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Komatsu Galeo BR380JG-1E0 Mobile Crusher Service Manual

842 pages · Publication SEN01341-03

$89.63
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Models
Galeo BR380JG-1E0
Serial coverage
2001 and up
Manual type
Service Manual
Pages
842
Publication
SEN01341-03
Condition
Brand new
Komatsu Galeo BR380JG-1E0 Mobile Crusher Service Manual, publication SEN01341-03

What's inside

From the manual's own table of contents: 167 sections, 323 entries. See sample pages (PDF, 870 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
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
Track roller
Show all 167 sections
Track shoe
Hydraulic piping drawing
Hydraulic tank and hydraulic oil filter
Hydraulic pump
Control valve
Self pressure reducing valve
CLSS
Functions and operation by valve48 topics
  • Crusher motor
  • Grizzly feeder motor
  • Conveyor motor
  • Travel motor
  • Valve control
  • 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
  • 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 return rate and leakage
  • Bleeding air from fuel circuit
  • Checking fuel circuit for leakage
  • 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
  • Bleeding air from each part
  • 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
Procedure for turning on KOMTRAX terminal
KOMTRAX terminal lamp indications
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
Wiring table for connector pin numbers
T-adapter box and T-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
    • switch on the monitor
  • KOMTRAX system does not operate normally
  • 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
Disassembly and assembly of crusher
Replacing cheek plates
Turning over and replacing fixed jaw plate
Turning over and replacing swing jaw plate
Replacing toggle plate
Replacing toggle seats
Disassembly and assembly of lock cylinder
Removal and installation of primary conveyor assembly
Replacement of belt
Replacement procedure for primary belt conveyor motor
Replacement procedure for 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 (842 pages). Open the sample pages (PDF, 869 KB)

Sample pages from the Komatsu Galeo BR380JG-1E0 Mobile Crusher Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram
  • Specifications, page 218: 10 Structure, function and maintenance standard
  • Troubleshooting, page 556: Failure code [7RJSMA] Abnormality in magnetic separator pressure
  • Diagram, page 647: Failure code [CA2185] Throttle pedal sensor power source too high
  • Foldout diagram, page 836: Electrical circuit diagram (1/4)

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, 842 pages

Quantity one is the manual described above.

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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

Komatsu BR380JG-1E0Operation & Maintenance Manual · TEN00168-03 · $69.65Komatsu BR380JG-1E0Operation & Maintenance Manual · TEN00358-01 · $69.59Komatsu BR380JG-1E0Operation & Maintenance Manual · TEN00476-02 · $69.91Komatsu BR380JG-1E0Service Manual · SEN01341-07 · $99.73Komatsu BR380JG-1E0Service Manual · SEN01341-08 · $99.85

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