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Komatsu BR380JG-1E0 Shop Manual
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Komatsu BR380JG-1E0 Shop Manual

Mobile crusher
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SEN01343-03
Composition of shop manual
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
Shop Manual, contents binder, binder label and tabs
00 Index and foreword
Index
Foreword and general information
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
Engine and cooling system
Power train
Undercarriage and frame
Hydraulic sysmtem, Part 1
Hydraulic system, Part 2
Hydraulic system, Part 3
Work equipment
Electrical system
20 Standard value table
Standard service value table
30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 2
Testing and adjusting, Part 3
40 Troubleshooting
Failure code table and fuse locations
General information on troubleshooting
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 2
Troubleshooting by failure code, Part 3
Troubleshooting by failure code, Part 4
Troubleshooting by failure code, Part 5
Troubleshooting of electrical system (E-mode)
2
00 Index and foreword
Form Number
SEN01341-03
SEN01342-03
SEN01343-03 q
SEN01344-00
SEN01345-00
SEN01346-00
SEN01347-00
SEN01348-00
SEN01349-00
SEN01350-00
SEN01351-00
SEN01352-00
SEN01353-00
SEN01354-00
SEN01355-00
SEN01356-00
SEN02288-00
SEN01357-01
SEN02303-00
SEN02304-00
SEN02305-01 q
SEN01358-02
SEN02088-00
SEN02089-01
SEN02090-00
SEN02091-00
SEN02092-00
SEN02093-00
SEN02094-00
SEN02095-00
BR380JG-1E0
1

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Summary of Contents for Komatsu BR380JG-1E0

  • Page 1 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 BR380JG-1E0...
  • Page 2 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 Work equipment SEN02738-00 90 Diagrams and drawings SEN01360-01 Hydraulic diagrams and drawings SEN01361-00 Electrical diagrams and drawings SEN01362-01 BR380JG-1E0...
  • Page 3 Hydraulic sysmtem, Part 1 SEN01351-00 Hydraulic piping drawing ......................Hydraulic tank and hydraulic oil filter................... Hydraulic pump ........................... Hydraulic system, Part 2 SEN01352-00 Control valve ..........................Self pressure reducing valve ....................... 10 CLSS ............................15 Functions and operation by valve....................19 BR380JG-1E0...
  • Page 4 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 BR380JG-1E0...
  • Page 5 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 BR380JG-1E0...
  • Page 6 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 BR380JG-1E0...
  • Page 7 Failure code [DXE0KY] Short circuit in LS-EPC solenoid ............37 Troubleshooting of electrical system (E-mode) SEN02095-00 Information in troubleshooting table .................... E-1 Engine does not start (Engine does not turn) ............... E-2 The engine stops while it is running..................BR380JG-1E0...
  • Page 8 S-3 Engine does not pick up smoothly..................10 S-4 Engine stops during operations .................... 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 BR380JG-1E0...
  • Page 9 Hydraulic circuit diagram (2/2)..................... Electrical diagrams and drawings SEN01362-01 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) ..................11 Connector arrangement diagram (2/2) ..................13 BR380JG-1E0...
  • Page 10 00 Index and foreword SEN01343-03 BR380JG-1E0...
  • Page 11 SEN01343-03 BR380JG-1E0 Mobile crusher Form No. SEN01343-03 © 2007 KOMATSU All Rights Reserved Printed in Japan 02-07 (01)

  • Page 12: Table Of Contents

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

  • Page 13: 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.
  • Page 14 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. BR380JG-1E0...
  • Page 15 If you grasp them, your fingers as large as 39.2 kN {4,000 kg}. may be caught. After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads. BR380JG-1E0...
  • Page 16 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. BR380JG-1E0...
  • Page 17 (R134a) (DENSO: ND-OIL8, ZEXEL: ZXL100PG (equivalent to PAG46)) to its O-rings. a Example of O-ring (Fitted to every joint of hoses and tubes) a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly". BR380JG-1E0...

  • Page 18: How To Read The Shop Manual

    Engine volume This section explains the method of reproducing, repairing, and replacing parts. 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. BR380JG-1E0...
  • Page 19 Places where oil, etc. must be drained, and quantity to be drained. 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 { }. BR380JG-1E0...

  • Page 20: Explanation Of Terms For Maintenance Standard

    The tightness of fit is decided by the toler- ance. Indication of size of rotating shaft and hole and relationship drawing of them Example: Tolerance Standard size Shaft Hole –0.030 +0.046 –0.076 BR380JG-1E0...
  • Page 21 If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from vari- ous tests or experiences in most cases, however, it must be judged after consider- ing the operating condition and customer's requirement. BR380JG-1E0...

  • Page 22: Handling Electric Equipment And Hydraulic Component

    The pins of the male and female connec- tors are in contact at the crimped terminal or soldered portion, but if there is exces- sive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. BR380JG-1E0...
  • Page 23 If there is oil or water in the com- pressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air com- pletely before cleaning with com- pressed air. BR380JG-1E0...
  • Page 24 If the machine is left disassem- bled for a long time, it is particu- larly easy for improper contact to occur, so always cover the con- nector. BR380JG-1E0...
  • Page 25 If the connector cannot be cor- rected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps. BR380JG-1E0...
  • Page 26 (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks BR380JG-1E0...
  • Page 27 After completely drying the con- n e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble. BR380JG-1E0...
  • Page 28 If there is any change, there is proba- bly defective contact in that circuit. BR380JG-1E0...
  • Page 29 If an oil clean- ing device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. BR380JG-1E0...
  • Page 30 The oil cleaning equipment is used to remove the ultra fine (about 3 ) particles that the filter built in the hydraulic equipment can- not remove, so it is an extremely effective device. BR380JG-1E0...
  • Page 31 Even if lock (L2) is pressed, connec- tor (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screw- driver while press lock (L2), and then pull out connector (1) toward you. BR380JG-1E0...
  • Page 32 If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connec- tor with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. BR380JG-1E0...
  • Page 33 Insert the connector to the end, while setting its groove. Turn housing (H1) in the direction of the arrow until it “clicks”. Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up. BR380JG-1E0...

  • Page 34: How To Read Electric Wire Code

    (Nominal No. 3 and below) Insulator Soft polyvinyl chloride automobile Conduc- Annealed copper for elec- Heat-resis- General wiring in extremely tric appliance tant low-volt- –50 to +110 cold district, wiring at high-tem- age wire for Heat-resistant crosslinked perature place Insulator automobile polyethylene BR380JG-1E0...
  • Page 35 (mm d (approx.) 10.4 12.0 13.6 Standard – – – – – – – – – Cov- Standard 10.8 11.4 13.0 13.6 16.0 17.6 er D Standard 10.8 11.4 13.0 13.6 16.0 17.6 “f” of nominal No. denotes flexible”. BR380JG-1E0...
  • Page 36 – – – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – BR380JG-1E0...

  • Page 37: Precautions When Carrying Out Operation

    07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 BR380JG-1E0...
  • Page 38 If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it. BR380JG-1E0...
  • Page 39 If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”. BR380JG-1E0...