Komatsu BR380JG-1E0 Install guide

SEN01343-03 00 Index and foreword
2BR380JG-1E0
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN01341-03
00 Index and foreword SEN01342-03
Index SEN01343-03 q
Foreword and general information SEN01344-00
01 Specification SEN01345-00
Specification and technical data SEN01346-00
10 Structure, function and maintenance standard SEN01347-00
Engine and cooling system SEN01348-00
Power train SEN01349-00
Undercarriage and frame SEN01350-00
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic system, Part 2 SEN01352-00
Hydraulic system, Part 3 SEN01353-00
Work equipment SEN01354-00
Electrical system SEN01355-00
20 Standard value table SEN01356-00
Standard service value table SEN02288-00
30 Testing and adjusting SEN01357-01
Testing and adjusting, Part 1 SEN02303-00
Testing and adjusting, Part 2 SEN02304-00
Testing and adjusting, Part 3 SEN02305-01 q
40 Troubleshooting SEN01358-02
Failure code table and fuse locations SEN02088-00
General information on troubleshooting SEN02089-01
Troubleshooting by failure code, Part 1 SEN02090-00
Troubleshooting by failure code, Part 2 SEN02091-00
Troubleshooting by failure code, Part 3 SEN02092-00
Troubleshooting by failure code, Part 4 SEN02093-00
Troubleshooting by failure code, Part 5 SEN02094-00
Troubleshooting of electrical system (E-mode) SEN02095-00

00 Index and foreword SEN01343-03
BR380JG-1E0 3
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02306-01
Troubleshooting of engine (S-mode) SEN02307-00
50 Disassembly and assembly SEN01359-00
General information on disassembly and assembly SEN02737-00 Q
Work equipment SEN02738-00 Q
90 Diagrams and drawings SEN01360-01
Hydraulic diagrams and drawings SEN01361-00
Electrical diagrams and drawings SEN01362-01

SEN01343-03 00 Index and foreword
4BR380JG-1E0
Table of contents 1
00 Index and foreword
Index SEN01343-03
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN01344-00
Safety notice................................................................................................................................ 2
How to read the shop manual .....................................................................................................7
Explanation of terms for maintenance standard.......................................................................... 9
Handling electric equipment and hydraulic component............................................................... 11
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN01346-00
Specification dimension drawings ............................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 5
Table of fuel, coolant and lubricants ............................................................................................ 6
10 Structure, function and maintenance standard
Engine and cooling system SEN01348-00
Engine mount, damper ................................................................................................................ 2
Radiator, oil cooler and aftercooler.............................................................................................. 3
Power train SEN01349-00
Power train .................................................................................................................................. 2
Drive system for components...................................................................................................... 3
Final drive.................................................................................................................................... 4
Sprocket ...................................................................................................................................... 6
Undercarriage and frame SEN01350-00
Track frame and recoil spring ...................................................................................................... 2
Idler ............................................................................................................................................. 4
Carrier roller ................................................................................................................................ 6
Track roller................................................................................................................................... 7
Track shoe................................................................................................................................... 8
Hydraulic sysmtem, Part 1 SEN01351-00
Hydraulic piping drawing ............................................................................................................. 2
Hydraulic tank and hydraulic oil filter........................................................................................... 3
Hydraulic pump ........................................................................................................................... 4
Hydraulic system, Part 2 SEN01352-00
Control valve ............................................................................................................................... 2
Self pressure reducing valve ....................................................................................................... 10
CLSS ........................................................................................................................................... 15
Functions and operation by valve................................................................................................19

00 Index and foreword SEN01343-03
BR380JG-1E0 5
Hydraulic system, Part 3 SEN01353-00
Crusher motor ............................................................................................................................. 2
Grizzly feeder motor.................................................................................................................... 6
Conveyor motor........................................................................................................................... 7
Travel motor ................................................................................................................................ 8
Valve control................................................................................................................................ 16
Solenoid valve............................................................................................................................. 26
EPC valve ................................................................................................................................... 28
Electromagnetic selector valve ................................................................................................... 32
Hydraulic cylinder........................................................................................................................ 34
Work equipment SEN01354-00
Grizzly feeder semiautomatic system ......................................................................................... 2
Abnormal load stop system......................................................................................................... 3
Primary belt conveyor ................................................................................................................. 4
Grizzly feeder .............................................................................................................................. 8
Crusher ....................................................................................................................................... 9
Crusher tooth tip adjustment system........................................................................................... 14
Vibrator........................................................................................................................................ 17
Electrical system SEN01355-00
Engine control ............................................................................................................................. 2
Work equipment and pump controller ......................................................................................... 12
Electronic control system ............................................................................................................ 15
Machine monitor system ............................................................................................................. 28
Sensor......................................................................................................................................... 54
20 Standard value table
Standard service value table SEN02288-00
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting
Testing and adjusting, Part 1 SEN02303-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed............................................................................................................. 6
Measuring intake air pressure (boost pressure).......................................................................... 7
Checking exhaust gas color ........................................................................................................ 8
Adjusting valve clearance ........................................................................................................... 9
Measuring compression pressure ............................................................................................... 11
Measuring blow-by pressure ....................................................................................................... 13
Measuring engine oil pressure .................................................................................................... 14
Handling fuel system parts.......................................................................................................... 15
Releasing residual pressure from fuel system ............................................................................ 15
Measuring fuel pressure.............................................................................................................. 16
Measuring fuel return rate and leakage ...................................................................................... 18
Bleeding air from fuel circuit........................................................................................................ 20
Checking fuel circuit for leakage ................................................................................................. 22
Checking and adjusting track shoe tension................................................................................. 23
Measuring and adjusting oil pressure in work equipment and travel circuits .............................. 25
Measuring control circuit basic pressure..................................................................................... 29
Measuring and adjusting oil pressure in pump PC control circuit ............................................... 30
Measuring and adjusting oil pressure in pump LS control circuit ................................................ 33
Measuring solenoid valve output pressure.................................................................................. 37
Measuring PPC valve output pressure........................................................................................ 40
Measuring oil leakage ................................................................................................................. 41
Bleeding air from each part ......................................................................................................... 42
Testing travel deviation................................................................................................................ 45
Adjusting mirrors ......................................................................................................................... 46

SEN01343-03 00 Index and foreword
6BR380JG-1E0
Testing and adjusting, Part 2 SEN02304-00
Special functions of machine monitor.......................................................................................... 2
Testing and adjusting, Part 3 SEN02305-01
Check and adjustment of jaw crusher ......................................................................................... 2
Check and adjustment of outlet clearance .................................................................................. 4
Adjusting tension of crusher drive V-belt ..................................................................................... 37
Check and adjustment of primary conveyor ................................................................................ 38
Inspection and maintenance of magnetic separator.................................................................... 44
Check and adjustment of muck discharge conveyor................................................................... 46
List of companies which handles radio controllers ...................................................................... 48
Handling voltage circuit of engine controller................................................................................ 49
Procedure for turning on KOMTRAX terminal ............................................................................. 50
KOMTRAX terminal lamp indications .......................................................................................... 53
Preparation work for troubleshooting for electrical system.......................................................... 56
Procedure for testing diodes ....................................................................................................... 60
40 Troubleshooting
Failure code table and fuse locations SEN02088-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02089-01
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
Classification and procedures of troubleshooting........................................................................ 6
Contents of troubleshooting table................................................................................................ 10
Wiring table for connector pin numbers....................................................................................... 12
T-adapter box and T-adapter table .............................................................................................. 45
Troubleshooting by failure code, Part 1 SEN02090-00
Failure code [7RC1KB] Short circuit conveyor ON switch........................................................... 4
Failure code [7RC2KA] Disconnection in conveyor OFF switch ................................................. 6
Failure code [7RC5KB] Short circuit in feeder ON switch ........................................................... 8
Failure code [7RD2KB] Short circuit in conveyor reverse relay .................................................. 10
Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay ....................... 12
Failure code [7RE1KB] Short circuit in crusher ON switch.......................................................... 14
Failure code [7RE2KA] Disconnection in crusher OFF switch .................................................... 16
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch............................. 18
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch ....................... 20
Failure code [7RE8KB] Short circuit in magnetic separator ON switch ....................................... 22
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch ................................. 24
Failure code [7REAKB] Short circuit in accessory input circuit ................................................... 26
Failure code [7REDMA] Abnormality in primary conveyor pressure sensor ............................... 28
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor ................................... 30
Failure code [7RENKZ] Abnormality in clearance potentiometer ................................................ 32
Failure code [7REPKA] Disconnection in feeder OFF switch...................................................... 34
Failure code [7RESKB] Short circuit in one-touch start switch.................................................... 36
Failure code [7RETKA] Disconnection in one-touch stop switch ................................................ 38
Failure code [7RF2KA] Disconnection in crusher forward EPC valve......................................... 40
Failure code [7RF2KB] Short circuit in crusher forward EPC valve ............................................ 41
Failure code [7RF2KY] Short circuit in crusher forward EPC valve ............................................ 42
Failure code [7RF3KA] Disconnection in crusher reverse EPC valve......................................... 43
Failure code [7RF3KB] Short circuit in crusher reverse EPC valve ............................................ 44
Failure code [7RF3KY] Short circuit in crusher reverse EPC valve ............................................ 45
Failure code [7RF4KA] Disconnection in feeder forward EPC valve........................................... 46
Failure code [7RF4KB] Short circuit in feeder forward EPC valve .............................................. 47
Failure code [7RF4KY] Short circuit in feeder forward EPC valve .............................................. 48