Komatsu BR380JG-1E0 Mobile Crusher Service Manual
925 pages · Publication SEN01341-07
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- BR380JG-1E0
- Serial coverage
- 2001 and up
- Manual type
- Service Manual
- Pages
- 925
- Publication
- SEN01341-07
- Condition
- Brand new
What's inside
From the manual's own table of contents: 181 sections, 334 entries. See sample pages (PDF, 840 KB)
Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine mount, damper
Radiator, oil cooler and aftercooler
Power train
Drive system for components
Final drive
Sprocket
Track frame and recoil spring
Idler
Carrier roller
Show all 181 sections
Track roller
Track shoe
Hydraulic piping drawing
Hydraulic tank and hydraulic oil filter
Hydraulic pump
Control valve
Self pressure reducing valve
CLSS
Functions and operation by valve
Crusher motor
Grizzly feeder motor
Conveyor motor
Travel motor
Valve control45 topics
- Solenoid valve
- EPC valve
- Electromagnetic selector valve
- Hydraulic cylinder
- Grizzly feeder semiautomatic system
- Abnormal load stop system
- Primary belt conveyor
- Grizzly feeder
- Crusher
- Crusher tooth tip adjustment system
- Vibrator
- Engine control
- Work equipment and pump controller
- Electronic control system
- Machine monitor system
- Sensor
- KOMTRAX system
- Standard value table for engine
- Standard value table for chassis
- Tools for testing, adjusting, and troubleshooting
- Measuring engine speed
- Measuring intake air pressure (boost pressure)
- Checking exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
- Measuring engine oil pressure
- Handling fuel system parts
- Releasing residual pressure from fuel system
- Measuring fuel pressure
- Measuring fuel delivery, return rate and leakage
- Bleeding air from fuel circuit
- Checking fuel circuit for leakage
- Replacing fan belt
- Checking and adjusting track shoe tension
- Measuring and adjusting oil pressure in work equipment and travel circuits
- Measuring control circuit basic pressure
- Measuring and adjusting oil pressure in pump PC control circuit
- Measuring and adjusting oil pressure in pump LS control circuit
- Measuring solenoid valve output pressure
- Measuring PPC valve output pressure
- Measuring oil leakage
- Testing travel deviation
- Adjusting mirrors
- Special functions of machine monitor
Check and adjustment of jaw crusher
Check and adjustment of outlet clearance
Adjusting tension of crusher drive V-belt
Check and adjustment of primary conveyor
Inspection and maintenance of magnetic separator
Check and adjustment of muck discharge conveyor
List of companies which handles radio controllers
Handling voltage circuit of engine controller
Starting KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Preparation work for troubleshooting for electrical system
Procedure for testing diodes
Failure code table
Fuse locations
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Failure code [7RC1KB] Short circuit conveyor ON switch
Failure code [7RC2KA] Disconnection in conveyor OFF switch
Failure code [7RC5KB] Short circuit in feeder ON switch
Failure code [7RD2KB] Short circuit in conveyor reverse relay
Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay
Failure code [7RE1KB] Short circuit in crusher ON switch
Failure code [7RE2KA] Disconnection in crusher OFF switch
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch
Failure code [7RE8KB] Short circuit in magnetic separator ON switch
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch
Failure code [7REAKB] Short circuit in accessory input circuit
Failure code [7REDMA] Abnormality in primary conveyor pressure sensor
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor
Failure code [7RENKZ] Abnormality in clearance potentiometer
Failure code [7REPKA] Disconnection in feeder OFF switch
Failure code [7RESKB] Short circuit in one-touch start switch
Failure code [7RETKA] Disconnection in one-touch stop switch
Failure code [7RF2KA] Disconnection in crusher forward EPC valve
Failure code [7RF2KB] Short circuit in crusher forward EPC valve
Failure code [7RF2KY] Short circuit in crusher forward EPC valve
Failure code [7RF3KA] Disconnection in crusher reverse EPC valve
Failure code [7RF3KB] Short circuit in crusher reverse EPC valve
Failure code [7RF3KY] Short circuit in crusher reverse EPC valve
Failure code [7RF4KA] Disconnection in feeder forward EPC valve
Failure code [7RF4KB] Short circuit in feeder forward EPC valve
Failure code [7RF4KY] Short circuit in feeder forward EPC valve56 topics
- Failure code [7RFAKY] Short circuit in engine stop relay
- Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay
- Failure code [7RFBKB] Short circuit in muck conveyor solenoid
- Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid
- Failure code [7RFCKA] Disconnection in magnetic separator solenoid
- Failure code [7RFCKB] Short circuit in magnetic separator solenoid
- Failure code [7RFCKY] Short circuit in magnetic separator solenoid
- Failure code [7RFHKB] Short circuit in conveyor forward relay
- Failure code [7RFHKY] Short circuit in conveyor forward relay
- Failure code [7RFKKB] Short circuit in lock cylinder pull relay
- Failure code [7RFKKY] Short circuit in lock cylinder pull relay
- Failure code [7RFLKA] Disconnection in accessory EPC solenoid
- Failure code [7RFLKB] Short circuit in accessory EPC solenoid
- Failure code [7RFLKY] Short circuit in accessory EPC solenoid
- Failure code [7RFMKY] Short circuit in abnormal pressure relay
- Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay
- Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve
- Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve
- Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve
- Failure code [7RFPKB] Short circuit in lock cylinder push relay
- Failure code [7RFPKY] Short circuit in lock cylinder push relay
- Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor
- Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve
- Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve
- Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve
- Failure code [7RJMMW] Lock cylinder slipping
- Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor
- Failure code [7RJPKB] Short circuit in radio control work-mode switch
- Failure code [7RJQKB] Short circuit in radio control travel-mode switch
- Failure code [7RJRKB] Short circuit on travel signal
- Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor
- Failure code [AA10NX] Air cleaner Clogging
- Failure code [AB00KE] Charge voltage too low
- Failure code [B@BAZG] Engine oil pressure too low
- Failure code [B@BAZK] Engine oil level reduction
- Failure code [B@BCNS] Radiator coolant overheat
- Failure code [B@BCZK] Radiator coolant level reduction
- Failure code [B@HANS] Hydraulic oil overheat
- Failure code [CA111] Abnormality in engine controller
- Failure code [CA115] Abnormality in engine NE and Bkup speed sensors
- Failure code [CA122] Charge pressure sensor too high
- Failure code [CA123] Charge pressure sensor too low
- Failure code [CA131] Throttle sensor too high
- Failure code [CA132] Throttle sensor too low
- Failure code [CA144] Coolant temperature sensor too high
- Failure code [CA145] Coolant temperature sensor too low
- Failure code [CA153] Charge temperature sensor too high
- Failure code [CA154] Charge temperature sensor too low
- Failure code [CA155] Charge temperature too high and engine speed derated
- Failure code [CA187] Sensor power source 2 too low
- Failure code [CA221] Ambient pressure sensor too high
- Failure code [CA222] Ambient pressure sensor too low
- Failure code [CA227] Sensor power source 2 too high
- Failure code [CA234] Engine overspeed
- Failure code [CA238] Abnormal power source for Ne speed sensor
- Failure code [CA271] Short circuit in fuel pump actuator
Failure code [CA272] Disconnection in fuel pump actuator
Failure code [CA322] Disconnection or short circuit in injector No.1
Failure code [CA323] Disconnection or short circuit in injector No.5
Failure code [CA324] Disconnection or short circuit in injector No.3
Failure code [CA325] Disconnection or short circuit in injector No.6
Failure code [CA331] Disconnection or short circuit in injector No.2
Failure code [CA332] Disconnection or short circuit in injector No.4
Failure code [CA342] Abnormality in engine controller data consistency
Failure code [CA351] Abnormality in injector drive circuit
Failure code [CA352] Sensor power source 1 too low
Failure code [CA386] Sensor power source 1 too high
Failure code [CA428] Water detection sensor too high
Failure code [CA429] Water detection sensor too low
Failure code [CA435] Abnormality in engine oil pressure switch
Failure code [CA441] Power source voltage too low
Failure code [CA442] Power source voltage too high
Failure code [CA449] Common rail pressure sensor too high (2)
Failure code [CA451] Common rail pressure sensor too high
Failure code [CA452] Common rail pressure sensor too low
Failure code [CA488] Charge temperature too high and torque derated
Failure code [CA553] Common rail pressure sensor too high (1)
Failure code [CA559] Supply pump no pressure
Failure code [CA689] Abnormality in engine Ne speed sensor
Failure code [CA731] Abnormal phase in engine Bkup speed sensor
Failure code [CA757] Loss of all engine controller data
Failure code [CA778] Abnormality in engine Bkup speed sensor
Failure code [CA1633] CAN communication error (engine controller)
Failure code [CA2185] Throttle pedal sensor power source too high
Failure code [CA2186] Throttle pedal sensor power source too low
Failure code [CA2249] Supply pump no pressure (2)
Failure code [CA2311] Abnormal resistance in pump regulator valve
Failure code [CA2555] Disconnection in air intake heater relay
Failure code [CA2556] Short circuit in air intake heater relay
Failure code [D162KY] Short circuit in horn relay
Failure code [D162KZ] Disconnection or short circuit in horn relay
Failure code [DA22KK] Solenoid power source too low
Failure code [DA25KP] Abnormality in pressure sensor power source
Failure code [DA2RMC] CAN communication error (work equipment and pump controller)
Failure code [DA2SKQ] Abnormality in model code input
Failure code [DAFRMC] CAN communication error (monitor controller)
Failure code [DDA6KA] Disconnection in engine stop switch
Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor
Failure code [DHPAMA] Abnormality in F pump pressure sensor
Failure code [DHPBMA] Abnormality in R pump pressure sensor
Failure code [DUB0KY] Short circuit in beacon solid state relay
Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay
Failure code [DXA0KA] Disconnection in PC-EPC Solenoid
Failure code [DXA0KB] Short circuit in PC-EPC Solenoid
Failure code [DXA0KY] Short circuit in PC-EPC Solenoid
Failure code [DXE0KA] Disconnection in LS-EPC solenoid
Failure code [DXE0KB] Short circuit in LS-EPC solenoid
Failure code [DXE0KY] Short circuit in LS-EPC solenoid
Information in troubleshooting table
Engine does not start (Engine does not turn)
The engine stops while it is running52 topics
- The automatic warm-up function does not work
- Preheater does not operate
- The whole work equipment stops suddenly
- The red mark of emergency stop is indicated just after the engine is started
- The machine monitor does not display any item
- Some items are not displayed on the machine monitor
- Contents of display by machine monitor are different from applicable machine
- Fuel level monitor was lighted in red while engine running
- Engine coolant temperature gauge does not indicate normally
- The fuel level gauge does not display normally
- The hydraulic oil temperature gauge does not display normally
- The travel, work, and inspection modes do not change
- The crusher clearance adjustment mode does not change
- The crusher rotation direction does not change
- Machine does not travel
- Travel cannot be controlled by radio control
- The feeder cannot be turned ON and OFF by radio control
- One-touch start, stop switch cannot be operated by radio control
- The monitor switches do not work
- FORWARD/REVERSE switch on the monitor
- The KOMTRAX system does not work properly
- System chart for hydraulic and mechanical systems
- Information contained in troubleshooting table
- The speed or power of the whole work equipment and travel is low
- The engine speed lowers extremely or the engine stalls
- The work equipment and travel systems do not work
- Abnormal sound comes out from around the hydraulic pump
- Fine control performance or response is low
- The conveyor does not operate
- The speed or power of the conveyor is low
- The crusher does not operate
- The speed or power of crusher is low
- The feeder does not operate
- The feeder does not feed smoothly (Vibration frequency is low)
- The magnetic separator does not operate
- The speed of magnetic separator belt is low
- The side conveyor does not operate
- The speed or power of the side conveyor is low
- The primary conveyor and the side conveyor do not move up and down
- The machine deviates during travel
- The travel speed is low
- The machine is not steered well or steering power is low
- The travel motor does not work (only one side)
- The crusher clearance cannot be adjusted
- Method of using troubleshooting chart
- Starting performance is poor
- Engine does not start
- Engine does not pick up smoothly
- Engine stops during operations
- Engine does not rotate smoothly
- Engine lack output (or lacks power)
- Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant/fuel)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
How to read this manual
Coating materials list
Removal and installation of crusher lock cylinder assembly
Disassembly and assembly of crusher lock cylinder assembly
Bleeding air from crusher lock cylinder
Removal and installation of cheek plates
Removal and installation of fixed tooth
Removal and installation of swing tooth
Removal and installation of toggle plate
Replacement of toggle plate
Replacement of toggle seats
Removal and installation of fixed link
Removal and installation of swing jaw assembly
Removal and installation of crusher main bearing
Removal and installation of crusher motor V-sheave
Removal and installation of V-sheave and balance weight
Removal and installation of potentiometer
Removal and installation of crusher assembly
Removal and installation of primary belt conveyor assembly
Replacement of belt
Replacement of primary belt conveyor motor
Replacement of primary belt conveyor head pulley frame
Procedure for folding engine front cover
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (2/2)
Electrical circuit diagram (1/4)
Electrical circuit diagram (2/4)
Electrical circuit diagram (3/4)
Electrical circuit diagram (4/4)
Connector arrangement diagram (1/2)
Connector arrangement diagram (2/2)
Inside this manual
Real pages from this service manual (925 pages). Open the sample pages (PDF, 839 KB)
- Specifications, page 152: 10 Structure, function and maintenance standard
- Diagram, page 544: Failure code [7RFLKA] Disconnection in accessory EPC solenoid
- Troubleshooting, page 628: Failure code [CA331] Disconnection or short circuit in injector No.2
- Foldout diagram: Electrical circuit diagram (1/4)
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the BR380JG-1E0 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual SEN01341-07$99.73
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 925 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).