Komatsu BR380JG-1E0 Mobile Crusher Service Repair Shop Manual (2001 and up) - SEN01341-06

This Complete Service Repair Workshop Manual PDF Download for the BR380JG-1E0 Komatsu Mobile Crusher (SN: 2001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu BR380JG-1E0 Mobile Crusher
Serial Numbers : 2001 and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure, function and maintenance standard
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
90 Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEN01341-06
Total Pages : 924


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

01 Specification
Specification and technical data
Specification dimension drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system
Engine mount, damper
Radiator, oil cooler and aftercooler
Power train
Power train
Drive system for components
Final drive
Sprocket
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic sysmtem, Part 1
Hydraulic piping drawing
Hydraulic tank and hydraulic oil filter
Hydraulic pump
Hydraulic system, Part 2
Control valve
Self pressure reducing valve
CLSS
Functions and operation by valve
Hydraulic system, Part 3
Crusher motor
Grizzly feeder motor
Conveyor motor
Travel motor
Valve control
Solenoid valve
EPC valve
Electromagnetic selector valve
Hydraulic cylinder
Work equipment
Grizzly feeder semiautomatic system
Abnormal load stop system
Primary belt conveyor
Grizzly feeder
Crusher
Crusher tooth tip adjustment system
Vibrator
Electrical system
Engine control
Work equipment and pump controller
Electronic control system
Machine monitor system
Sensor
KOMTRAX system

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis

30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel delivery, return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Replacing fan belt
Checking and adjusting track shoe tension
Measuring and adjusting oil pressure in work equipment and travel circuits
Measuring control circuit basic pressure
Measuring and adjusting oil pressure in pump PC control circuit
Measuring and adjusting oil pressure in pump LS control circuit
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Measuring oil leakage
Bleeding air from each part
Testing travel deviation
Adjusting mirrors
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Check and adjustment of jaw crusher
Check and adjustment of outlet clearance
Adjusting tension of crusher drive V-belt
Check and adjustment of primary conveyor
Inspection and maintenance of magnetic separator
Check and adjustment of muck discharge conveyor
List of companies which handles radio controllers
Handling voltage circuit of engine controller
Starting KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Preparation work for troubleshooting for electrical system
Procedure for testing diodes

40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code, Part 1
Failure code [7RC1KB] Short circuit conveyor ON switch
Failure code [7RC2KA] Disconnection in conveyor OFF switch
Failure code [7RC5KB] Short circuit in feeder ON switch
Failure code [7RD2KB] Short circuit in conveyor reverse relay
Failure code [7RD2KZ] Disconnection or short circuit in conveyor reverse relay
Failure code [7RE1KB] Short circuit in crusher ON switch
Failure code [7RE2KA] Disconnection in crusher OFF switch
Failure code [7RE6KB] Short circuit in muck discharge conveyor ON switch
Failure code [7RE7KA] Disconnection in muck discharge conveyor OFF switch
Failure code [7RE8KB] Short circuit in magnetic separator ON switch
Failure code [7RE9KA] Disconnection in magnetic separator OFF switch
Failure code [7REAKB] Short circuit in accessory input circuit
Failure code [7REDMA] Abnormality in primary conveyor pressure sensor
Failure code [7REEMA] Abnormality in muck conveyor pressure sensor
Failure code [7RENKZ] Abnormality in clearance potentiometer
Failure code [7REPKA] Disconnection in feeder OFF switch
Failure code [7RESKB] Short circuit in one-touch start switch
Failure code [7RETKA] Disconnection in one-touch stop switch
Failure code [7RF2KA] Disconnection in crusher forward EPC valve
Failure code [7RF2KB] Short circuit in crusher forward EPC valve
Failure code [7RF2KY] Short circuit in crusher forward EPC valve
Failure code [7RF3KA] Disconnection in crusher reverse EPC valve
Failure code [7RF3KB] Short circuit in crusher reverse EPC valve
Failure code [7RF3KY] Short circuit in crusher reverse EPC valve
Failure code [7RF4KA] Disconnection in feeder forward EPC valve
Failure code [7RF4KB] Short circuit in feeder forward EPC valve
Failure code [7RF4KY] Short circuit in feeder forward EPC valve
Troubleshooting by failure code, Part 2
Failure code [7RFAKY] Short circuit in engine stop relay
Failure code [7RFAKZ] Disconnection or short circuit in engine stop relay
Failure code [7RFBKB] Short circuit in muck conveyor solenoid
Failure code [7RFBKZ] Disconnection or short circuit in muck conveyor solenoid
Failure code [7RFCKA] Disconnection in magnetic separator solenoid
Failure code [7RFCKB] Short circuit in magnetic separator solenoid
Failure code [7RFCKY] Short circuit in magnetic separator solenoid
Failure code [7RFHKB] Short circuit in conveyor forward relay
Failure code [7RFHKY] Short circuit in conveyor forward relay
Failure code [7RFKKB] Short circuit in lock cylinder pull relay
Failure code [7RFKKY] Short circuit in lock cylinder pull relay
Failure code [7RFLKA] Disconnection in accessory EPC solenoid
Failure code [7RFLKB] Short circuit in accessory EPC solenoid
Failure code [7RFLKY] Short circuit in accessory EPC solenoid
Failure code [7RFMKY] Short circuit in abnormal pressure relay
Failure code [7RFMKZ] Disconnection or short circuit in abnormal pressure relay
Failure code [7RFNKA] Disconnection in lock cylinder unlock solenoid valve
Failure code [7RFNKB] Short circuit in lock cylinder unlock solenoid valve
Failure code [7RFNKY] Short circuit in lock cylinder unlock solenoid valve
Failure code [7RFPKB] Short circuit in lock cylinder push relay
Failure code [7RFPKY] Short circuit in lock cylinder push relay
Failure code [7RGAMA] Abnormality in 2nd conveyor pressure sensor
Failure code [7RJAKA] Disconnection in travel lock EPC solenoid valve
Failure code [7RJAKB] Short circuit in travel lock EPC solenoid valve
Failure code [7RJAKY] Short circuit in travel lock EPC solenoid valve
Failure code [7RJMMW] Lock cylinder slipping
Failure code [7RJNMA] Abnormality in vibratory screen pressure sensor
Failure code [7RJPKB] Short circuit in radio control work-mode switch
Failure code [7RJQKB] Short circuit in radio control travel-mode switch
Failure code [7RJRKB] Short circuit on travel signal
Failure code [7RJSMA] Abnormality in magnetic separator pressure sensor
Failure code [AA10NX] Air cleaner Clogging
Failure code [AB00KE] Charge voltage too low
Troubleshooting by failure code, Part 3
Failure code [B@BAZG] Engine oil pressure too low
Failure code [B@BAZK] Engine oil level reduction
Failure code [B@BCNS] Radiator coolant overheat
Failure code [B@BCZK] Radiator coolant level reduction
Failure code [B@HANS] Hydraulic oil overheat
Failure code [CA111] Abnormality in engine controller
Failure code [CA115] Abnormality in engine NE and Bkup speed sensors
Failure code [CA122] Charge pressure sensor too high
Failure code [CA123] Charge pressure sensor too low
Failure code [CA131] Throttle sensor too high
Failure code [CA132] Throttle sensor too low
Failure code [CA144] Coolant temperature sensor too high
Failure code [CA145] Coolant temperature sensor too low
Failure code [CA153] Charge temperature sensor too high
Failure code [CA154] Charge temperature sensor too low
Failure code [CA155] Charge temperature too high and engine speed derated
Failure code [CA187] Sensor power source 2 too low
Failure code [CA221] Ambient pressure sensor too high
Failure code [CA222] Ambient pressure sensor too low
Failure code [CA227] Sensor power source 2 too high
Failure code [CA234] Engine overspeed
Failure code [CA238] Abnormal power source for Ne speed sensor
Failure code [CA271] Short circuit in fuel pump actuator
Failure code [CA272] Disconnection in fuel pump actuator
Failure code [CA322] Disconnection or short circuit in injector No.1
Failure code [CA323] Disconnection or short circuit in injector No.5
Failure code [CA324] Disconnection or short circuit in injector No.3
Failure code [CA325] Disconnection or short circuit in injector No.6
Failure code [CA331] Disconnection or short circuit in injector No.2
Failure code [CA332] Disconnection or short circuit in injector No.4
Troubleshooting by failure code, Part 4
Failure code [CA342] Abnormality in engine controller data consistency
Failure code [CA351] Abnormality in injector drive circuit
Failure code [CA352] Sensor power source 1 too low
Failure code [CA386] Sensor power source 1 too high
Failure code [CA428] Water detection sensor too high
Failure code [CA429] Water detection sensor too low
Failure code [CA435] Abnormality in engine oil pressure switch
Failure code [CA441] Power source voltage too low
Failure code [CA442] Power source voltage too high
Failure code [CA449] Common rail pressure sensor too high (2)
Failure code [CA451] Common rail pressure sensor too high
Failure code [CA452] Common rail pressure sensor too low
Failure code [CA488] Charge temperature too high and torque derated
Failure code [CA553] Common rail pressure sensor too high (1)
Failure code [CA559] Supply pump no pressure
Failure code [CA689] Abnormality in engine Ne speed sensor
Failure code [CA731] Abnormal phase in engine Bkup speed sensor
Failure code [CA757] Loss of all engine controller data
Failure code [CA778] Abnormality in engine Bkup speed sensor
Failure code [CA1633] CAN communication error (engine controller)
Failure code [CA2185] Throttle pedal sensor power source too high
Failure code [CA2186] Throttle pedal sensor power source too low
Failure code [CA2249] Supply pump no pressure (2)
Failure code [CA2311] Abnormal resistance in pump regulator valve
Failure code [CA2555] Disconnection in air intake heater relay
Failure code [CA2556] Short circuit in air intake heater relay
Troubleshooting by failure code, Part 5
Failure code [D162KY] Short circuit in horn relay
Failure code [D162KZ] Disconnection or short circuit in horn relay
Failure code [DA22KK] Solenoid power source too low
Failure code [DA25KP] Abnormality in pressure sensor power source
Failure code [DA2RMC] CAN communication error (work equipment and pump controller)
Failure code [DA2SKQ] Abnormality in model code input
Failure code [DAFRMC] CAN communication error (monitor controller)
Failure code [DDA6KA] Disconnection in engine stop switch
Failure code [DGH2KB] Short circuit in hydraulic oil temperature sensor
Failure code [DHPAMA] Abnormality in F pump pressure sensor
Failure code [DHPBMA] Abnormality in R pump pressure sensor
Failure code [DUB0KY] Short circuit in beacon solid state relay
Failure code [DUB0KZ] Disconnection or short circuit in beacon solid state relay
Failure code [DXA0KA] Disconnection in PC-EPC Solenoid
Failure code [DXA0KB] Short circuit in PC-EPC Solenoid
Failure code [DXA0KY] Short circuit in PC-EPC Solenoid
Failure code [DXE0KA] Disconnection in LS-EPC solenoid
Failure code [DXE0KB] Short circuit in LS-EPC solenoid
Failure code [DXE0KY] Short circuit in LS-EPC solenoid
Troubleshooting of electrical system (E-mode)
Information in troubleshooting table
E-1 Engine does not start (Engine does not turn)
E-2 The engine stops while it is running
E-3 The automatic warm-up function does not work.
E-4 Preheater does not operate
E-5 The whole work equipment stops suddenly
E-6 The red mark of emergency stop is indicated just after the engine is started
E-7 The machine monitor does not display any item
E-8 Some items are not displayed on the machine monitor
E-9 Contents of display by machine monitor are different from applicable machine
E-10 Fuel level monitor was lighted in red while engine running
E-11 Engine coolant temperature gauge does not indicate normally
E-12 The fuel level gauge does not display normally.
E-13 The hydraulic oil temperature gauge does not display normally
E-14 The travel, work, and inspection modes do not change.
E-15 The crusher clearance adjustment mode does not change
E-16 The crusher rotation direction does not change
E-17 Machine does not travel
E-18 Travel cannot be controlled by radio control
E-19 The feeder cannot be turned ON and OFF by radio control
E-20 One-touch start, stop switch cannot be operated by radio control
E-21 The monitor switches do not work
E-22 The crusher cannot be operated with the crusher manual FORWARD/REVERSE switch on the monitor
E-23 The conveyor cannot be operated with the conveyor manual FORWARD/REVERSE switch on the monitor
E-24 The KOMTRAX system does not work properly
Troubleshooting of hydraulic and mechanical system (H-mode)
System chart for hydraulic and mechanical systems
Information contained in troubleshooting table
H-1 The speed or power of the whole work equipment and travel is low
H-2 The engine speed lowers extremely or the engine stalls
H-3 The work equipment and travel systems do not work
H-4 Abnormal sound comes out from around the hydraulic pump
H-5 Fine control performance or response is low
H-6 The conveyor does not operate
H-7 The speed or power of the conveyor is low
H-8 The crusher does not operate
H-9 The speed or power of crusher is low
H-10 The feeder does not operate
H-11 The feeder does not feed smoothly (Vibration frequency is low)
H-12 The magnetic separator does not operate
H-13 The speed of magnetic separator belt is low
H-14 The side conveyor does not operate
H-15 The speed or power of the side conveyor is low
H-16 The primary conveyor and the side conveyor do not move up and down
H-17 The machine deviates during travel
H-18 The travel speed is low
H-19 The machine is not steered well or steering power is low
H-20 The travel motor does not work (only one side)
H-21 When the travel switch of the radio controller is depressed, the machine does not travel
H-22 The crusher clearance cannot be adjusted
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Hydraulic system
Removal and installation of crusher lock cylinder assembly
Disassembly and assembly of crusher lock cylinder assembly
Bleeding air from crusher lock cylinder
Work equipment
Removal and installation of cheek plates
Removal and installation of fixed tooth
Removal and installation of swing tooth
Removal and installation of toggle plate
Replacement of toggle plate
Replacement of toggle seats
Removal and installation of fixed link
Removal and installation of swing jaw assembly
Removal and installation of crusher main bearing
Removal and installation of crusher motor V-sheave
Removal and installation of V-sheave and balance weight
Removal and installation of potentiometer
Removal and installation of crusher assembly
Removal and installation of primary belt conveyor assembly
Replacement of belt
Replacement of primary belt conveyor motor
Replacement of primary belt conveyor head pulley frame
Procedure for folding engine front cover

90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (2/2)
Electrical diagrams and drawings
Electrical circuit diagram (1/4)
Electrical circuit diagram (2/4)
Electrical circuit diagram (3/4)
Electrical circuit diagram (4/4)
Connector arrangement diagram (1/2)
Connector arrangement diagram (2/2)

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