The Komatsu BR380JG-1 Mobile Crusher is a tracked crusher used on demolition sites, quarries, and recycling yards to turn rock and concrete into usable aggregate. People who usually reach for the Komatsu BR380JG-1 Mobile Crusher Shop Manual (SEBM034106) are shop mechanics, field techs, and owners trying to keep an older unit earning money instead of sitting dead. They’re usually chasing electrical faults, crusher or travel issues, or planning bigger repairs so they don’t have to call in the dealer every time.
What this manual helps you do
- Trace hydraulic issues in the crusher, travel, and feeder circuits so you can find whether the problem is pump, valve, or actuator related.
- Diagnose engine, electrical, and control system faults using wiring information and step‑by‑step test routines you’d expect in a shop manual.
- Follow teardown and reassembly procedures for major components like the crusher unit, undercarriage, swing conveyor, and cylinders.
- Check adjustment methods for tracks, crusher mechanisms, and linkages so you can set things up correctly after repairs.
- Verify correct routing and installation order for hoses, harnesses, and guards so the machine can go back to work safely.
Who this is for
This manual is aimed at workshop mechanics, field service technicians, and hands‑on owners who already have basic tools and some heavy equipment experience. If you just want to learn how to operate or do daily inspections, you’d be better off with the Operation & Maintenance manual instead of this shop manual.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, it’s a digital PDF you can download, search by keyword, and print pages you need in the shop.
Q: Is this enough for full repairs, or only basic checks?
A: The Komatsu BR380JG-1 Mobile Crusher Shop Manual walks through diagnostic procedures, disassembly sequences, and workshop-level repair methods, so it’s meant for full repair work, not just light maintenance.
Q: How do I know if it matches my exact BR380JG-1 machine?
A: This manual is written for the BR380JG-1 variant; if your ID plate shows a different model code, you’ll want the matching manual for that version.
Bottom line: if you’re repairing or diagnosing a Komatsu BR380JG-1 in a shop or field setting, this is the right manual; if you only need operating tips or service intervals, keep looking for the O&M book instead.
📘 Show Index
Table of Contents:
- CONTENTS
- 01 GENERAL
- SPECIFICATION DRAWINGS
- SPECIFICATIONS
- WEIGHT TABLE
- FUEL, COOLANT AND LUBRICANTS
- 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
- ENGINE RELATED PARTS
- RADIATOR, OIL COOLER, AFTERCOOLER
- POWER TRAIN
- DRIVE SYSTEM FOR COMPONENTS
- FINAL DRIVE
- TRACK FRAME AND RECOIL SPR
- IDLER
- CARRIER ROLLER
- TRACK ROLLER
- TRACK SHOE
- ARRANGEMENT OF HYDRAULIC EQUIPMENT
- HYDRAULIC TANK AND HYDRAULIC OIL FILTER
- HYDRAULIC PUMP
- CONTROL VALVE
- SELF-REDUCING PRESSURE VALVE
- CLSS
- CRUSHER MOTOR
- GRIZZLY FEEDER MOTOR
- CONVEYOR MOTOR
- TRAVEL MOTOR
- TRAVEL JUNCTION VALVE
- VALVE CONTROL
- TRAVEL PPC VALVE
- SOLENOID VALVE
- EPC VALVE
- ELECTROMAGNETIC SELECTOR VALVE
- GRIZZLY FEEDER SEMIAUTOMATIC SYSTEM
- ABNORMAL LOAD STOP SYSTEM
- PRIMARY BELT CONVEYOR
- GRIZZLY FEEDER
- CRUSHER
- CRUSHER TOOTH TIP ADJUSTMENT SYSTEM
- VIBRATOR
- ENGINE CONTROL
- ELECTRONIC CONTROL SYSTEM DEVICES
- MULTI MONITOR SYSTEM
- SENSOR
- 20 TESTING AND ADJUSTING
- STANDARD VALUE TABLE FOR ENGINE
- STANDARD VALUE TABLE FOR CHASSIS
- TESTING AND ADJUSTING
- TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
- INSPECTION AND ADJUSTMENT OF ENGINE RPM
- MEASURING EXHAUST GAS COLOR
- ADJUSTING VALVE CLEARANCE
- MEASURING COMPRESSION PRESSURE
- MEASURING BLOW-BY PRESSURE
- INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING
- MEASUREMENT OF ENGINE OIL PRESSURE
- ADJUSTMENT OF ENGINE SPEED SENSOR
- DIODE INSPECTION PROCEDURE
- EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM
- TESTING AND ADJUSTING OIL PRESSURES IN WORK EQUIPMENT AND TRAVEL CIRCUITS
- TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE REDUCED BY SELF-PRESSURE)
- TESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURE
- TESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE
- MEASURING SOLENOID VALVE OUTPUT PRESSURE
- MEASURING PPC VALVE OUTPUT PRESSURE
- MEASURING OIL LEAKAGE
- BLEEDING AIR FROM EACH PART
- TESTING TRAVEL DEVIATION
- INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
- SPECIAL FUNCTIONS OF MONITOR PANEL
- TESTING AND ADJUSTING JAW CRUSHER
- TESTING AND ADJUSTING CRUSHER DRIVE BELT TENSION
- TESTING AND ADJUSTING PRIMARY BELT CONVEYOR
- TESTING AND ADJUSTING MAGNETIC SEPARATOR
- LIST OF COMPANIES WHICH HANDLES RADIO CONTROLLERS
- PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL SYSTEM
- TROUBLESHOOTING
- POINTS TO REMEMBER WHEN TROUBLESHOOTING
- SEQUENCE OF EVENTS IN TROUBLESHOOTING
- POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
- CHECKS BEFORE TROUBLESHOOTING
- CHECKING WATER PUMP FOR WATER LEAKAGE
- CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
- TYPES AND LOCATIONS OF CONNECTORS
- CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
- T-BRANCH BOX AND T-BRANCH TABLE
- TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED
- INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
- Electrical System Error Code [E201] (Disconnection in primary belt conveyor forward solenoid)
- Electrical System Error Code [E202] (Short circuit in primary belt conveyor forward solenoid)
- Electrical System Error Code [E203] (Disconnection in crusher forward EPC valve)
- Electrical System Error Code [E204] (Short circuit in crusher forward EPC valve)
- Electrical System Error Code [E205] (Disconnection in crusher reverse EPC valve)
- Electrical System Error Code [E206] (Short circuit in crusher reverse EPC valve)
- Electrical System Error Code [E207] (Disconnection in feeder forward EPC valve)
- Electrical System Error Code [E208] (Short circuit in feeder forward EPC valve)
- Electrical System Error Code [E211] (Short circuit in electrical intake air heater relay)
- Electrical System Error Code [E212] (Disconnection in pressure abnormality processingrelay)
- Electrical System Error Code [E213] (Disconnection in accessory drive EPC valve)
- Electrical System Error Code [E214] (Short circuit in accessory drive EPC valve)
- Electrical System Error Code [E217] (Disconnection, short circuit, or abnormal input inmodel selection circuit)
- Electrical System Error Code [E218] (Disconnection in S-NET signal line)
- Electrical System Error Code [E222] (Short circuit in LS-EPC solenoid)
- Electrical System Error Code [E223] (Disconnection in LS-EPC solenoid)
- Electrical System Error Code [E224] (Abnormality in F pump pressure sensor)
- Electrical System Error Code [E225] (Abnormality in R pump pressure sensor)
- Electrical System Error Code [E226] (Abnormality in pressure sensor power supply)
- Electrical System Error Code [E227] (Abnormality in engine speed sensor)
- Electrical System Error Code [E232] (Short circuit in PC-EPC solenoid)
- Electrical System Error Code [E233] (Disconnection in PC-EPC solenoid)
- Electrical System Error Code [E234] (Short circuit in rotary lamp SSR)
- Electrical System Error Code [E235] (Short circuit in horn relay)
- Electrical System Error Code [E240] (Short circuit in pressure abnormality processing relay)
- Electrical System Error Code [E241] (Disconnection in primary belt conveyor reverse solenoid)
- Electrical System Error Code [E242] (Short circuit in primary belt conveyor reverse solenoid)
- Electrical System Error Code [E243] (Disconnection in lock cylinder reset solenoid)
- Electrical System Error Code [E244] (Short circuit in lock cylinder reset solenoid)
- Electrical System Error Code [E246] (Short circuit in lock cylinder extension relay)
- Electrical System Error Code [E247] (Disconnection in lock cylinder retraction sole noid)
- Electrical System Error Code [E248] (Short circuit in lock cylinder retraction solenoid)
- Electrical System Error Code [E249] (Disconnection in magnetic separator relay)
- Electrical System Error Code [E250] (Short circuit in magnetic separator relay)
- Electrical System Error Code [E301] (Disconnection in engine stop switch)
- Electrical System Error Code [E302] (Short circuit in primary belt conveyor-ON switch)
- Electrical System Error Code [E303] (Disconnection in primary belt conveyor-OFF switch)
- Electrical System Error Code [E304] (Short circuit in crusher-ON switch)
- Electrical System Error Code [E305] (Disconnection in crusher-OFF switch)
- Electrical System Error Code [E306] (Abnormality in governor potentiometer)
- Electrical System Error Code [E308] (Abnormality in fuel control dial)
- Electrical System Error Code [E315] (Short circuit of battery relay output)
- Electrical System Error Code [E316] (Stepping out of governor motor)
- Electrical System Error Code [E317] (Disconnection in governor motor phases A and B)
- Electrical System Error Code [E318] (Short circuit in governor motor phases A and B)
- Electrical System Error Code [E320] (Short circuit in feeder-ON switch)
- Electrical System Error Code [E321] (Disconnection in feeder-OFF switch)
- Electrical System Error Code [E322] (Short circuit in conveyor RAISE switch)
- Electrical System Error Code [E323] (Short circuit in conveyor lower switch)
- Electrical System Error Code [E331] (Abnormality in clearance sensor potentiometer)
- Electrical System Error Code [E332] (Short circuit in one-touch start switch)
- Electrical System Error Code [E333] (Disconnection in one-touch stop switch)
- Electrical System Error Code [E334] (Short circuit in magnetic separator-ON switch)
- Electrical System Error Code [E335] (Disconnection in magnetic separator-OFF switch)
- Mechanical System Error Code [A000N1] (Engine high idling speed out of standard)
- Mechanical System Error Code [A000N2] (Engine low idling speed out of standard)
- Mechanical System Error Code [AA10NX] (Clogged air cleaner)
- Mechanical System Error Code [AB00KE] (Abnormal lowering of charging voltage)
- Mechanical System Error Code [B@BAZG] (Abnormal lowering of engine oil pressure)
- Mechanical System Error Code [B@BAZK] (Abnormal lowering of engine oil level)
- Mechanical System Error Code [B@BCNS] (Overheating of engine coolant)
- Mechanical System Error Code [B@BCZK] (Abnormal lowering of radiator coolant level)
- Mechanical System Error Code [B@HANS] (Overheating of hydraulic oil)
- TROUBLESHOOTING OFELECTRICAL SYSTEM (E-MODE)
- INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
- E-1 The engine does not start (The engine does not crank).
- E-2 The engine stops while it is running.
- E-3 The engine rotation is unstable (The engine hunts).
- E-4 The engine does not stop.
- E-5 The whole work equipment stops suddenly.
- E-6 The automatic warm-up function does not work.
- E-7 The engine preheater does not operate.
- E-8 The red mark of emergency stop is indicated just after the engine is started.
- E-9 The monitor panel does not display any item.
- E-10 Some items are not displayed on the monitor panel.
- E-11 The fuel level monitor lights red while the engine is running.
- E-12 The engine coolant temperature gauge does not display normally
- E-13 The fuel level gauge does not display normally.
- E-14 The hydraulic oil temperature gauge does not display normally
- E-15 The travel, work, and inspection modes do not change.
- E-16 The crusher clearance adjustment mode does not change.
- E-17 The crusher rotation direction does not change.
- E-18 Travel cannot be controlled by radio control.
- E-19 The feeder cannot be turned ON and OFF by radio control.
- E-20 The crusher cannot be turned ON and OFF 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.
- 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 CHARTS
- S-1 Starting performance is poor (Starting always takes time)
- S-2 Engine does not start
- (1) Engine does not turn
- (2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)
- (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)
- S-3 Engine does not pick up smoothly (Follow-up is poor)
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly (Hunting)
- S-6 Engine lacks 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 cooling water, or water spurts back, or water level goes down
- S-12 Oil pressure monitor lights up (Drop in oil pressure)
- S-13 Oil level rises (Water, fuel in oil)
- S-14 Water temperature becomes too high (Overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
- 30 DISASSEMBLY AND ASSEMBLY
- METHOD OF USING MANUAL
- PRECAUTIONS WHEN CARRYING OUT OPERATION
- DISASSEMBLY AND ASSEMBLY OF CRUSHER
- DISASSEMBLY AND ASSEMBLY OF LOCK CYLINDER
- REMOVAL ANDINSTALLATION OF PRIMARYCONVEYOR ASSEMBLY
- REPLACEMENT OF BELT
- REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR MOTOR
- REPLACEMENT PROCEDURE FOR PRIMARY BELT CONVEYOR HEAD PULLEY FRAME
- PROCEDURE FOR FOLDING ENGINE FRONT COVER
- 90 OTHERS
- HYDRAULIC CIRCUIT DIAGRAM (1/2)
- HYDRAULIC CIRCUIT DIAGRAM (2/2)
- ELECTRICAL CIRCUIT DIAGRAM (1/3)
- ELECTRICAL CIRCUIT DIAGRAM (2/3)
- ELECTRICAL CIRCUIT DIAGRAM (3/3)
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