No. 1 inlet and chassis ground
10
(Contact with ground Between wiring harness between battery relay terminal
BR and starting switch terminal BR and chassis ground
Between wiring harness between R1 (female) (2) and P2
Between wiring harness between R1 (female) (3) and E9
aPrepare with starting switch OFF, then turn starting switch ON and carry out trouble-
Short circuit with power shooting.
11 source in wiring harness Between wiring harness between E9 (female) (2), M2
(Contact with 24-V circuit) (female) (1), D1 (female) (6), and P2 (female) (11) and Voltage Max. 1 V
chassis ground
BR380JG-1 20-405
TROUBLESHOOTING E-1
Electrical circuit diagram related to engine starting, stopping and charging
20-406 BR380JG-1
TROUBLESHOOTING E-2
E-2 The engine stops while it is running.
Phenomenon
occurring on • The engine stops while it is running.
machine
Relative
• Input from the fuel control dial (voltage) can be checked in the monitoring function of the monitor panel.
information

Disconnection in
starting switch ON.
ACC line
1 (Defective contact in C1 (female) Starting switch Voltage
connector or looseness Between (23) and OFF Max. 1 V
of round terminal screw) chassis ground ACC 20 – 30 V
Presumed cause and

harness or defective Between C1 (female) (19) and E10 (female) (2) Resistance Max. 1 z
contact in connector)
3
bleshooting.
4
and pump controller
(22) – (21) 4.5 – 5.5 V
(19) – (21) 0.5 – 4.5 V
Electrical circuit diagram related to fuel control dial
BR380JG-1 20-407
TROUBLESHOOTING E-3
E-3 The engine rotation is unstable (The engine hunts).
Phenomenon • The low idling speed is unstable.

occurring on • The engine hunts.
machine • The high idling speed is low.
Relative
• The engine speed can be checked in the monitoring function of the monitor panel.
information

Defective model code bleshooting.
1
signal Item Normal display
Controller model code 380
2 Adjust the governor lever. [See TESTING AND ADJUSTING.]
governor lever
When the following operation is performed, if the governor motor lever can be oper-
Malfunction of governor ated smoothly, it is normal.

3
Presumed cause and
motor • Operate the fuel control dial between LOW IDLING and HIGH IDLING.
• Turn the starting switch OFF to stop the engine.
Defective engine fuel
4 See 102 Series Engine Shop Manual.
control system
harness or defective Between C1 (female) (23) and starting switch terminal
Resistance Max. 1 z
contact in connector) ACC
6
starting switch terminal ACC and chassis ground
7 pump controller.
and pump controller
(If none of causes 1 – 6 is the cause of the failure, the controller must be defective.)
20-408 BR380JG-1
TROUBLESHOOTING E-3
BR380JG-1 20-409
TROUBLESHOOTING E-4
E-4 The engine does not stop.
Phenomenon
occurring on • The engine does not stop.
machine
• The engine throttle and pump controller drives the battery relay for 4 – 7 seconds after the starting switch
Relative is turned OFF until the engine is stopped completely.
information • The operating condition of the battery relay can be checked in the monitoring function of the monitor
panel.

When the starting switch is operated, if the operating sound of the battery relay con-
1 Defective battery relay tacts is heard, the battery relay is normal.
• Starting switch: OFF o ON o OFF
Defective assembled- starting switch ON.
2 type diode D1
Presumed cause and
D1 (male) Digital tester Continuity

Between (5) and (1) Diode mode Made
Disconnection in wiring
starting switch ON.
harness
3 (Disconnection in wiring Between C3 (female) (4) and D1 (female) (5) Resistance Max. 1 z
harness or defective Between D1 (female) (1) and battery relay terminal BR Resistance Max. 1 z
Between battery relay terminal E and chassis ground Resistance Max. 1 z
bleshooting.
4 Defective controller C3 Starting switch Voltage
Between (4) and
ON o OFF 20 – 30 V (4 – 7 sec)
chassis ground
20-410 BR380JG-1
TROUBLESHOOTING E-4
BR380JG-1 20-411
TROUBLESHOOTING E-5
E-5 The whole work equipment stops suddenly.
Phenomenon
occurring on • The whole work equipment stops suddenly.
machine
• The work equipment stops suddenly while no switches are operated in the following cases; (1) The work
equipment is overloaded. (2) Engine has abnormality. In these cases, the horn sounds.
Relative
• In addition to the above cases, the output is turned OFF at the instant when the engine speed exceeds
information
a certain level. In this case, the horn does not sound, however. If the engine speed sensor is shorted
momentarily while the machine is in operation, the work equipment may stop for this reason.

Defective engine speed starting switch ON.
sensor E6 (male) Resistance
1
disconnection) Between (1) and (2) 500 – 1,000 z

Presumed cause and

Between C2 (female) (40) and E6 (female) (1) Resistance Max. 1 z
contact in connector) Between C2 (female) (39) and E6 (female) (2) Resistance Max. 1 z
Short circuit in wiring starting switch ON.
harness
3 500 –
(Grounding fault or short C2 (female) (39) and C2 (female) (40) Resistance
1,000 z
circuit)
Between C2 (female) (40) and chassis ground Resistance Min. 1 Mz
20-412 BR380JG-1
TROUBLESHOOTING E-6
E-6 The automatic warm-up function does not work.
Phenomenon
occurring on • The automatic warm-up function does not work.
machine
• When the engine coolant temperature is below 30°C, the automatic warm-up device raise the engine
Relative speed to 1,200 rpm.
information • If the fuel control dial is opened more than 70% for 3 seconds when the starting switch is turned ON or
after the engine is started, the automatic warm-up function is reset.

Presumed cause and
If the monitor does not display normally, go to troubleshooting No. E-12.

Monitoring code Monitoring item Normal display
Defective engine coolant
1 Compare with actual
temperature signal Engine coolant
041 engine coolant tempera-
temperature
ture.
Troubleshooting cannot be carried out since the defect is in the controller.

2 Defective controller
(If the above cause is not the cause of the failure, the controller must be defective.)
BR380JG-1 20-413
TROUBLESHOOTING E-7
E-7 The engine preheater does not operate.
Phenomenon
occurring on • When the starting switch is turned to the PREHEAT position, the preheater monitor does not light up.
machine (1)
Relative • The preheating signal can be checked in the monitoring function of the monitor panel.
information (Code 045: Monitor input 1)

Defective starting switch If the engine is not preheated (the heater unit does not become hot), carry out trou-
1
system bleshooting for Phenomenon occurring on machine (2)

Presumed cause and
harness or defective Between P2 (female) (18) and starting switch terminal
Resistance Max. 1 z
contact in connector) R1
aPrepare with starting switch OFF.
P2 Starting switch Voltage
chassis ground HEAT 20 – 30 V
Phenomenon
occurring on • When the starting switch is turned to the PREHEAT position, the heater unit does not become hot.
machine (2)
• When the temperature is low (the coolant temperature is below 30°C), the engine throttle and pump con-
Relative troller drives the heater relay automatically to preheat the engine for 100 seconds after the engine is
information started.
• The preheating signal can be checked in the monitoring function of the monitor panel.

aPrepare with starting switch OFF.
Defective starting switch Starting switch Starting switch Voltage
1 system
(Internal disconnection) Between terminal R1 OFF Max. 1 V
and chassis ground Position R1 20 – 30 V
starting switch ON.

Presumed cause and
Defective heater relay Heater relay Continuity/Resistance

2
Between coil terminals Continuity made
Between contact terminals (T6 – T5) Min. 1 Mz
Defective electrical aPrepare with starting switch OFF, then carry out troubleshooting without turning
3 intake air heater (Internal starting switch ON.
disconnection) Between heater terminals If continuity is found, it is normal
harness Between C3 (female) (18) and terminal T7 Resistance Max. 1 z
harness or defective Between key switch terminal R1 and terminal T7 Resistance Max. 1 z
contact in connector) Wiring harness between battery relay terminal M and
Resistance Max. 1 z
terminal T6
20-414 BR380JG-1
TROUBLESHOOTING E-7
Electrical circuit diagram related to engine preheating
BR380JG-1 20-415
TROUBLESHOOTING E-8
E-8 The red mark of emergency stop is indicated just after the engine is started.
Phenomenon
• The red mark of emergency stop is indicated just after the starting switch is turned ON.
occurring on
• In this case, the work equipment cannot be started.
machine
Relative
• The emergency stop signal can be checked in the monitoring function of the monitor panel.
information

Defective emergency starting switch ON.
stop switch
B12 (male), B19 (male), B20 (male),
B30 (male), B31 (male), B53 (male), Resistance
B54 (male)
Presumed cause and

harness Between C2 (male) (36) and A36 (male) (1) Resistance Max. 1 z
Between A36 (male) (2) and (3) Resistance Max. 1 z
contact) Between A36 (male) (4) and (5) Resistance Max. 1 z
Between A36 (male) (6) and chassis ground Resistance Max. 1 z
starting switch ON.
3 Defective controller
C2 (female) Resistance
20-416 BR380JG-1
TROUBLESHOOTING E-8
BR380JG-1 20-417
TROUBLESHOOTING E-9
E-9 The monitor panel does not display any item.
Phenomenon
occurring on • When the starting switch is turned ON, the monitor panel does not display any item.
machine
Relative
—
information

1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault.
Presumed cause and
Between P1 (female) (1), (2) and fuse (11) Resistance Max. 1 z

contact in connector) Between P1 (female) (6), (7) and chassis ground Resistance Max. 1 z
3
(Contact with ground Between wiring harness between P1 (female) (1), (2)
and fuse (11) and chassis ground
bleshooting.
P1 Voltage
Between (1), (2) and (6), (7) 20 – 30 V
Electrical circuit diagram related to monitor panel power supply system
20-418 BR380JG-1
TROUBLESHOOTING E-10
E-10 Some items are not displayed on the monitor panel.
Phenomenon
occurring on • When the starting switch is turned ON, some items are not displayed on the monitor panel.
machine
Relative
—
information

Presumed cause and
If all the LCD units on the panel light up (white) when the following switches are oper-
Defective monitor panel
1 ated, the LCD units are normal.
LCD
• Operation of switches: [ ] + [e] (Depress simultaneously)
Troubleshooting cannot be carried out since the defect is in the monitor panel.
2 Defective monitor panel (If the above cause is not the cause of the failure, the monitor panel must be defec-
tive.)
BR380JG-1 20-419
E-11 The fuel level monitor lights red while the engine is running.
Phenomenon
occurring on • The fuel level monitor lights red while the engine is running.
machine
• The input signals from the fuel level sensor can be checked in the monitoring function of the monitor
Relative
panel.
information
• If the fuel level gauge on the monitor panel enters the red range, the fuel level monitor lights red.

Lowering of fuel level
1 aAdd fuel.
starting switch ON.
Defective fuel level
2 sensor S14 (male) Fuel level Resistance

Presumed cause and
(Internal disconnection) Between (1) and FULL (Upper limit) Approx. 12 z

chassis ground EMPTY (Lower limit) 85 – 110 z
harness or defective Between P2 (female) (2) and S14 (female) (1) Resistance Max. 1 z
starting switch ON.
4 Defective controller P2 (female) Fuel level Resistance
Between (2) and FULL (Upper limit) Approx. 12 z
Electrical circuit diagram related to fuel level sensor
20-420 BR380JG-1
E-12 The engine coolant temperature gauge does not display normally
• While the engine coolant temperature rises normally, the temperature gauge does not rise from the
Phenomenon
white range (C).
occurring on
• While the engine coolant temperature is stabled normally, the temperature gauge rises to the red range
machine
(H).
Relative • Input from the engine coolant temperature sensor (temperature) can be checked in the monitoring func-
information tion of the monitor panel.

starting switch ON.
Defective engine coolant Engine coolant
temperature sensor E4 (male) Resistance
1 temperature
(Internal disconnection or
short circuit) Between (1) and (2) 90 – 3.5 kz
Min. 1 Mz
chassis ground
Between P2 (female) (1) and E4 (female) (1) Resistance Max. 1 z
Presumed cause and
contact in connector) Between P2 (female) (13) and E4 (female) (2) Resistance Max. 1 z
3
E4 (female) (1)
4
(Contact with 24-V Between wiring harness between P2 (female) (1) and
E4 (female) (1)
starting switch ON.
Engine coolant
P2 (female) Resistance
5 Defective controller temperature
Between (1) and (13) 90 – 3.5 kz
Min. 1 Mz
chassis ground
Electrical circuit diagram related to monitor panel engine coolant sensor
BR380JG-1 20-421
E-13 The fuel level gauge does not display normally.
Phenomenon
• After fuel is added, the fuel level gauge does not rise from the red range (E).
occurring on
• After the fuel level lowers, the fuel level gauge does not lower from the green range (F).
machine
Relative
• Input from the fuel level sensor (voltage) can be checked in the monitoring function.
information

Defective fuel level starting switch ON.
sensor S14 (male) Fuel level Resistance
1
short circuit) Between (1) and FULL (Upper limit) Approx. 12 z
Presumed cause and
harness or defective Between P2 (female) (2) and S14 (female) (1) Resistance Max. 1 z
3
4
starting switch ON.
5 Defective monitor panel P2 (female) Fuel level Resistance
Between (2) and FULL (Upper limit) Approx. 12 z
Electrical circuit diagram related to fuel level sensor
20-422 BR380JG-1
E-14 The hydraulic oil temperature gauge does not display normally
Phenomenon • While the hydraulic oil temperature rises normally, the temperature gauge does not rise from the white
occurring on range (C).
machine • While the hydraulic oil temperature is stabled normally, the temperature gauge rises to the red range (H).
Relative • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring function
information of the monitor panel. (Code 044: Hydraulic oil temperature)

starting switch ON.
Defective hydraulic oil
temperature sensor S17 (male) Hydraulic oil temperature Resistance
1
(Internal disconnection or Between (1) and (2) 38 z – 3.9 kz
short circuit) 25 – 100°C
Between (1) and
Min. 1 Mz
chassis ground
Between P2 (female) (12) and S17 (female) (1) Resistance Max. 1 z
Presumed cause and
contact in connector) Between P2 (female) (13) and S17 (female) (2) Resistance Max. 1 z
3
S17 (female) (1)
4
S17 (female) (1)
starting switch ON.
P2 (female) Hydraulic oil temperature Resistance
Between (12) and (13) 38 z – 3.9 kz
Min. 1 Mz
chassis ground
Electrical circuit diagram related to monitor panel hydraulic oil temperature sensor
BR380JG-1 20-423
E-15 The travel, work, and inspection modes do not change.
Phenomenon
occurring on • When the mode selector switch is changed, the current mode does not change.
machine
Relative • The mode selector switches (Mode selector work switch of switch input 2 and mode selector travel
information switch) can be checked in the monitoring function of the monitor panel.

Disconnection of S-NET If "Disconnection of S-NET signal" is displayed in the electrical system error on the
1
signal monitor, carry out troubleshooting for it.
starting switch ON.
Selector switch B13
Position of selector switch Resistance
(male)
Defective mode selector
Between (2) and (4) Min. 1 Mz
switch Inspection
2 Between (3) and (4) Min. 1 Mz
Work
Travel
3 Defective fuse (10) If the fuse or block fuse is broken, the circuit probably has a grounding fault, etc.

Presumed cause and
Between C1 (female) (5) and B13 (female) (2) Resistance Max. 1 z
contact in connector) Between C1 (female) (11) and B13 (female) (3) Resistance Max. 1 z
Grounding fault in wiring bleshooting.
harness Between wiring harness between C1 (female) (5) and
5 Voltage Max. 1 V
(Contact with power B13 (female) (2) and chassis ground
Voltage Max. 1 V
bleshooting.
C1 (female) Position of selector switch Voltage
Between (5) and
Max. 1 V
chassis ground
Inspection
Between (11) and
Max. 1 V
chassis ground
6 Defective controller Between (5) and
Max. 1 V
chassis ground
Work
Between (11) and
20 – 30 V
chassis ground
Between (5) and
20 – 30 V
chassis ground
Travel
Between (11) and
20 – 30 V
chassis ground
20-424 BR380JG-1
Electrical circuit diagram related to mode selector switch
BR380JG-1 20-425
E-16 The crusher clearance adjustment mode does not change.
Phenomenon
occurring on • When the crusher clearance mode selector switch is changed, the current mode does not change.
machine
Relative • The cause may be disconnection of the S-NET signal. Check the failure record on the monitor panel to
information see if disconnection of the S-NET (E218) is indicated. If it is indicated, carry out troubleshooting for it.

Disconnection of S-NET If "Disconnection of S-NET signal" is displayed in the electrical system error on the
1
signal monitor, carry out troubleshooting for it.
starting switch ON.
Selector switch B52
Position of selector switch Resistance
(male)
Defective mode selector
Between (2) and (4) Min. 1 Mz
switch Manual
2 Between (3) and (4) Min. 1 Mz
Semiautomatic
Automatic
starting switch ON.
harness
Max. 1 z
3 (Disconnection in wiring Between C2 (female) (2) and B52 (female) (2) Resistance
Presumed cause and
harness or defective Between C2 (female) (38) and B52 (female) (3) Resistance Max. 1 z
Between B52 (female) (4) and chassis ground Resistance Max. 1 z
Grounding fault in wiring starting switch ON.
harness Between wiring harness between C2 (female) (2) and
(Contact with grounding B52 (female) (2) and chassis ground
starting switch ON.
C2 (female) Position of selector switch Resistance
Between (2) and
Min. 1 Mz
chassis ground
Manual
Between (38) and
Min. 1 Mz
chassis ground
5 Defective controller Between (2) and
Min. 1 Mz
chassis ground
Semiautomatic
Between (38) and
Max. 1 z
chassis ground
Between (2) and
Max. 1 z
chassis ground
Automatic
Between (38) and
Max. 1 z
chassis ground
20-426 BR380JG-1
Electrical circuit diagram related to crusher clearance adjustment mode selector switch
BR380JG-1 20-427
E-17 The crusher rotation direction does not change.
Phenomenon
occurring on • The crusher rotation direction does not change.
machine
Relative • The signals of the crusher forward-reverse selector switch can be checked in the monitoring function.
information • The operation of the crusher forward-reverse selector switch is ignored while the crusher is in operation.

forward-reverse selector Selector switch B15
1 switch Position of selector switch Resistance
(male)
short circuit) FORWARD Min. 1 Mz
Between (2) and (4)
REVERSE Max. 1 z
Presumed cause and
Between C2 (female) (35) and B15 (female) (2) Resistance Max. 1 z
contact in connector) Between B15 (female) (4) and chassis ground Resistance Max. 1 z
3
B15 (female) (2)
starting switch ON.
4 Defective controller C2 (female) Position of selector switch Resistance
Between (35) and FORWARD Min. 1 Mz
chassis ground REVERSE Max. 1 z
Electrical circuit diagram related to crusher forward-reverse selector switch
20-428 BR380JG-1
E-18 Travel cannot be controlled by radio control.
Phenomenon
occurring on • Travel cannot be controlled by radio control.
machine
• Radio control system is an optional specification.
• (1) Turn the power switch of the radio control transmitter ON, (2) Start the engine and turn the radio con-
trol selector switch to the REMOTE position, and (3) Check that the radio wave from the radio control
transmitter is received by the receiver (The antenna of the receiver is built in). If the radio wave is re-
Relative
ceived, the yellow radio control lamp lights up and the machine can be radio-controlled.
information
• If the mode selector switch is set in the TRAVEL position under the above condition, the machine can
be driven.
• If any of (1), (2), and (3) above is not established (If the radio control lamp does not light up), the machine
cannot be radio-controlled.

bleshooting.
Defective radio control
power supply circuit Receiver connector A33 Radio control
2 Voltage
(Disconnection or short (female) selector switch
circuit) DIRECT Max. 1 V
Between (1) and (2)
REMOTE 20 – 30 V
starting switch ON.
Between A33 (female) (3) and A32 (female) (2) Resistance Max. 1 z
Between A33 (female) (3) and chassis ground Resistance Max. 1 z
Between A33 (female) (4) and RR7 (female) (6) Resistance Max. 1 z
Presumed cause and
Disconnection in wiring Between A33 (female) (1) and RR4 (female) (1), (3) Resistance Max. 1 z
harness Between A33 (female) (1) and RR7 (female) (4), (5) Resistance Max. 1 z
Between A33 (female) (1) and RR8 (female) (4), (5) Resistance Max. 1 z
contact in connector) Between A33 (female) (1) and RR9 (female) (4), (5) Resistance Max. 1 z
Between A33 (female) (1) and RR10 (female) (4), (5) Resistance Max. 1 z
Between RR7 (female) (3) and V20 (female) (2) Resistance Max. 1 z
Between V20 (female) (1) and chassis ground Resistance Max. 1 z
BR380JG-1 20-429

Presumed cause and
starting switch ON.

V20 (male), V21 (male),
4 Defective solenoid Resistance
V22 (male), V23 (male)
Between (1) and (2) 20 – 60 z
Defective transmitter and If all the results of above checks 1 – 4 are normal, the transmitter or receiver is defec-
5
receiver tive.
20-430 BR380JG-1
BR380JG-1 20-431
E-19 The feeder cannot be turned ON and OFF by radio control.
Phenomenon
occurring on • The feeder cannot be turned ON and OFF by radio control.
machine
Relative
information
If the mode selector switch is set in the WORK position under the above condition, the feeder can be
operated.

bleshooting.
2 Voltage
Between (1) and (2)
REMOTE 20 – 30 V
starting switch ON.
Presumed cause and
harness Between A33 (female) (10) and C3 (female) (10) Resistance Max. 1 z
harness or defective Between A33 (female) (13) and RR1 (female) (2) Resistance Max. 1 z
contact in connector) Between A33 (female) (1), RR1 (female) (1), and RR4
Resistance Max. 1 z
(female) (1)
Between RR1 (female) (6) and C3 (female) (20) Resistance Max. 1 z
Between RR1 (female) (3) and chassis ground Resistance Max. 1 z
starting switch ON.
Defective relay
4 (Internal disconnection or RR1 (male) Resistance
short circuit) Between (1) and (2) 250 – 350 z
If any of the following errors is displayed in the electrical system errors on the monitor,
see the troubleshooting for it.
When controller detects • Short circuit in feeder-ON switch [E320]
5
failure of related section • Disconnection in feeder-OFF switch [E321]
• Disconnection in feeder forward EPC valve [E207]
• Short circuit in feeder forward EPC valve [E208]
Defective transmitter or If all the results of above checks 1 – 5 are normal, the transmitter or receiver is defec-
6
receiver tive.
20-432 BR380JG-1
BR380JG-1 20-433
E-20 The crusher cannot be turned ON and OFF by radio control.
Phenomenon
occurring on • The crusher cannot be turned ON and OFF by radio control.
machine
Relative
information
If the mode selector switch is set in the WORK position under the above condition, the crusher can be
operated.

bleshooting.
2 Voltage
Between (1) and (2)
REMOTE 20 – 30 V
starting switch ON.
Presumed cause and
harness Between A33 (female) (11) and C1 (female) (12) Resistance Max. 1 z
harness or defective Between A33 (female) (14) and RR2 (female) (2) Resistance Max. 1 z
contact in connector) Between A33 (female) (1), RR2 (female) (1), and RR4
Resistance Max. 1 z
(female) (1)
Between RR2 (female) (6) and C1 (female) (6) Resistance Max. 1 z
Between RR2 (female) (3) and chassis ground Resistance Max. 1 z
starting switch ON.
Defective relay
4 (Internal disconnection or RR2 (male) Resistance
short circuit) Between (1) and (2) 250 – 350 z
If any of the following errors is displayed in the electrical system errors on the monitor,
see the troubleshooting for it.
When controller detects • Short circuit in crusher-ON switch [E304]
5
failure of related section • Disconnection in crusher-OFF switch [E305]
• Disconnection in crusher forward EPC valve [E203]
• Short circuit in crusher forward EPC valve [E204]
Defective transmitter or If all the results of above checks 1 – 5 are normal, the transmitter or receiver is defec-
6
receiver tive.
20-434 BR380JG-1
BR380JG-1 20-435
E-21 The monitor switches do not work.
Phenomenon
• When the maintenance switch is operated, the item screen does not appear.
occurring on
• When the contrast/brightness setting screen selector switch is operated, the screen does not change.
machine (1)
Relative
—
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Defective monitor
1 Troubleshooting cannot be carried out since the defect is in the monitor panel.
in normalcy panel
Phenomenon
occurring on • When the crusher speed setting screen selector switch is operated, the setting screen does not appear.
machine (2)
Relative
—
information

cause and
in normalcy panel
Phenomenon
occurring on • When the feeder speed setting screen selector switch is operated, the setting screen does not appear.
machine (3)
Relative
—
information

cause and
in normalcy panel
Phenomenon
occurring on • When the crusher load setting screen selector switch is operated, the setting screen does not appear.
machine (4)
Relative
—
information

cause and
in normalcy panel
20-436 BR380JG-1
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE
switch on the monitor.
Phenomenon
• The crusher cannot be rotated forward or in reverse with the crusher manual FORWARD/REVERSE
occurring on
machine
• The crusher can be operated with the crusher manual FORWARD/REVERSE switch under the following
Relative condition:
information (1) The mode selector switch is in the WORK or INSPECTION position and the crusher is stopped.
(2) The radio control selector switch is in the DIRECT position.

Disconnection in S-NET If error code [E218] (Disconnection in S-NET signal) is displayed, carry out trouble-
1
signal shooting for it first.

Presumed cause and
Disconnection in crusher If error code [E203] (Disconnection in crusher forward EPC valve) is displayed, carry
2
forward EPC valve out troubleshooting for it first.
Short circuit in crusher If error code [E204] (Short circuit in crusher forward EPC valve) is displayed, carry
3
forward EPC valve out troubleshooting for it first.
Disconnection in crusher If error code [E205] (Disconnection in crusher reverse EPC valve) is displayed, carry
4
reverse EPC valve out troubleshooting for it first.
Short circuit in crusher If error code [E206] (Short circuit in crusher reverse EPC valve) is displayed, carry out
5
reverse EPC valve troubleshooting for it first.
6 Defective monitor If the results of above checks 1 – 5 are normal, the monitor is probably defective.
BR380JG-1 20-437
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/
REVERSE switch on the monitor.
Phenomenon
• The conveyor cannot be rotated forward or in reverse with the conveyor manual FORWARD/REVERSE
occurring on
machine
• The conveyor can be operated with the conveyor manual FORWARD/REVERSE switch under the fol-
Relative lowing condition:
information (1) The mode selector switch is in the INSPECTION position and the conveyor is stopped.
(2) The radio control selector switch is in the DIRECT position.

Disconnection in S-NET If error code [E218] (Disconnection in S-NET signal) is displayed, carry out trouble-
1
signal shooting for it first.

Presumed cause and
Disconnection in con- If error code [E201] (Disconnection in primary belt conveyor forward solenoid) is dis-
2
veyor forward solenoid played, carry out troubleshooting for it first.
Short circuit in conveyor If error code [E202] (Short circuit in primary belt conveyor forward solenoid) is dis-
3
forward solenoid played, carry out troubleshooting for it first.
Disconnection in con- If error code [E241] (Disconnection in primary belt conveyor reverse solenoid) is dis-
4
veyor reverse solenoid played, carry out troubleshooting for it first.
Short circuit in conveyor If error code [E242] (Short circuit in primary belt conveyor reverse solenoid) is dis-
5
reverse solenoid played, carry out troubleshooting for it first.
6 Defective monitor If the results of above checks 1 – 5 are normal, the monitor is probably defective.
20-438 BR380JG-1
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-502

H-1 The speed or power of the whole work equipment and travel is low. ............................................... 20-505
H-2 The engine speed lowers extremely or the engine stalls. ................................................................. 20-507
H-3 The work equipment and travel systems do not work....................................................................... 20-508
H-4 Abnormal sound comes out from around the hydraulic pump. ......................................................... 20-508
H-5 Fine control performance or response is low. ................................................................................... 20-509
H-6 The conveyor does not operate. ....................................................................................................... 20-510
H-7 The speed or power of the conveyor is low. ..................................................................................... 20- 511
H-8 The crusher does not operate........................................................................................................... 20- 511
H-9 The speed or power of crusher is low. .............................................................................................. 20-512
H-10 The feeder does not operate. ........................................................................................................... 20-512
H-11 The feeder does not feed smoothly (Vibration frequency is low). ..................................................... 20-513
H-12 The magnetic separator does not operate. ....................................................................................... 20-513
H-13 The speed of magnetic separator belt is low..................................................................................... 20-514
H-14 The side conveyor does not operate. ............................................................................................... 20-514
H-15 The speed or power of the side conveyor is low............................................................................... 20-515
H-16 The primary conveyor and the side conveyor do not move up and down. ....................................... 20-515
H-17 The machine deviates during travel. ................................................................................................. 20-516
H-18 The travel speed is low. .................................................................................................................... 20-517
H-19 The machine is not steered well or steering power is low................................................................. 20-518
H-20 The travel motor does not work (only one side)................................................................................ 20-519
H-21 When the travel switch of the radio controller is depressed, the machine does not travel ............... 20-519
H-22 The crusher clearance cannot be adjusted....................................................................................... 20-520
BR380JG-1 20-501
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
20-502 BR380JG-1
TROUBLESHOOTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
a This is a system chart that has been drawn up by simplifying the whole hydraulic and mechanical circuit chart.
Use it as a reference material when troubleshooting the hydraulic and mechanical systems.
BR380JG-1 20-503

Phenomenon
occurring on Phenomena occuring on machine
machine
Relative
Information on occurred failures and troubleshooting
information
1
Presumed cause and
2 Cause that presumably

<Content Included>
tion
3 (The assigned No. is for
the presumed cause
4 priority)
20-504 BR380JG-1
TROUBLESHOOTING H-1
H-1 The speed or power of the whole work equipment and travel is low.
Phenomenon
occurring on • The speed or power of the whole work equipment and travel is low.
machine
Relative
• Carry out troubleshooting in the WORK or TRAVEL mode.
information

aPrepare with engine stopped, then run engine at high idling and carry out trouble-
shooting.
Malfunction of unload
1 Work equipment switches and travel lever Unload pressure
valve
Turn all switches OFF and 3.9 ± 1.0 MPa
set lever in neutral. {40 ± 10 kg/cm2}
shooting.
Measurement condition Main relief pressure
Defective adjustment or
2 malfunction of main relief +1.0
39.2 –2.5 MPa
valve Relieve travel circuit (Note 1). +10
{400 –25 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may
have a malfunction or a defect in it. Check the main relief valve directly.
shooting.
Malfunction of self-reduc-
3 Work equipment switches and travel lever Control circuit basic pressure
ing pressure valve
Turn all switches OFF and 2.83 – 3.43 MPa

Presumed cause and
set lever in neutral. {29 – 35 kg/cm2}

shooting.
Oil pressure to be
Measurement condition Ratio of oil pressure
Defective adjustment or measured
4
malfunction of PC valve Pump discharge pressure 1
Relieve travel circuit
If the oil pressure does not become normal after adjustment, the PC valve may have
a malfunction or a defect in it. Check the PC valve directly.
shooting.
Malfunction of LS-EPC
5 Work equipment switches and travel lever LS-EPC output pressure
valve
Turn all switches OFF and Approx. 2.9 MPa
set lever in neutral. {Approx. 30 kg/cm2}
shooting.
Ratio of oil pressure
Oil pressure to be
measured Turn all work equipment Turn all work equipment
Defective adjustment or switches OFF switches ON (with no load)
6
malfunction of LS valve
Almost same
If the oil pressure does not become normal after adjustment, the LS valve may have
a malfunction or a defect in it. Check the LS valve directly.
BR380JG-1 20-505
TROUBLESHOOTING H-1

Presumed cause and
Malfunction of servo
7 The servo piston may have malfunction. Check it directly.
piston
If all the results of the above checks are normal, the cause may be lowering of perfor-
8 Defective piston pump
mance, malfunction, or internal defect of the piston pump.
Abnormality in engine
9 Carry out troubleshooting according to electrical system error code [E227].
speed sensor
Note 1: Disconnect the hydraulic hose and piping (travel main circuit) and install adapters to block the ends.
20-506 BR380JG-1
TROUBLESHOOTING H-2
H-2 The engine speed lowers extremely or the engine stalls.
Phenomenon
occurring on • The engine speed lowers extremely or the engine stalls.
machine
Relative
• Carry out troubleshooting in the WORK or TRAVEL mode.
information

shooting.
Measurement condition Main relief pressure
1 malfunction of main relief +1.0
39.2 –2.5 MPa
valve Relieve travel circuit (Note 1). +10
{400 –25 kg/cm2}
If the oil pressure does not become normal after adjustment, the main relief valve may
have a malfunction or a defect in it. Check the main relief valve directly.
shooting.
Oil pressure to be
Measurement condition Ratio of oil pressure

measured
Presumed cause and
2
malfunction of PC valve Pump discharge pressure Relieve travel circuit 1
PC valve output pressure (Note 1). Approx. 3/5
If the oil pressure does not become normal after adjustment, the PC valve may have
a malfunction or a defect in it. Check the PC valve directly.
shooting.
Oil pressure to be
3
Almost same
Clogging of orifice or filter An orifice or a filter in the pump servo equipment may be clogged. Check them
4
in servo equipment directly.
5 The servo piston may have malfunction. Check it directly.
piston
BR380JG-1 20-507
TROUBLESHOOTING H-3, H-4
H-3 The work equipment and travel systems do not work.
Phenomenon
occurring on • The work equipment and travel systems do not work.
machine
Relative
—
information

shooting.
Presumed cause and
Malfunction of self-reduc- Work equipment switches

1 Control circuit basic pressure
ing pressure valve and travel lever
Turn all switches OFF and 2.83 – 3.43 MPa
set lever in neutral {29 – 35 kg/cm2}
The piston pump may have a malfunction or a defect in it. Check it by the following
method.
2 Defective piston pump
• Remove the oil pressure pickup plug and crank the engine. If oil flows out, the pis-
ton pump is normal.
The pump shaft may not rotate because of a defect in the damper. Check the damper
3 Defective damper
directly.
H-4 Abnormal sound comes out from around the hydraulic pump.
Phenomenon
occurring on • Abnormal sound comes out from around the hydraulic pump.
machine
Relative
—
information

Lowering of hydraulic oil

Presumed cause and
1 Check directly.
level
2 Defective hydraulic oil Hydraulic oil may contain air. Check it directly.
Clogging of hydraulic The hydraulic tank cap may be clogged and negative pressure may be applied to the
3
tank cap tank. Check the cap directly.
Clogging of hydraulic The hydraulic tank strainer may be clogged and negative pressure may be applied to
4
tank strainer the suction circuit. Check the strainer directly.
5 Defective piston pump The piston pump may have a defect in it. Check it directly.
20-508 BR380JG-1
TROUBLESHOOTING H-5
H-5 Fine control performance or response is low.
Phenomenon
occurring on • Fine control performance or response is low.
machine
Relative
• Carry out troubleshooting in the WORK mode.
information

shooting.
1 Work equipment switch and travel lever LS-EPC output pressure
valve
set lever in neutral {Approx. 30 kg/cm2}
Clogging of LS circuit
Presumed cause and
2 The LS circuit orifice may be clogged. Check it directly.

orifice
shooting.
Oil pressure to be
3
Almost same
4 The servo piston may have a malfunction. Check it directly.
piston
BR380JG-1 20-509
TROUBLESHOOTING H-6
H-6 The conveyor does not operate.
Phenomenon
occurring on • The conveyor does not operate.
machine
Relative
• Carry out the following troubleshooting when the travel system and other work equipment are normal.
information

shooting.
Malfunction of accessory aCarry out troubleshooting in the WORK mode.
1
EPC valve Operation EPC valve output pressure
Min. 2.5 MPa
Turn conveyor switch ON
{Min. 26 kg/cm2}
Malfunction of accessory
Presumed cause and
2 The accessory control valve spool may have a malfunction. Check it directly.
control valve (spool)
Malfunction of conveyor
3 The conveyor rotation solenoid valve may have a malfunction. Check it directly.
rotation solenoid valve
4 Check the conveyor motor machinery oil for foreign matter.
motor machinery
1) Disconnection or short 1) Carry out troubleshooting according to electrical system error codes [E302] and
circuit in conveyor-ON/ [E303].
OFF switch system
circuit in accessory [E214].
5
EPC valve system
circuit in conveyor for- [E202].
ward solenoid valve
system
20-510 BR380JG-1
H-7 The speed or power of the conveyor is low.
Phenomenon
occurring on • The speed or power of the conveyor is low.
machine
Relative
• Carry out the following troubleshooting when the travel speed is normal.
information

shooting.
1 Operation LS-EPC output pressure
valve
Presumed cause and
2.34 ± 0.15 MPa

Turn conveyor switch ON
{23.9 ± 1.5 kg/cm2}
Malfunction of pressure
compensation valve or The pressure compensation valve or pressure compensation piston of the control
3
pressure compensation valve may have a malfunction. Check them directly.
piston
Disconnection in acces-
sory EPC valve system
5 Defective conveyor motor Conveyor speed: 97 – 150 m/min
H-8 The crusher does not operate.
Phenomenon
occurring on • The crusher does not operate.
machine
Relative
information

shooting.
Malfunction of crusher aCarry out troubleshooting in the WORK mode.
1 EPC valve
Operation EPC valve output pressure
(Forward or reverse)
Min. 2.5 MPa

Turn crusher switch ON
Presumed cause and
{Min. 26 kg/cm2}
Malfunction of crusher
2 The crusher control valve spool may have a malfunction. Check it directly.
circuit in crusher-ON/ [E305].
OFF switch system
circuit in crusher for- [E204].
3 ward EPC valve sys-
tem
circuit in crusher [E206].
reverse EPC valve
system
BR380JG-1 20-511
H-9 The speed or power of crusher is low.
Phenomenon
occurring on • The speed or power of crusher is low.
machine
Relative
information

shooting.
valve
2.34 ± 0.15 MPa

Presumed cause and
Turn crusher switch ON

{23.9 ± 1.5 kg/cm2}
Malfunction of crusher
2 The crusher control valve spool may have a malfunction. Check it directly.
3
piston
Disconnection in crusher
Carry out troubleshooting according to electrical system error codes [E203] and
4 EPC valve system
[E205].
(Forward or reverse)
5 Defective crusher motor Crusher speed (Max.): 330 ± 36 rpm
H-10 The feeder does not operate.
Phenomenon
occurring on • The feeder does not operate.
machine
Relative
information

shooting.
aCarry out troubleshooting in the WORK mode.
Malfunction of feeder
1
Presumed cause and

Min. 2.5 MPa
Turn feeder switch ON
{Min. 26 kg/cm2}
2 The feeder control valve spool may have a malfunction. Check it directly.
circuit in feeder-ON/ [E321].
OFF switch system
3
circuit in feeder forward [E208].
EPC valve system
20-512 BR380JG-1
H-11 The feeder does not feed smoothly (Vibration frequency is low).
Phenomenon
occurring on • The feeder does not feed smoothly (Vibration frequency is low).
machine
Relative
information

shooting.
valve
Presumed cause and
2.34 ± 0.15 MPa

Turn feeder switch ON
{23.9 ± 1.5 kg/cm2}
2 The feeder control valve spool may have a malfunction. Check it directly.
3
piston
Disconnection in feeder
EPC valve system
5 Defective feeder motor Feeder vibration frequency (Max.): 1,000 – 1,100 cpm
H-12 The magnetic separator does not operate.
Phenomenon
occurring on • The magnetic separator does not operate.
machine
Relative
information

shooting.
Malfunction of magnetic aCarry out troubleshooting in the WORK mode.
1
separator solenoid valve Operation Solenoid valve output pressure

Presumed cause and
2.83 – 3.43 MPa

Turn magnetic separator switch ON
{29 – 35 kg/cm2}
Malfunction of magnetic
2 separator control valve The magnetic separator control valve spool may have a malfunction. Check it directly.
(spool)
circuit in magnetic [E335].
separator-ON/OFF
3 switch system
circuit in magnetic [E250].
separator relay system
BR380JG-1 20-513
H-13 The speed of magnetic separator belt is low.
Phenomenon
occurring on • The speed of magnetic separator belt is low.
machine
Relative
• Carry out the travel speed is normal.
information

shooting.
valve
2.34 ± 0.15 MPa

Turn magnetic separator switch ON
Presumed cause and
{23.9 ± 1.5 kg/cm2}

Malfunction of magnetic
2 separator control valve The magnetic separator control valve spool may have a malfunction. Check it directly.
(spool)
3
piston
Malfunction of magnetic The magnetic separator suction valve of the control valve may have a malfunction.
4
separator suction valve Check it directly.
Defective magnetic
5 Magnetic separator belt speed: 66 – 108 m/min
separator motor
H-14 The side conveyor does not operate.
Phenomenon
occurring on • The side conveyor does not operate.
machine
Relative
information

shooting.
Malfunction of side aCarry out troubleshooting in the WORK mode.
1
conveyor solenoid valve Operation Solenoid valve output pressure
2.83 – 3.43 MPa
Turn side conveyor switch ON

{29 – 35 kg/cm2}
Presumed cause and
Malfunction of side
2 conveyor control valve The side conveyor control valve spool may have a malfunction. Check it directly.
(spool)
Malfunction of side con-
3 The side conveyor proximity switch may have a malfunction. Check it directly.
veyor proximity switch
1) Short circuit, disconnec- 1) The side conveyor-ON/OFF switch system may have a short circuit, disconnec-
tion, or defective con- tion, or defective contact. Check it directly.
tact in side conveyor-
ON/OFF switch system
4
2) Short circuit, disconnec- 2) The side conveyor relay system may have a short circuit, disconnection, or defec-
tion, or defective con- tive contact. Check it directly.
tact in side conveyor
relay system
20-514 BR380JG-1
H-15 The speed or power of the side conveyor is low.
Phenomenon
occurring on • The speed or power of the side conveyor is low.
machine
Relative
• Carry out the travel speed is normal.
information

shooting.
valve
2.34 ± 0.15 MPa

Turn side conveyor switch ON
Presumed cause and
{23.9 ± 1.5 kg/cm2}

Malfunction of side
2 conveyor control valve The side conveyor control valve spool may have a malfunction. Check it directly.
(spool)
3
piston
Malfunction of side The side conveyor suction valve of the control valve may have a malfunction. Check
4
conveyor suction valve it directly.
Defective side conveyor
5 Conveyor speed: 90 – 135 m/min
motor
H-16 The primary conveyor and the side conveyor do not move up and down.
Phenomenon
occurring on • The primary conveyor and the side conveyor do not move up and down.
machine
Relative
information

shooting.
Malfunction of accessory aCarry out troubleshooting in the WORK mode.
1

Presumed cause and
Min. 2.5 MPa

Turn conveyor elevator switch ON
{Min. 26 kg/cm2}
3 The conveyor elevator solenoid valve may have a malfunction. Check it directly.
elevator solenoid valve
1) Short circuit in con- 1) Carry out troubleshooting according to electrical system error codes [E322] and
veyor elevator switch [E323].
system
4
circuit in accessory [E214].
EPC valve
BR380JG-1 20-515
TROUBLESHOOTING H-17
H-17 The machine deviates during travel.
Phenomenon
occurring on • The machine deviates during travel.
machine
Relative • Before carrying out the troubleshooting, set the mode selector switch in the TRAVEL mode.
information • Carry out the following troubleshooting when the work equipment speed is normal.

shooting.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.5 MPa
valve FORWARD or REVERSE
{Min. 26 kg/cm2}
Output difference between forward Max. 0.39 MPa
and lateral directions {Max. 4 kg/cm2}
shooting.
2 Travel lever Control circuit basic pressure
ing pressure valve
2.84 – 3.43 MPa
Set lever in neutral
{29 – 35 kg/cm2}
shooting.
aSet the mode selector switch in the WORK mode and carry out troubleshooting.
Defective adjustment or Ratio of oil pressure

Oil pressure to be
3
malfunction of LS valve measured Turn all work equipment Turn all work equipment
Presumed cause and
switches OFF switches ON (with no load)

Almost same
LS valve output pressure Approx. 3/5
shooting.
Malfunction of travel Travel lever Solenoid output pressure
4
junction solenoid valve Operate both sides 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operate one side
{29 – 35 kg/cm2}
Malfunction of shuttle The shuttle valve may have a malfunction. Check it directly. (When radio control
5
valve specification is installed)
Malfunction of travel
6 The travel junction valve may have a malfunction. Check it directly.
junction valve
7 The travel control valve spool may have a malfunction. Check it directly.
shooting.
8 Defective travel motor Travel lever Main relief pressure

+1.0
39.2 –2.5 MPa
Relieve travel circuit. (Note 1) +10
{400 –25 kg/cm2}
The final drive may have a defect in it. Check it directly.
9 Defective final drive aYou may check the final drive by abnormal sound, abnormal heating, metal powder
in drain oil, etc.
20-516 BR380JG-1
H-18 The travel speed is low.
Phenomenon
occurring on • The travel speed is low.
machine

shooting.
Travel lever PPC valve output pressure
Malfunction of travel PPC
1 Min. 2.5 MPa
valve FORWARD or REVERSE
{Min. 26 kg/cm2}
Output difference between forward Max. 0.39 MPa
and lateral directions {Max. 4 kg/cm2}
shooting.
2 Travel lever Control circuit basic pressure
ing pressure valve
2.83 – 3.43 MPa
Set lever in neutral
{29 – 35 kg/cm2}
Presumed cause and
shooting.
3 Work equipment switch and travel lever LS-EPC output pressure
valve
set lever in neutral. {Approx. 30 kg/cm2}
5
piston
Malfunction of travel con-
6 The suction valve of the travel control valve may have a malfunction. Check it directly.
trol valve (suction valve)
Malfunction of shuttle The shuttle valve may have a malfunction. Check it directly. (When radio control
7
valve specification is installed)
shooting.
8 Defective travel motor
Travel lever Leakage from travel motor
Relieve travel circuit. (Note 1) Min. 27.2 l/min
in drain oil, etc.
BR380JG-1 20-517
H-19 The machine is not steered well or steering power is low.
Phenomenon
occurring on • The machine is not steered well or steering power is low.
machine

Malfunction of travel PPC shooting.
1
valve Travel lever PPC valve output pressure
Set lever in neutral 0 MPa {0 kg/cm2}
shooting.
Malfunction of travel Travel lever Solenoid output pressure
2
junction solenoid valve Operate both sides 0 MPa {0 kg/cm2}
2.84 – 3.43 MPa
Operate one side
{29 – 35 kg/cm2}
Presumed cause and
3 The travel junction valve may have a malfunction. Check it directly.

junction valve
The pressure compensation valve of the travel control valve may have a malfunction.
5 control valve (pressure
Check it directly.
compensation valve)
Malfunction of travel con-
6 The suction valve of the travel control valve may have a malfunction. Check it directly.
trol valve (suction valve)
Malfunction of shuttle The shuttle valve may have a malfunction. Check it directly.
7
valve (When radio control specification is installed)
Defective seal of check
The seal of the check valve of the LS pressure pickup plug may be defective. Check
8 valve of LS pressure
it directly.
pickup plug
The seal of the safety valve of travel motor may be defective. Check it directly.
9 aYou may judge by replacing the same motors between the forward and reverse units
motor (safety valve)
or between right and left units and checking the change of the phenomenon.
The seal of the check valve of travel motor may be defective. Check it directly.
10 aYou may judge by replacing the same motors between the forward and reverse units
motor (Check valve)
or between right and left units and checking the change of the phenomenon.
20-518 BR380JG-1
H-20 The travel motor does not work (only one side).
Phenomenon
occurring on • The travel motor does not work (only one side).
machine
Relative
• Before carrying out the troubleshooting, set the mode selector switch in the TRAVEL mode.
information

Defective seat of travel
1 control valve The suction valve seat of the travel control valve may be malfunction. Check it directly.
(suction valve)

Presumed cause and
2 The safety valve seat of the travel motor may be malfunction. Check it directly.
motor (safety valve)
3 The check valve seat of the travel motor may be malfunction. Check it directly.
motor (check valve)
Lowering of travel motor shooting.
4
performance Travel lever Leakage from travel motor
Relieve travel circuit. (Note 1) Min. 27.2 l/min
in drain oil, etc.
H-21 When the travel switch of the radio controller is depressed, the machine does
not travel
Phenomenon
occurring on • When the travel switch of the radio controller is depressed, the machine does not travel
machine
• Carry out the following troubleshooting when the machine travels when the travel lever is operated.
information • Before carrying out the troubleshooting, turn the radio control selector switch ON (RADIO CONTROL
position).

aPrepare with engine stopped, then run engine at high idling and carry out
Malfunction of radio troubleshooting.
1 control travel Operation Solenoid valve output pressure
Presumed solenoid
cause and Turn radio control travel switch ON 2.84 – 3.43 MPa
standard value (each position). {29 – 35 kg/cm2}
in normalcy Malfunction of shuttle
2 The shuttle valve may have a malfunction. Check it directly.
valve
Disconnection or
The travel solenoid system may have a short circuit or disconnection. Check it
3 short circuit in travel
directly.
solenoid system
BR380JG-1 20-519
H-22 The crusher clearance cannot be adjusted.
Phenomenon
occurring on • The crusher clearance cannot be adjusted.
machine
• Carry out the following troubleshooting when no foreign matter is caught between the fixed jaw and
Relative swing jaw of the crusher.
information • Before carrying out the troubleshooting, set the mode selector switch in the INSPECTION mode.

Malfunction of lock
The lock cylinder extension/retraction solenoid valve may have a malfunction.
1 cylinder extension/retrac-
Check it directly.
tion solenoid valve
shooting.
Malfunction of lock cylin-
2 Operation Solenoid valve output pressure
der reset solenoid valve
Turn crusher clearance open or 2.84 – 3.43 MPa
close switch on monitor ON {29 – 35 kg/cm2}
3 der reset control valve The lock cylinder reset control valve spool may have a malfunction. Check it directly.
(spool)
Presumed cause and
4
piston
Malfunction of lock cylin- The suction valve of the lock cylinder reset control valve may have a malfunction.
5
der reset suction valve Check it directly.
6 The lock cylinder may have a malfunction. Check it directly.
der
1) Disconnection in S-NET 1) Carry out troubleshooting according to electrical system error code [E218].
signal
2) Short circuit in lock cyl- 2) Carry out troubleshooting according to electrical system error code [E246].
inder extension relay
system
7 circuit in lock cylinder [E248].
retraction solenoid
valve system
circuit in lock cylinder [E244].
reset solenoid valve
system
20-520 BR380JG-1
TROUBLESHOOTING OF ENGINE
(S-MODE)
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-602

S-1 Starting performance is poor (Starting always takes time)................................................................ 20-606
S-2 Engine does not start ........................................................................................................................ 20-608
(1) Engine does not turn ................................................................................................................... 20-608
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ............................... 20-609
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)............................. 20-610
S-3 Engine does not pick up smoothly (Follow-up is poor) ..................................................................... 20- 611
S-4 Engine stops during operations ........................................................................................................ 20-612
S-5 Engine does not rotate smoothly (Hunting)....................................................................................... 20-613
S-6 Engine lacks output (or lacks power) ................................................................................................ 20-614
S-7 Exhaust smoke is black (Incomplete combustion) ............................................................................ 20-615
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................................ 20-616
S-9 Oil becomes contaminated quickly ................................................................................................... 20-617
S-10 Fuel consumption is excessive ......................................................................................................... 20-618
S-11 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-619
S-12 Oil pressure monitor lights up (Drop in oil pressure)......................................................................... 20-620
S-13 Oil level rises (Water, fuel in oil)........................................................................................................ 20-621
S-14 Water temperature becomes too high (Overheating)........................................................................ 20-622
S-15 Abnormal noise is made ................................................................................................................... 20-623
S-16 Vibration is excessive ....................................................................................................................... 20-624
BR380JG-1 20-601
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in [B] are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under [C] in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting] Causes
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
(1) (2) (3)
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-602 BR380JG-1
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and
mark the Cause column with E to use Causes
as reference for locating the cause of
tion)
the failure. However, do not use this
injec
when making calculations to narrow
down the causes.
fuel
2. Use the E in the Cause column as ref-
sive
zzle
xces
erence for [Degree of use (Operated for
nce
n no
long period)] in the [Questions] section
p (e
fere
g
t
jectio
as reference. As a rule, do not use it
men
timin
pum
inter
r
nde
when calculating the points for locating
le
uel in
tion
ction
er e
ger,
, cyli
the cause, but it can be included if nec-
injec
lean
ed f
l inje
char
ring
essary to determine the order for trou-
, seiz
fuel
air c
r fue
urbo
ton
bleshooting.
ctive
n pis
ged
ged
rope
ed t
Defe
Clog
Clog
Seiz
Wor
Imp
Confirm recent repair history
Degree of use Operatred for long period
BR380JG-1 20-603
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
d
hea
tion)
)
ized
der
injec
r se
cylin
fuel
nge
e, va rger and
sive
k, plu
eat
zle
xces
lve s
(rac
ction tion noz
leme nce
a
boch
p (e
re
ump
g
nt
terfe
timin
pum
r
n tu
jec
der
ance
on p
uffle
valv
er, in
el in
tion
twee
n
er e
, cyli
jecti
lear
dm
ct of
injec
d fu
harg
lean
ir be
l inje
lve c
el in
ring
gge
conta
eize
Legend
rboc
fuel
air c
of a
r fue
, clo
e fu
n
r va
: Possible causes (judging from Questions and check items)
to
s
ed tu
ctive
ctive
,
n pis
ectiv
kage
hed
ged
ged
rope
rope
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period) Defe
Crus
Defe
Clog
Clog
Seiz
Wor
Deff
Imp
Imp
Lea
: Items to confirm the cause.
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting
Check items
engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on fuel injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and cylinder head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating on
Troubleshooting
reduced cylinders
When check is made using delivery method, fuel injection timing

is found to be incorrect
Fuel injection pump test shows that fuel injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does not
return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-604 BR380JG-1
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and cylinder head:
(3) Clogged, seized fuel injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting
area and carry out the troubleshooting item
marked . The Remedy is given as [Clean], so
carry out cleaning, and the exhaust gas color
should return to normal.
BR380JG-1 20-605
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below,
ASTM D975 No. 2 diesel fuel is used)
a Battery charging rate
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
temperature
20°C 1.28 1.26 1.24 1.23 1.22
0°C 1.29 1.27 1.25 1.24 1.23
–10°C 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value for the

charging rate of 70% in the above table.
• In cold areas the specific gravity must exceed the value
for the charging rate of 75% in the above table.
20-606 BR380JG-1
Replace Defe
ctive
Replace Defe regu
lator
ctive
Replace Defe alter
nato
ctive r
Replace or de
BR380JG-1
Defe terio
ctive rated
Adjust Defe injec
tion batte
tive nozz ry
Replace Defe
injec
tion le
tive timin
Correct injec g
Leak tion
age, pum
Clean c lo p
TROUBLESHOOTING
Clog ggin (rack

ged g, air , plu
nger
Replace Defe
air b
reath
in fu
el pip stuc
ctive er ho ing k)
Replace Defe feed
p
le in
f
Causes
ctive ump uel t

boos ank
t com
pens
ator
canc
el
20-607
S-1
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn Causes
• Internal parts of engine seized

a If internal parts of the engine are seized, car-
ry out troubleshooting for "Engine stops dur-
ing operations".
n
ectio
it
ery
• Failure in hydraulic pump system
circu
conn
batt
• Defective electrical system
ting
inal
ted
ch
tor
star
y
term
swit
iora
lay
rela
m o
y re
g of
eter
ting
rting
ery
ery
ear
afet
wirin
or d
star
batt
batt
ing g
t a
s
s
ctive
ctive
ctive
ctive
ctive
ctive
ctive
en r
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
Questions
Degree of use of machine Operated for long period

Condition of horn when Horn sounds
starting switch is turned ON Horn volume is low
Speed of rotation is low

When starting switch is Makes grating noise
turned to START, pinion
moves out, but Soon disengages pinion again
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
move out
Check items
When starting switch is turned to ON, there is no clicking

Troubleshooting of defective wiring in starting circuit
sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 4), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
Troubleshooting
connected, engine starts

2) When terminal B and terminal C of starting motor are
connected, engine starts
3) When terminal B and terminal C of safety relay are connected,
engine starts
4) There is no 24V between battery relay terminal b and terminal
E
When ring gear is inspected directly, tooth surface is found to be
chipped
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-608 BR380JG-1
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust

smoke comes out
• Supply of fuel impossible Causes

• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
)
ized
a Standards for use of fuel
r se
nge
y
nk
t, ke
el ta
k, plu
ton
shaf
in fu
p pis
c
p (ra
iner
g
drive
pipin
r
hole
e
pum
rain
a
pum
r
ank
ump
s t
fuel
her
r, st
eed
ump
d
l in t
tion
on p
l use
reat
king
l filte
en f
p
injec
t fue
air b
jecti
feed
r fue
, lea
brok
u e
n
f
ctive
en in
fficie
ged
ged
ged
rope
ged
ed,
Defe
Clog
Clog
Clog
Clog
Brok
Seiz
Insu
Imp
Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When fuel filter is drained, fuel does not come out
Check items
When engine is cranked with starting motor,

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
Troubleshooting
not return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
BR380JG-1 20-609
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but engine

does not start (Fuel is being injected)
General causes why exhaust smoke comes out but Causes
engine does not start
etc.)
• Lack of rotating force due to defective electrical
ck)
k, plu er lever,
system
r stu
ap
y
spra
nk c
nge
rock
em
ctive
el ta
syst
alve,
ttery
• Improper selection of fuel
in fu
r
e
r line
m (v
(rac
fuel
e f
t
d ba
r
men
aine
le, d
ater
iner
syste
hole
mp
ir in
rate
d
e
p str
nozz
stra
ir he
n
l
n pu
er e
g, a
i
her
, cyl
alve
erio
d
pum
ter,
ke a
l use
lean
tion
reat
ggin
io
ken v
ring
t
t
e
el fil
c
or d
a
injec
je
feed
air b
air c
, clo
r fue
t
, bro
ton
n
in
i
f
ctive
ctive
ctive
n pis
kage
ged
ged
ged
ged
ged
rope
ctive
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Lea
Imp
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Air cleaner clogging monitor lights up
Preheating monitor does not light up
Starting motor cranks engine slowly
When fuel dial is placed at FULL position, it does not contact stopper
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to

be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-610 BR380JG-1
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up Causes

smoothly

ap
y
seat
spra
nk c
• Improper condition of fuel injction
alve
tive
• Improper fuel used
el ta
nce
nd v
efec
in fu
r
fere
nge
r line
nt
g
iner
ve a
le, d
pipin
leme
inter
p plu
aine
ance
hole
inde
stra
f val
nozz
er e
, str
fuel
ger,
pum
lear
her
, cyl
mp
act o
lean
filter
tion
char
reat
king
lve c
u
ring
n
p
jectio
cont
injec
feed
air c
air b
, lea
urbo
fuel
r va
ton
ed in
ctive
n pis
ged
ged
rope
ged
ged
ged
ed t
ged
Clog
Defe
Clog
Clog
Clog
Clog
Seiz
Seiz
Clog
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
BR380JG-1 20-611
TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops during operations
• Seized parts inside engine

• Overheating
a If there is overheating and the engine stops,
carry out troubleshooting for overheating.
• Failure in hydraulic pump

a If the engine stops because of a failure in the
hydraulic pump, carry out troubleshooting for
H mode.
20-612 BR380JG-1
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
Gener al c auses why engine does not rotate Causes

smoothly
p
zzle
pum
• Air in fuel system
d no
feed
• Defective governor mechanism
n
mp a
and
• Defective governor motor mechanism
nk
a If hunting stops when governor spring is dis-
tank
d pu
el ta
ck
r
erno
ol ra
rnor
n fee
fuel
connected, carry out troubleshooting for E
in fu
r
v
r
gove
een
mode.
aine
f go
twee
low
t
ner
f con
hole
betw
i
p str
nt o
too
stra
it be
tank
n of
ion o
her
stme
cuit
ed is
pum
circu
ter,
ratio
el in
reat
erat
ir
el fil
c
adju
e
ope
eed
air b
air in
nt fu
air in
g sp
o p
u
f
f
ctive
ctive
ctive
fficie
idlin
ged
ged
ged
ged,
ged,
Clog
Defe
Clog
Clog
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idling

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
Replacement of filters has not been carried out according
to Operation Manual
Fuel tank is found to be empty
Rust, water are found when fuel tank is drained
Leakage from fuel piping
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting

does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
BR380JG-1 20-613
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power)
General causes why engine lacks output Causes

nt
tme
pray
eat
ragm
• Improper fuel used
lve s
djus
k
ve s
l tan
iaph
(if non-specified fuel is used, output drops)
ce
ve a
d va
fecti
e
or d
eren
• Lack of output due to overtaking
in fu
er
fecti
e an
, de
ung
nt
a If there is overheating and lack of output, car-
iping
iner
nsat
f
iner
leme
inter
hole
e
r
e
e
inde
valv
l
c
stra
g, d
l
ry out troubleshooting for overheating.
uel p
mpe
n
nozz
stra
ump
a
er e
ger,
her
lear
, cyl
prin
ct of
p
st co
pum
ing f
lter,
ion p
tion
reat
lean
char
lve c
ring
or s
onta
i
boo
injec
f
air b
feed
air c
, lea
urbo
fuel
vern
c
r va
ton
c
j e
ctive
ctive
ed in
n pis
ged
ged
ged
ged
rope
ged
ged
ed t
t go
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Seiz
Seiz
Ben
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

Replacement of filters has not been carried out according
to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
There is hunting from engine (rotation is irregular)
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When fuel dial is placed at FULL position, lever does not contact stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-614 BR380JG-1
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
ifold
man
d)
on)
eize
take
jecti
at
er s
y
nd in
spra
e se
ve in
lung
ger a
valv
timin efective
essi
nce
ck, p
char
and
fere
(exc
nt
p (ra
turbo
le, d
leme
alve
inter
ance
r
r
p
inde
uffle
pum
pum
nozz
een
v
er e
ger,
lear
, cyl
dm
f
act o
tion
tion
betw
ction
lean
tion
char
ve c
gge
ring
injec
injec
cont
injec
of air
air c
r inje
, clo
l
urbo
r va
ton
ctive
ctive
ctive
n pis
hed
ged
rope
ged
rope
age
ed t
Defe
Defe
Defe
Crus
Clog
Leak
Clog
Seiz
Wor
Imp
Imp
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
BR380JG-1 20-615
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 Causes

minutes continuously. (Both low and high idling)
rger
ocha
General causes why oil consumption is excessive
Turb
• Abnormal combustion of oil
seal
ad
ace
r he
• External leakage of oil
stem
hose
oler
ken
f
l sur
inde
• Wear of lubrication system
il co
, bro
e sy
her
, sea
ug
r cyl
or o
reat
r
intak
ide)
in pl
nde
nd
nd
iping
seal
an o
ine e
er e
or b
lter
, gu
, cyli
om
r
oil d
oil p
oil p
oil fi
rear
blow
ring
stem
ther
turb
in fr
oler
ring
from
from
from
rom
n
iston
brea
il co
al at
lve (
al at
ked
roke
ton
en o
n pis
t suc
en p
kage
kage
kage
n se
kage
n va
n se
ged
n, b
Brok
Clog
Brok
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Lea
Lea
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in damper chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-616 BR380JG-1
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated

quickly
• Entry of exhaust gas due to internal wear

• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
BR380JG-1 20-617
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes
• Leakage of fuel
n)
jectio
n)
er
pisto
el filt
g
sprin
ive in
mp (
g, fu
r
rnor
cess
cove
er
d pu
pipin
lung
y
gove
a
p (ex
timin
head
e
r
p
p
fuel
e
s
f
p
e
nt of
lder
pum
pum
ction
id
side
from
s
o
al in
stme
h
tion
ction
el in
l inje
age
le
oil se
nozz
injec
adju
of fu
je
e
leak
u
in
f
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items

Timing lock on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Speed does not change when operation of certain cylinders is stopped
Troubleshooting
When control rack is pushed, it is found to be heavy, or does not return

When check is made using delivery method, injection timing is
found to be incorrect
Remove head cover and inspect directly
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-618 BR380JG-1
S-11 Oil is in cooling water, or water

spurts back, or water level goes
down
General causes why oil is in cooling water Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
sket
k
d ga
bloc
ring
r
a
oole
, O-
der
, he
g
cylin
pittin
core
oil c
head
ks in
oler
ulic
b y
r
linde
used
a
il co
crac
y d r
y
en o
en h
en c
s ca
rnal
Brok
Brok
Hole
Brok
Inte
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil is cloudy white
When hydraulic oil is drained, water is found

shooting
Trouble-
Pressure-tightness test of cylinder head shows there is leakage

Remove oil pan and inspect directly
Replace
Replace
Replace
Replace
Replace
Remedy
BR380JG-1 20-619
S-12 Oil pressure monitor lights up

(Drop in oil pressure)
General causes why oil pressure monitor lights up
• Leakage, clogging, wear of lubricating system

• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for engine oil selection
20-620 BR380JG-1
S-13 Oil level rises (Water, fuel in oil)
a If there is oil in the cooling water, carry out trou- Causes

bleshooting for "Oil is in cooling water".
General causes why oil level rises
over
ad c
al
nt se
• Water in oil (milky white)
e he
mp
et
• Fuel in oil (diluted, and smells of diesel fuel)
ipme
ace
gask
nsid
n pu
• Entry of oil from other component
eve
surf
ring
equ
i
o
k
ead
g
r sle
bloc
t
pipin
c
, O-
seal
e
ary
d, h
n j
e
der
core
ting
i
hold
l i
om
rear
t
side
i
hea
osta
x
p au
cylin
y pit
el fr
oler
zzle
rt in
ged
erm
der
pum
de b
of fu
side
il co
a
n
ama
h
n
p
l i
t
y
s ma
ctive
ctive
ctive
ks in
ctive
en o
en c
kage
n, d
Defe
Defe
Defe
Hole
Brok
Defe
Crac
Brok
Wor
Lea
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
Check items
an abnormal number of bubbles appear, or water spurts back

Oil level goes down in damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Inspect rear seal directly

When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
BR380JG-1 20-621
S-14 Water temperature becomes too

high (Overheating)
General causes why water temperature becomes
too high
• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in hydraulic pump system
a Carry out troubleshooting for H mode.
20-622 BR380JG-1
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an exter- Causes

nal noise.
ifold
e)
etc.)
man
engin
d)
n)
General causes why abnormal noise is made
tion)
ver,
eize
ositio
ta ke
less
er le
c
er s
nd in
e
ce
t of p
j
• Abnormality due to defective parts
liner
ve in
k
aran
lung
c
e, ro
d ou
ger a
e
• Abnormal combustion
der (
renc
essi
nce
e cle
ck, p
e
(valv
boar
• Air sucked in from intake system
ozzl
ch a r
cylin
fere
(exc
erfe
sh
valv
p (ra
ystem
ion n
iding
turbo
a
ing,
inter
lt int
ackl
mp
g
t of
pum
ton r
r (div
t
n pu
lve s
een
c
ushi
ain b
n be
ger,
n
e
e
of pis
d inj
tion
b e tw
uffle
justm
ic va
o
ed b
char
n, fa
ar tr
t i
injec
eize
njec
ide m
wear
ynam
of air
seiz
urbo
d
d fa
r ge
a
s
i
ctive
ctive
ctive
ct ins
,
ssive
rme
rope
ged
en d
ed t
ing,
age
Defe
Defe
Defo
Defe
Leak
Clog
Miss
Defe
Seiz
Exce
Brok
Imp
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
BR380JG-1 20-623
S-16 Vibration is excessive
a If there is abnormal noise together with the vibra- Causes

tion, carry out troubleshooting also for "Abnormal
k)
. stuc
noise is made".
tion)
d
gne
r, etc
on
injec
isali
ushi
r leve
General causes why vibration is excessive
fuel
pm
en c
ocke
sive
pum
ring
• Defective parts (abnormal wear, breakage)
brok
lve, r
xces
bea
• Improper alignment
ulic
m (va
olts,
ash
ydra
• Abnormal combustion
p (e
main
r
mpe
ing b
ackl
syste
pum
h
rod,
e da
ain b
and
t
alve
oun
g
tion
ushin
cting
nsid
mic v
gine
ar tr
em
injec
art i
dyna
f en
ngin
nne
r ge
mb
ctive
en p
ter o
n co
n ca
rope
se e
ctive
Defe
Brok
Wor
Wor
Cen
Defe
Loo
Imp
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black
Remove oil pan and inspect directly

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside damper directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-624 BR380JG-1
30 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL .................................................................................................................. 30- 3
PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................ 30- 5
DISASSEMBLY AND ASSEMBLY OF CRUSHER ..................................................................................... 30- 7
DISASSEMBLY AND ASSEMBLY OF LOCK CYLINDER.......................................................................... 30- 15
REMOVAL AND INSTALLATION OF PRIMARY CONVEYOR ASSEMBLY .............................................. 30- 19
REPLACEMENT OF BELT ......................................................................................................................... 30- 22
REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR MOTOR ......................................... 30- 24
REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR HEAD PULLEY FRAME ................ 30- 26
PROCEDURE FOR FOLDING ENGINE FRONT COVER.......................................................................... 30- 36
BR380JG-1 30-1
(4)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
1) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly a This mark gives guidance or precau-
developed for this model.
2 This mark stands for a specific coating
tions when doing the procedure.
R: Tools with upgraded part numbers,
remodeled from already available tools
3 This mark indicates the specified
agent to be used.
for other models.
Blank: Tools already available for other mod-
5
torque.
els, used without any modification. This mark indicates an amount of oil or
2) Circle mark (Q) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T means • Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
BR380JG-1 30-3
(2)
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS ASSEMBLY

• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this sec- precautions and the know-how for the work, as
tion. well as the amount of oil or water to be added.
• List of the special tools contains the following • Various symbols used in the ASSEMBLY Sec-
kind of information. tion are explained and listed below.
k
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
2 This mark stands for a specific coating

mercially available tools. tions when doing the procedure.
2) Distinction of new and existing special tools
3 This mark indicates the specified
agent to be used.
N: Tools with new part numbers, newly
developed for this model.
5
torque.
R: Tools with upgraded part numbers,
This mark indicates an amount of oil or
remodeled from already available tools
water to be added.
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
SKETCHES OF SPECIAL TOOLS
3) Circle mark (Q) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k This mark indicates safety-related pre-

doing the work.
a This mark gives guidance or precautions
when doing the procedure.
[*1] This mark shows that there are instruc-
tions or precautions for installing parts.
6 This mark shows oil or water to be

drained.
30-4 BR380JG-1
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
BR380JG-1 30-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6 BR380JG-1
(2)
DISASSEMBLY AND ASSEMBLY CRUSHER
DISASSEMBLY AND ASSEMBLY OF CRUSHER
1. Cheek plate 10. Toggle seat

2. Protector 11. Swing jaw
3. V-belt 12. Swing jaw plate
4. Lock cylinder 13. Crusher chamber
5. Crusher motor 14. Fixed jaw plate
6. Swing jaw plate wedge bolt 15. Front frame
7. Fixing link 16. Tension rod
8. Toggle seat 17. Tension spring
9. Toggle plate
BR380JG-1 30-7
(2)
REPLACING CHEEK PLATES 3. After removing the upper and lower cheek
plates, remove all dirt and sand from the cheek
• Prepare the special tools for the cheek plate. plate mounting faces (front, rear, right, and left).
Part No. of eyebolt: 04530-11628 a In particular, remove all dirt and sand from
Part No. of bracket: 8240-98-1130 both sides of the fixed jaw plate.
Part No. of clamping bolt: 01016-51240
4. Insert new cheek plates in order from the lowest
1. Remove dirt and sand in hanging hole A of one along the fixed jaw plate and guide of the
upper cheek plate (1) with an air gun or a wire side frame.
brush, then lift off upper cheek plate (1) with the
special tool.
4 Upper cheek plate: 74 kg
2. Remove dirt and sand in hanging hole A of

lower cheek plate (2) with an air gun or a wire
brush, then lift off upper cheek plate (2) with the
special tool.
4 Lower cheek plate: 36 kg
5. After installing upper and lower cheek plates (1)

and (2), tighten clamping bolts (3).
30-8 BR380JG-1
(2)
TURNING OVER AND REPLACING 4. Measure the clearance on each side of fixed jaw
FIXED JAW PLATE plate (3) and determine the point where the fixed
jaw plate is aligned with the crusher frame.
1. Remove the cheek plates.
See REPLACING CHEEK PLATES. 5. Insert block B (wood block, etc.) between fixed
jaw plate (3) and swing jaw plate (4).
2. Using the attached tools, remove fixed jaw plate
wedge bolt (1) and fixed jaw plate wedge block
(2).
6. Referring to the method of adjusting the clear-

ance of discharge setting, push out swing jaw
plate (4) to press fixed jaw plate (3) against the
3. Sling fixed jaw plate (3) with wires A. front frame.
When turning over
Lower fixed jaw plate (3) on a stand. Install the 7. Install the fixed jaw plate wedge and fixed jaw
wires on the opposite side and insert the fixed plate wedge bolt (5).
jaw plate in the crusher frame. a Length L of fixed jaw plate wedge bolt spring:
When replacing 108 – 110 mm
Remove fixed jaw plate (3) and install new one
in the crusher frame.
a After removeing the fixed jaw plate, remove
all dirt and sand from the fixed jaw plate
mounting faces (the front frame and the top
of the fixed jaw plate mount stopper).
8. Install the cheek plates.

See REPLACING CHEEK PLATES.
BR380JG-1 30-9
(2)
TURNING OVER AND REPLACING 4. Install hooks A to the hooks on the top of the
SWING JAW PLATE swing jaw plate (4) and sling the swing jaw plate.
4 Swing jaw plate: 735 kg
Removal a After removing the swing jaw plate, remove
1. Loosen the bolt of the crusher inspection hatch, all dirt and sand from the mounting face. Dirt
open the crusher inspection hatch, and fix it to and sand on the mounting face can cause a
the hook. play of the swing jaw plate.
2. Loosen 2 swing jaw plate wedge bolts (1) and

remove one of them. After removing swing jaw Installation
plate wedge spring (2), install the nut to the 1. When turning over swing jaw plate (4), lower it to
remaining bolt and keep that bolt inserted. the stand. Install the wires on the opposite side
and insert the swing jaw plate in the crusher
frame.
When replacing swing jaw plate (4), lower it to
the stand. Sling a new swing jaw plate with the
wires and insert it in the crusher frame.
2. Install swing jaw plate wedge (2) and swing jaw

plate wedge bolt (1). Set length L of the swing
jaw plate wedge spring to 108 – 110 mm.
3. Check that swing jaw plate wedge (3) is loos-

ened fully. Install wire A to the center, remove
the remaining bolt, and sling the swing jaw plate
wedge.
a Push out the swing jaw plate about 30 mm so
that you can easily install wire A to it.
30-10 BR380JG-1
(2)
REPLACING TOGGLE PLATE 5. Set mode selector switch (3) in the inspection
position.
1. Loosen the bolt of the crusher inspection hatch, k Put a warning tag to the starting switch to
open the crusher inspection hatch, and fix it to notify the persons around the machine that
the hook. you are working on the machine.
2. Remove the dust prevntion rubber plates on the

sides (right and left) of the crusher.
6. Press crusher clearance decrease switch (4) on

the control box to move the fixing link until the
swing jaw plate touches the fixed jaw plate.
3. Wind nylon sling onto toggle plate (1) and lift it
up temporarily.
7. Stop the engine.
8. Fully loosen tension springs (2) (M42 on both

sides).
k It is very dangerous to go to the following
step without fully loosening tension springs
(2). Accordingly, remove tension spring
nuts (9) from the rod.
4. Start the engine.
BR380JG-1 30-11
(2)
9. Pass the wire through the hole in the bottom of 14. Wind the nylon sling onto new toggle plate (1).
the swing jaw (6), then use a chain block to pull Lower the toggle plate to set it to the center of
the crusher case and the track frame and fix the seat on the fixing link side.
them in position.

16. Set mode selector switch (3) in the inspection
11. Press the crusher clearance increase switch (5) position.
on the control box to pull the fixing link slowly. k Put a warning tag to the starting switch to
notify the persons around the machine that
you are working on the machine.
17. Press crusher clearance decrease switch (4) on

the control box to push out fixing link (7) and
adjust the hanging height of the wire simultane-
ously. Set the center of the front contact surface
of the toggle plate to that of the swing jaw seat.
12. Stop the engine.
13. Take out toggle plate (1).

4 Toggle plate: 101 kg
18. Stop the engine.
19. Remove the nylon sling from the toggle plate.
30-12 BR380JG-1
(2)
20. Install tension spring (8) and compress it to the

specified tightening length. Set tightening
length L of the tension spring to 258 – 260 mm
when the crusher outlet clearance is 50 (OSS).
21. Install rubber cover (1 piece) to the top of the

toggle plate.
22. Loosen the chain block installed under the

swing jaw and remove the wire.
23. Close the crusher inspection hatch and fix it with

the bolt.
24. Install the dust prevention rubber plates to the

sides (right and left) of the crusher.
25. Check clearance of discharge setting A and

adjust it to the desired value.
For the method of adjust the clearance of dis-
charge setting, see TESTING AND ADJUST-
I NG , Tes ti ng an d ad ju st in g c le ar a nc e o f
discharge setting.
BR380JG-1 30-13
(2)
REPLACING TOGGLE SEATS 4. Sling the toggle seat.

4 Toggle seat on swing jaw side: 44.3 kg
Before replacing the toggle seats, be sure to per-
form the following items.
• Since the toggle seats are not interchangeable,
take care not to mistake them when installing.
Toggle seat on swing jaw side: The height of the
projection is 32.5 mm (at the center). The pro-
jection is on the lower side.
Toggle seat on fixing link side: The height of the
projection is 47 mm. The projection is on the
lower side.
• Perform the work with the lock cylinder extracted
fully so that the toggle seat on the fixing link side
will not fall.
1. Referring to REPLACING TOGGLE PLATE,

5. Remove toggle seat holding plate (2) from only
remove the toggle plate.
one side on the fixing link side.
2. Remove toggle seat holding plates (1) on both
sides on the swing jaw side.
6. Tighten an eyebolt into the side where the hold-

ing plate was removed and sling the toggle seat
temporarily to prevent it from falling.
3. Tighten eyebolts in tap holes h on both sides of
the toggle seat and install a wire to them.
7. After slinging the toggle seat temporarily,
remove the toggle seat holding plate on the
opposite side.
8. Insert eyebolts into both sides on the toggle

block side and sling the toggle seat.
4 Toggle seat on toggle block side:
40.0 kg
9. Insert a new toggle seat by performing the

above procedures in the reverse order.
30-14 BR380JG-1
(2)
DISASSEMBLY AND ASSEMBLY LOCK CYLINDER
DISASSEMBLY AND 2) Using a pipe of a proper size, remove clevis

(1) and washer (3).
ASSEMBLY OF LOCK a Protect the pipe contact parts with
CYLINDER cloths.
k Do not disassemble the parts other than those

a After clevis (1) is loosened, disconnect it
slowly so that it will not be seized.
described in this section.
DISASSEMBLY
1. Removal of clevis and flange

1) Remove the lock screw of clevis (1) and
flange (2).
• Screw size: M10
a After removing the lock screw, be sure to
clean the screw hole with compressed
air and apply anti-seizure compound to
2 Lock screw hole:

it.
Anti-seizure compound
(Molybdenum spray, etc.)
3) Fit the hook spanner to flange (2) and hit it

with a hammer to loosen the flange, and
then remove the flange.
• Nominal diameter of hook spanner:
155/165 (mm)
BR380JG-1 30-15
(2)
4) Remove seals (4), (5), (6), and (7). 2. Disassembly of clevis

a Take care that rings (8) and (9) will not 1) Remove ring (10) with snap ring pliers.
be damaged.
a Check the positions of the seal and ring
and the direction of the lip.
2) Using tool (11) (shown below) and a ham-

mer, remove bushing (12).
Tool (11)
• Material: SS400 or equivalent

• Heat treatment: Unnecessary
30-16 BR380JG-1
(2)
2. Installation of clevis and flange

1) Install seals (4), (5), (6), and (7).
a Take care not to mistake the positions of
the seal and ring or the direction of the
lip.
a If there is rust or a flaw on the fitting part,
remove it.
ASSEMBLY
1. Assembly of clevis
2 Fitting part:
1) Clean the part to fit bushing (12).
2 Fitting part:
(Molybdenum spray, etc.) 2) Install flange (2) with the hook spanner.
2) Using tool (11) and a hammer, press fit Same oil as currently applied
2 Threaded part:
bushing (12). one, grease, etc. (Apply thinly)
a Adjusting the center of the bushing,
press fit the bushing slowly. Anti-seizure compound
a Tighten the flange slowly so that it will
not be seized.
3 Flange: 980 Nm {100 kgm}

a Retighten the flange by using a hammer.
3) Install ring (10) with snap ring pliers.
BR380JG-1 30-17
(2)
3) Using a pipe, install clevis (1) and washer

(3).
a Protect the pipe contact parts with
2 Fitting part:
cloths.
Same oil as currently applied
2 Threaded part:
one, grease, etc. (Apply thinly)
a Tighten the flange slowly so that it will
not be seized or will not catch some-
thing.
3 Clevis:
a Retighten the clevis by using a hammer.
706 – 784 Nm {72 – 80 kgm}
4) Tighten the lock screw of clevis (1) and
3 Screw: 59 Nm {6 kgm}
flange (2).
a Do not reuse the used lock screw.

a If the lock screw hole is deviated by
retightening, make a new lock screw
hole.
30-18 BR380JG-1
(4)
DISASSEMBLY AND ASSEMBLY PRIMARY CONVEYOR ASSEMBLY
REMOVAL AND 3. Remove either lock bracket (2).

(Prevention of interference when the conveyor is
INSTALLATION OF PRIMARY inserted)
CONVEYOR ASSEMBLY a Bolt size: M16 x 4 pieces
DISASSEMBLY
1. Remove conveyor hose (1).
a Put male and female plugs to the removed
hose and elbow.
• Size 03
(Flat face-to-face O-ring seal)...... 1 set
• Size 04
(Flat face-to-face O-ring seal)...... 2 sets
4. Install slings to conveyor sling bracket (3) and lift

up the conveyor assembly.
a Note that sling hook positions depend on the
serial No.
4 Weight of conveyor assembly:
Approx. 1,310 kg
2. Install a dummy plug to the block on the

machine side.
5. Remove magnetic separator chutes (4).

(2 places on the right and left sides)
a Bolt size: M12 x 4 pieces
(2 places on the right and left sides)
BR380JG-1 30-19
(4)
6. Remove pin (5) and rear sling bracket (6). 9. Lower the cylinder.
a Bolt size: M12 x 4 pieces a Place wooden blocks under the conveyor in
advance.
7. Loosen sling bracket mounting bolt (7) and

remove conveyor lock pin (8). 10. Remove the pin.
(2 places on the bright and left sides)
11. Move the machine in reverse to remove the con-

veyor assembly.
8. Lower the crane to lower the conveyor. a Take care that the conveyor will not collide
a Note that sling hook positions depend on the with the machine.
serial No.
4 Weight of conveyor assembly:
Approx. 1,310 kg
30-20 BR380JG-1
(4)
12. Place stable stands under the conveyor and lift INSTALLATION
off the conveyor assembly.
• Carry out installation in the reverse order to re-
moval.
BR380JG-1 30-21
(4)
DISASSEMBLY AND ASSEMBLY BELT
REPLACEMENT OF BELT
When performing the following work, call a belt stick-
ing work subcontractor (Operation and Maintenance
Manual 7-15) as a supervisor. Ask the subcontrac-
tor to carry out the sticking work (vulcanization at
normal temperature) in the field.
1. Loosen right and left tension adjustment bolts 3. Connect the existing belt and the new belt by
(1) alternately to reduce the belt tension. strong lines (or wires).
a Loosen the tension adjustment bolts fully.
a Make a mark at the original tension point in
advance.
(The following is shown for reference: Contents

of work performed by the subcontractor)
2. Cut the belt
a The cut point shown in the figure is for refer-
ence only.
a Cut the belt in a place where you can work
easily.
a If right and left head pulley joints (3) and (4)

are removed, the motor will be misaligned
and may be broken. Accordingly, do not re-
move those joints. (A) Connect by strong lines (or wires) at mini-
mum of 3 points (both ends and center).
(B) Strong line (or wire)
Cut belt
30-22 BR380JG-1
(4)
DISASSEMBLY AND ASSEMBLY BELT
4. Pull out the cut belt (C).

a At this time, do not remove the right and left
joints of the head pulley assembly.
5. Stick the belt.

a Ask the belt sticking work subcontractor
(See Operation and Maintenance Manual 7-
15) to stick the belt.
6. Referring to the value marked in step 1, adjust

the belt tension.
Stick belt
BR380JG-1 30-23
(4)
DISASSEMBLY AND ASSEMBLY PRIMARY BELT CONVEYOR MOTOR
REPLACEMENT PROCEDURE 3. Disconnect conveyor motor hoses (2) from the

body.
FOR PRIMARY BELT a After removing the hoses, put dummy plugs
CONVEYOR MOTOR to their ends and motor ports.
• Size 03
1. Loosen tension adjustment bolt (1) to reduce the (Flat face-to-face O-ring seal) ......1 set
belt tension. • Size 04
a Loosen the tension adjustment bolts fully. (Flat face-to-face O-ring seal) ......2 sets
advance.
4. Fix the head pulley with a block so that it will not

be misaligned with the frame.
2. Lower the conveyor assembly. a If right and left frame joints (3) and (4) are re-
(For removal, see "Removal and installation of moved, the motor will be misaligned and
primary belt conveyor".) may be broken. Accordingly, do not remove
those joints.
30-24 BR380JG-1
(4)
DISASSEMBLY AND ASSEMBLY PRIMARY BELT CONVEYOR MOTOR
7. Replace the motor and install the flange to the

new motor.
(A) Insert wooden block to fix pulley.

(B) Fix head pulley assembly with V-block to
prevent misalignment.
(C) Adjust height with jack.
8. Install the flange to the pulley.
5. Remove flange bolts (3) from the pulley.
a At this time, take care that the pulley shaft
will not move from the frame.
a At this time, take care that the pulley shaft
will not move from the frame.
Bolt size:
M12 x 10 pieces
9. Install the motor flange to the frame.

6. Remove motor flange mounting bolts (4) to
10. Increase the belt tension to the value marked in
remove flange (5) from motor (6).
step 1.
11. Install the conveyor assembly to the body.
Bolt size:
M12 x 10 pieces
BR380JG-1 30-25
(4)
DISASSEMBLY AND ASSEMBLY PRIMARY BELT CONVEYOR HEAD PULLEY FRAME
REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR

HEAD PULLEY FRAME
a If the belt conveyor head pulley frame has been deformed or its parts have been removed, perform the fol-
lowing check and then adjust or replace the parts.
1. Rotate the belt conveyor. 4. Lower the conveyor assembly.

a Engine speed: High idle (For removal, see "Removal and installation of
primary belt conveyor".)
2. Visually check the frame for lateral swing (D).
a If lateral swing is detected, replace the pulley
frame according to the following procedure.
Reference:
If lateral swing is 3 mm or larger, it can be
checked visually.
3. Loosen tension adjustment bolt (1) to reduce the

belt tension.
a Loosen the tension adjustment bolts fully.
advance.
a When replacing the frame without removing

the conveyor assembly, fix the head pulley
according to the following steps 1) – 3).
1) Remove belt cleaner (3).
30-26 BR380JG-1
(4)
2) Set blocks [1] between head pulley (4) and 6. Fix the head pulley with a V-block and wooden
guard (5) on both sides of the head pulley. block as shown below so that it will not be mis-
aligned with the frame.
3) Support the head pulley with jack [2].
(A) Insert wooden block to fix pulley.

(B) Fix head pulley assembly with V-block to
prevent misalignment.
5. Disconnect conveyor motor hoses (2) from the (C) Adjust height with jack.
body.
a After removing the hoses, put dummy plugs 7. Remove spring pin (3).
to their ends and motor ports.
• Size 03
(Flat face-to-face O-ring seal)...... 1 set
• Size 04
(Flat face-to-face O-ring seal)...... 2 sets
BR380JG-1 30-27
(4)
When replacing frame on motor side 11. Remove bolts (7) and cover (8).
8. Sling frame (4) with a crane in advance. a Bolt size: M12 x 8 pieces
12. Remove bolts (9), pulley and motor flange.

9. Remove upper bracket (5). a Bolt size: M12 x 10 pieces
a M16 x 3 (2 places on right and left sides)
13. Remove frame assembly (10) as a unit.

10. Remove lower bracket (6).
30-28 BR380JG-1
(4)
14. Install motor (12) and flange (13) to new frame 17. Install cover (16) to the head pulley frame and
(11). secure it with bolts (17).
15. Sling frame assembly (14) with the crane. 18. Go to step 29 (Sub-assembly of head pulley
frame).
16. Position the head pulley and motor flange and

connect them with bolts (15).
BR380JG-1 30-29
(4)
When replacing frame on bearing side 22. Remove bolts (21) and cover (22).
19. Sling frame (18) with the crane in advance.
23. Remove bearing cover (23).

20. Remove upper bracket (19).
24. Loosen bearing lock screws (24).

(2 places in total)
21. Remove lower bracket (20).
30-30 BR380JG-1
(4)
25. Remove bolts (25) to remove the bearing from 28. Install cover (27) to the head pulley frame and
the frame. secure it with bolts (28).
26. Remove the frame and replace it with a new

one.
27. Connect the bearing and frame by bolts (26).
BR380JG-1 30-31
(4)
Sub-assembly of head pulley frame

29. Apply jig (29) to measuring points f1 (E), f2 (F)
and f3 (G) in the figure and adjust the frame
width.
a When adjusting the frame width, adjust the
bearing side with a jack.
30. Apply jig (29) to measuring points h1 and h2 and

check that contact of jig (29) and belt is even at
points (J) and (K).
a If contact is uneven, adjust the position.
a Dimension in the figure is as follows:
h1 = h2 = 18 mm
30-32 BR380JG-1
(4)
BR380JG-1 30-33
(4)
31. Install upper bracket (25). 34. Remove bearing cover (28).
a M16 x 3 (2 places on right and left sides) a Before tightening the screws, see steps 29
and 30 and check the dimensions again.
32. Install lower bracket (26).

a M16 x 3 (2 places on right and left sides) 35. Install the shaft to the frame.
33. Tighten bearing lock screws (27). 36. Insert spring pin (29).
(2 places in total)
a Before tightening the screws, see steps 29
and 30 and check the dimensions again.
37. Install conveyor assembly to the body.
30-34 BR380JG-1
(4)
38. Rotate tension adjustment bolt (1) to increase

the belt tension.
a Increase the belt tension to the mark made
when he belt was loosened.
39. Referring to steps 29 and 30, check again that

the distance between the head pulley and frame
is in the standard range.
40. Start the belt conveyor and check that it rotates

smoothly.
a Engine speed: High idle
BR380JG-1 30-35
(4)
DISASSEMBLY AND ASSEMBLY FOLDING ENGINE FRONT COVER
PROCEDURE FOR FOLDING 3. Remove engine front cover bottom mounting

bolts (3).
ENGINE FRONT COVER Right and left side: 1 place each
M12: 2 pieces (Width across flats: 19 mm)
When the engine fuel supply pump or engine con- a Do not remove M16 bolts (4) (1 place each
troller needs to be replaced, the engine front cover on the right and left sides).
can be folded toward the magnetic separator to (These bolts prevent the folded engine front
make a work space in front of the engine. cover from falling.)
a The magnetic separator is constantly generating

strong magnetism.
A person using a heart pace maker or another
medical device must not approach the magnetic
separator.
Since an ATM card, watch, cellular phone, digi-
tal camera or another electric/electronic device
can be troubled by the magnetism, do not take
them near the magnetic separator.
1. Remove the wiring harnesses from the wiring

harness clamps of the headlamp and rotary
lamp installed to engine front cover (1) in
advance. 4. While supporting the engine front cover, remove
mounting bolts (5).
Right and left side: 1 place each
M12: 2 pieces (Width across flats: 19 mm)
2. Remove 2 caps (2) from the front side of engine

front cover (1).
30-36 BR380JG-1
(4)
DISASSEMBLY AND ASSEMBLY FOLDING ENGINE FRONT COVER
5. Slowly fold the engine front cover toward the

magnetic separator and rest it against the mag-
netic separator frame.
a Weight of engine front cover assembly:
Approx. 130 kg
a Put pads between the cover and magnetic
separator frame to protect the paint of the
cover.
Pads
a Clearance (A) about 200 mm wide can be

secured by the above work.
BR380JG-1 30-37
(4)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/2)........................................................................................................90- 3

HYDRAULIC CIRCUIT DIAGRAM (2/2)........................................................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/3) ......................................................................................................90- 7
BR380JG-1 90-1
HYDRAULIC CIRCUIT DIAGRAM (1/2)
BR380JG-1 90-3
OTHERS HYDRAULIC CIRCUIT DIAGRAM (2/2)
HYDRAULIC CIRCUIT DIAGRAM (2/2)
BR380JG-1 90-5
ELECTRICAL CIRCUIT DIAGRAM (1/3)
BR380JG-1 90-7
BR380JG-1 90-9
BR380JG-1 90-11

WA320-3 Shop Custom

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SEBM034104

MACHINE MODEL SERIAL NUMBER

BR380JG-1 1001 and up

• BR380JG-1 mounts the SAA6D102E-2 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal