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

00 Index and foreword SEN01343-03
BR380JG-1E0 7
Troubleshooting by failure code, Part 2 SEN02091-00
Failure code [7RFAKY] Short circuit in engine stop relay ........................................................... 4
Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay ................................ 6
Failure code [7RFBKB] Short circuit in muck conveyor solenoid ................................................ 8
Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid ..................... 9
Failure code [7RFCKA] Disconnection in magnetic separator solenoid...................................... 10
Failure code [7RFCKB] Short circuit in magnetic separator solenoid ......................................... 11
Failure code [7RFCKY] Short circuit in magnetic separator solenoid ......................................... 12
Failure code [7RFHKB] Short circuit in conveyor forward relay .................................................. 14
Failure code [7RFHKY] Short circuit in conveyor forward relay .................................................. 16
Failure code [7RFKKB] Short circuit in lock cylinder pull relay ................................................... 18
Failure code [7RFKKY] Short circuit in lock cylinder pull relay ................................................... 20
Failure code [7RFLKA] Disconnection in accessory EPC solenoid ............................................ 22
Failure code [7RFLKB] Short circuit in accessory EPC solenoid ................................................ 23
Failure code [7RFLKY] Short circuit in accessory EPC solenoid ................................................ 24
Failure code [7RFMKY] Short circuit in abnormal pressure relay ............................................... 26
Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay .................... 28
Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve ............................ 30
Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve ............................... 31
Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve ............................... 32
Failure code [7RFPKB] Short circuit in lock cylinder push relay ................................................. 34
Failure code [7RFPKY] Short circuit in lock cylinder push relay ................................................. 36
Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor ..................................... 38
Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve ................................... 40
Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve....................................... 42
Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve....................................... 44
Failure code [7RJMMW] Lock cylinder slipping .......................................................................... 45
Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor.................................. 46
Failure code [7RJPKB] Short circuit in radio control work-mode switch ..................................... 48
Failure code [7RJQKB] Short circuit in radio control travel-mode switch.................................... 49
Failure code [7RJRKB] Short circuit on travel signal .................................................................. 50
Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor ............................. 52
Failure code [AA10NX] Air cleaner Clogging .............................................................................. 54
Failure code [AB00KE] Charge voltage too low .......................................................................... 56
Troubleshooting by failure code, Part 3 SEN02092-00
Failure code [B@BAZG] Engine oil pressure too low ................................................................. 4
Failure code [B@BAZK] Engine oil level reduction ..................................................................... 6
Failure code [B@BCNS] Radiator coolant overheat ................................................................... 7
Failure code [B@BCZK] Radiator coolant level reduction .......................................................... 8
Failure code [B@HANS] Hydraulic oil overheat.......................................................................... 10
Failure code [CA111] Abnormality in engine controller................................................................ 10
Failure code [CA115] Abnormality in engine NE and Bkup speed sensors................................. 11
Failure code [CA122] Charge pressure sensor too high ............................................................. 12
Failure code [CA123] Charge pressure sensor too low .............................................................. 14
Failure code [CA131] Throttle sensor too high............................................................................ 16
Failure code [CA132] Throttle sensor too low ............................................................................. 18
Failure code [CA144] Coolant temperature sensor too high ....................................................... 20
Failure code [CA145] Coolant temperature sensor too low ........................................................ 22
Failure code [CA153] Charge temperature sensor too high........................................................ 24
Failure code [CA154] Charge temperature sensor too low ......................................................... 26
Failure code [CA155] Charge temperature too high and engine speed derated......................... 28
Failure code [CA187] Sensor power source 2 too low ................................................................ 30
Failure code [CA221] Ambient pressure sensor too high............................................................ 32
Failure code [CA222] Ambient pressure sensor too low ............................................................. 34
Failure code [CA227] Sensor power source 2 too high............................................................... 36
Failure code [CA234] Engine overspeed .................................................................................... 37
Failure code [CA238] Abnormal power source for Ne speed sensor .......................................... 38
Failure code [CA271] Short circuit in fuel pump actuator............................................................ 39

SEN01343-03 00 Index and foreword
8BR380JG-1E0
Failure code [CA272] Disconnection in fuel pump actuator ........................................................ 40
Failure code [CA322] Disconnection or short circuit in injector No.1 .......................................... 42
Failure code [CA323] Disconnection or short circuit in injector No.5 .......................................... 44
Failure code [CA324] Disconnection or short circuit in injector No.3 .......................................... 46
Failure code [CA325] Disconnection or short circuit in injector No.6 .......................................... 48
Failure code [CA331] Disconnection or short circuit in injector No.2 .......................................... 50
Failure code [CA332] Disconnection or short circuit in injector No.4 .......................................... 52
Troubleshooting by failure code, Part 4 SEN02093-00
Failure code [CA342] Abnormality in engine controller data consistency ................................... 3
Failure code [CA351] Abnormality in injector drive circuit ........................................................... 4
Failure code [CA352] Sensor power source 1 too low ................................................................ 6
Failure code [CA386] Sensor power source 1 too high............................................................... 8
Failure code [CA428] Water detection sensor too high ............................................................... 10
Failure code [CA429] Water detection sensor too low ................................................................ 12
Failure code [CA435] Abnormality in engine oil pressure switch ................................................ 14
Failure code [CA441] Power source voltage too low................................................................... 16
Failure code [CA442] Power source voltage too high ................................................................. 18
Failure code [CA449] Common rail pressure sensor too high (2) ............................................... 20
Failure code [CA451] Common rail pressure sensor too high..................................................... 22
Failure code [CA452] Common rail pressure sensor too low ...................................................... 24
Failure code [CA488] Charge temperature too high and torque derated .................................... 26
Failure code [CA553] Common rail pressure sensor too high (1) ............................................... 26
Failure code [CA559] Supply pump no pressure......................................................................... 27
Failure code [CA689] Abnormality in engine Ne speed sensor................................................... 28
Failure code [CA731] Abnormal phase in engine Bkup speed sensor ........................................ 30
Failure code [CA757] Loss of all engine controller data.............................................................. 32
Failure code [CA778] Abnormality in engine Bkup speed sensor ............................................... 34
Failure code [CA1633] CAN communication error (engine controller) ........................................ 36
Failure code [CA2185] Throttle pedal sensor power source too high ......................................... 38
Failure code [CA2186] Throttle pedal sensor power source too low........................................... 39
Failure code [CA2249] Supply pump no pressure (2) ................................................................. 40
Failure code [CA2311] Abnormal resistance in pump regulator valve......................................... 42
Failure code [CA2555] Disconnection in air intake heater relay.................................................. 44
Failure code [CA2556] Short circuit in air intake heater relay ..................................................... 46
Troubleshooting by failure code, Part 5 SEN02094-00
Failure code [D162KY] Short circuit in horn relay ....................................................................... 4
Failure code [D162KZ] Disconnection or short circuit in horn relay ............................................ 6
Failure code [DA22KK] Solenoid power source too low.............................................................. 8
Failure code [DA25KP] Abnormality in pressure sensor power source....................................... 10
Failure code [DA2RMC] CAN communication error (work equipment and pump controller) ...... 14
Failure code [DA2SKQ] Abnormality in model code input........................................................... 16
Failure code [DAFRMC] CAN communication error (monitor controller)..................................... 18
Failure code [DDA6KA] Disconnection in engine stop switch ..................................................... 20
Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor................................... 22
Failure code [DHPAMA] Abnormality in F pump pressure sensor............................................... 24
Failure code [DHPBMA] Abnormality in R pump pressure sensor .............................................. 26
Failure code [DUB0KY] Short circuit in beacon solid state relay................................................. 28
Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay...................... 30
Failure code [DXA0KA] Disconnection in PC-EPC Solenoid ...................................................... 32
Failure code [DXA0KB] Short circuit in PC-EPC Solenoid .......................................................... 33
Failure code [DXA0KY] Short circuit in PC-EPC Solenoid .......................................................... 34
Failure code [DXE0KA] Disconnection in LS-EPC solenoid........................................................ 35
Failure code [DXE0KB] Short circuit in LS-EPC solenoid ........................................................... 36
Failure code [DXE0KY] Short circuit in LS-EPC solenoid ........................................................... 37
Troubleshooting of electrical system (E-mode) SEN02095-00
Information in troubleshooting table ............................................................................................3
E-1 Engine does not start (Engine does not turn) ....................................................................... 4
E-2 The engine stops while it is running...................................................................................... 8

00 Index and foreword SEN01343-03
BR380JG-1E0 9
E-3 The automatic warm-up function does not work................................................................... 10
E-4 Preheater does not operate..................................................................................................12
E-5 The whole work equipment stops suddenly.......................................................................... 14
E-6 The red mark of emergency stop is indicated just after the engine is started....................... 16
E-7 The machine monitor does not display any item .................................................................. 20
E-8 Some items are not displayed on the machine monitor........................................................ 22
E-9 Contents of display by machine monitor are different from applicable machine................... 22
E-10 Fuel level monitor was lighted in red while engine running ................................................ 23
E-11 Engine coolant temperature gauge does not indicate normally .......................................... 24
E-12 The fuel level gauge does not display normally.................................................................. 26
E-13 The hydraulic oil temperature gauge does not display normally ........................................ 27
E-14 The travel, work, and inspection modes do not change. .................................................... 28
E-15 The crusher clearance adjustment mode does not change................................................ 30
E-16 The crusher rotation direction does not change ................................................................. 32
E-17 Machine does not travel ..................................................................................................... 34
E-18 Travel cannot be controlled by radio control....................................................................... 36
E-19 The feeder cannot be turned ON and OFF by radio control ............................................... 40
E-20 One-touch start, stop switch cannot be operated by radio control ..................................... 44
E-21 The monitor switches do not work ...................................................................................... 47
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE
switch on the monitor ......................................................................................................... 48
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE
switch on the monitor ......................................................................................................... 49
E-24 KOMTRAX system does not operate normally................................................................... 50
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02306-01
System chart for hydraulic and mechanical systems .................................................................. 4
Information contained in troubleshooting table............................................................................ 6
H-1 The speed or power of the whole work equipment and travel is low.................................... 8
H-2 The engine speed lowers extremely or the engine stalls ..................................................... 10
H-3 The work equipment and travel systems do not work .......................................................... 11
H-4 Abnormal sound comes out from around the hydraulic pump.............................................. 11
H-5 Fine control performance or response is low ....................................................................... 12
H-6 The conveyor does not operate............................................................................................ 13
H-7 The speed or power of the conveyor is low.......................................................................... 14
H-8 The crusher does not operate .............................................................................................. 15
H-9 The speed or power of crusher is low .................................................................................. 16
H-10 The feeder does not operate .............................................................................................. 16
H-11 The feeder does not feed smoothly (Vibration frequency is low)........................................ 17
H-12 The magnetic separator does not operate ......................................................................... 17
H-13 The speed of magnetic separator belt is low...................................................................... 18
H-14 The side conveyor does not operate .................................................................................. 18
H-15 The speed or power of the side conveyor is low ................................................................ 19
H-16 The primary conveyor and the side conveyor do not move up and down .......................... 20
H-17 The machine deviates during travel ................................................................................... 21
H-18 The travel speed is low....................................................................................................... 23
H-19 The machine is not steered well or steering power is low .................................................. 25
H-20 The travel motor does not work (only one side) ................................................................. 26
H-21 When the travel switch of the radio controller is depressed, the machine does not travel. 26
H-22 The crusher clearance cannot be adjusted ........................................................................ 27
Troubleshooting of engine (S-mode) SEN02307-00
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor ................................................................................................6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lack output (or lacks power) ..................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion)................................................................ 14

SEN01343-03 00 Index and foreword
10 BR380JG-1E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive ........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant/fuel) ................................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made .....................................................................................................22
S-16 Vibration is excessive ......................................................................................................... 23
50 Disassembly and assembly
General information on disassembly and assembly SEN02737-00
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Work equipment SEN02738-00
Disassembly and assembly of crusher........................................................................................ 2
Replacing cheek plates ............................................................................................................... 3
Turning over and replacing fixed jaw plate.................................................................................. 4
Turning over and replacing swing jaw plate ................................................................................ 5
Replacing toggle plate................................................................................................................. 7
Replacing toggle seats ................................................................................................................ 10
Disassembly and assembly of lock cylinder ................................................................................ 11
Removal and installation of primary conveyor assembly ............................................................ 15
Replacement of belt .................................................................................................................... 18
Replacement procedure for primary belt conveyor motor ........................................................... 20
Replacement procedure for primary belt conveyor head pulley frame........................................ 22
Procedure for folding engine front cover ..................................................................................... 31
90 Diagrams and drawings
Hydraulic diagrams and drawings SEN01361-00
Hydraulic circuit diagram (1/2)..................................................................................................... 3
Hydraulic circuit diagram (2/2)..................................................................................................... 5
Electrical diagrams and drawings SEN01362-01
Electrical circuit diagram (1/4) ..................................................................................................... 3
Electrical circuit diagram (2/4) ..................................................................................................... 5
Electrical circuit diagram (3/4) ..................................................................................................... 7
Electrical circuit diagram (4/4) ..................................................................................................... 9
Connector arrangement diagram (1/2) ........................................................................................ 11
Connector arrangement diagram (2/2) ........................................................................................ 13

00 Index and foreword SEN01343-03
BR380JG-1E0 11

12
SEN01343-03
BR380JG-1E0 Mobile crusher
Form No. SEN01343-03
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)

BR380JG-1E0 1
SEN01344-00
MOBILE CRUSHER
1SHOP MANUAL
BR380JG-1E0
Machine model Serial number
BR380JG-1E0 2001 and up
00 Index and foreword 1
Foreword and general information
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

SEN01344-00 00 Index and foreword
2BR380JG-1E0
(Rev. 2006/09)
Safety notice 1
Important safety notice
Proper service and repair are 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 kis used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions
kMistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Main-
tenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
qAlways wear safety glasses when hit-
ting parts with a hammer.
qAlways wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
7) If welding repairs are needed, always
have a trained and experienced welder
carry out the work. When carrying out
welding work, always wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
8) Before starting work, warm up your body
thoroughly to start work under good condi-
tion.
2. Preparations for work
1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7Wearing protective goggles
(for cleaning or grinding work)
8Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are
not used to or you are used to too much

00 Index and foreword SEN01344-00
BR380JG-1E0 3
3) When disassembling or assembling, sup-
port the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, lad-
ders or steps when getting on or off the
machine. Never jump on or off the
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
3. Precautions during work
1) Before disconnecting or removing compo-
nents of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative (–) terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
8) 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
and can even start fires.
9) As a general rule, do not use gasoline to
wash parts. Do not use it to clean electri-
cal parts, in particular.
10) Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be dam-
aged by contact with other parts when the
machine is operated.
11) When installing high pressure hoses,
make sure that they are not twisted. Dam-
aged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
that connecting parts are correctly
installed.
12) When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate vio-
lently or rotate at high speed, be particu-
larly careful to check that they are
installed correctly.
13) When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14) When measuring hydraulic pressure,
check that the measuring tools are cor-
rectly assembled.
15) Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
16) If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.

SEN01344-00 00 Index and foreword
4BR380JG-1E0
4. Precautions for sling work and making
signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
qDo not stand under the load.
qDo not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
kSlinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150°, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8) When installing wire ropes to an angular
load, apply pads to protect the wire ropes.
If the load is slippery, apply proper mate-
rial to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
qSlinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle por-
tion.
11) Do not use twisted or kinked wire ropes.
12) When lifting up a load, observe the follow-
ing.
qWind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
qAfter the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

00 Index and foreword SEN01344-00
BR380JG-1E0 5
qIf the load is unstable or the wire rope
or chains are twisted, lower the load
and lift it up again.
qDo not lift up the load slantingly.
13) When lifting down a load, observe the fol-
lowing.
qWhen lifting down a load, stop it tem-
porarily at 30 cm above the floor, and
then lower it slowly.
qCheck that the load is stable, and
then remove the sling.
qRemove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
5. Precautions for using mobile crane
aRead the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
6. Precautions for using overhead hoist crane
kWhen raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disas-
sembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock preven-
tion earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
13) If the hoist stops because of a power fail-
ure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
aThe allowable load is one-sixth of the
breaking strength of the rope used
(Safety coefficient: 6).
Wire ropes
(Standard “Z” twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4

SEN01344-00 00 Index and foreword
6BR380JG-1E0
8. Precautions for disconnecting and con-
necting hoses and tubes in air conditioner
circuit
1) Disconnection
kCollect the air conditioner refrigerant
gas (R134a).
kIf the refrigerant gas (R134a) gets in
your eyes, you may lose your sight.
Accordingly, when collecting or adding
it, you must be qualified for handling
the refrigerant and put on protective
goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
aExample of O-ring (Fitted to every joint of
hoses and tubes)
aFor tightening torque, see the precautions for
installation in each section of "Disassembly
and assembly".

00 Index and foreword SEN01344-00
BR380JG-1E0 7
How to read the shop manual 1
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
qChassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
qEngine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
qSome attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
qMaterials and specifications are subject to change without notice.
qShop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

SEN01344-00 00 Index and foreword
8BR380JG-1E0
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
qRevised edition mark
When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
qRevisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
Symbol Item Remarks
kSafety Special safety precautions are necessary when performing work.
aCaution Special technical precautions or other precautions for preserving stan-
dards are necessary when performing work.
4Weight Weight of parts of component or parts. Caution necessary when
selecting hoisting wire, or when working posture is important, etc.
3Tightening
torque
Places that require special attention for tightening torque during
assembly.
2Coat Places to be coated with adhesives, etc. during assembly.
5Oil, coolant Places where oil, etc. must be added, and capacity.
6Drain Places where oil, etc. must be drained, and quantity to be drained.

00 Index and foreword SEN01344-00
BR380JG-1E0 9
Explanation of terms for maintenance standard 1
The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance
qTo be accurate, the finishing size of parts
is a little different from one to another.
qTo specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
qThe above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
qThe tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
aThe tolerance may be indicated in the text
and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
qUsually, the size of a hole and the size of
the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
qIndication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size Tolerance
120 –0.022
–0.126
Example:
Standard size Tole r a nce
Shaft Hole
60 –0.030
–0.076
+0.046
+0