Komatsu BR380JG-3 Mobile Crusher Shop Manual SEN06703-05 – Full Workshop PDF

Description

Komatsu BR380JG-3 Mobile Crusher Shop Manual SEN06703-05

This is the complete Komatsu BR380JG-3 mobile crusher shop manual, document number SEN06703-05. It is the full workshop reference for servicing, diagnosing, and overhauling the BR380JG-3 jaw crusher, covering the machine from specifications and structure through testing, troubleshooting, disassembly, and maintenance standards. Every section is written for the technician working on the machine, not a summarized owner’s guide.

File Details

• Manual type: Shop Manual (workshop service reference)
• Brand: Komatsu
• Model: BR380JG-3 mobile jaw crusher
• Document number: SEN06703-05
• Publication date: November 2021
• Language: English
• Page count: Approximately 2,000 pages
• File format: PDF
• Engine: SAA6D107E-3

Chapters Covered

• 00 Index and foreword — abbreviations, safety notice for operation, precautions to prevent fire, handling of hydraulic/electrical/fuel system components, connector disconnection procedures, and the standard tightening torque table.
• 01 Specifications — specification drawing and full specification tables for the BR380JG-3, weight table, and the table of fuel, coolant and lubricants.
• 10 Structure and function — Urea SCR system (component layout, diagram, functions, components), starting system, engine system (VGT, EGR, KCCV, KDPF), cooling system, control system, machine monitor, KOMTRAX, hydraulic system (CLSS, pump and engine combined control, pump and valve control), work equipment system (valve control, grizzly feeder semi-automatic control, abnormal load shutdown, crusher jaw tip adjustment), travel system, undercarriage and frame, and work equipment (primary conveyor, grizzly feeder, crusher, vibrator).
• 20 Standard value table — standard value tables for engine and machine, plus the machine posture and measuring procedure drawings used for performance measurement.
• 30 Testing and adjusting — engine and cooling system testing (engine speed, boost pressure, exhaust gas color, valve clearance, compression pressure, blowby pressure, engine oil pressure, EGR and VGT oil pressures, fuel pressure, fuel discharged volume/return rate/leakage), SCR-related function testing, flushing the AdBlue/DEF tank, cleaning the AdBlue/DEF pump, track shoe tension, hydraulic system pressure testing (work equipment, travel, control, PC, LS), solenoid valve output pressure testing, PPC valve output pressure testing, oil leakage testing, air bleeding from the hydraulic circuit, mirror adjustment, machine monitor settings, KOMTRAX terminal startup, and Pm Clinic service.
• 40 Troubleshooting — failure codes table, troubleshooting by failure code (from 7RC1KB through CA5383 and beyond), electrical system troubleshooting (E mode, E-1 through E-47), hydraulic and mechanical troubleshooting (H mode, H-1 through H-22), engine troubleshooting (S mode, S-1 through S-26), connector list and layout, connector pin numbers and wiring table, T-box and T-adapter list, fuse location table, and the special precautions for KDPF cleaning and replacement.
• 50 Disassembly and assembly — engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, and electrical system. Covers removal and installation of the supply pump, injectors, cylinder head, EGR valve and cooler, starting motor, radiator, hydraulic oil cooler, aftercooler, engine and main pump assembly, fuel cooler, engine hood, fuel tank, AdBlue/DEF tank and sensors, KDPF and SCR assemblies, KCCV, AdBlue/DEF mixing tube and injector, AdBlue/DEF pump and hoses, air cleaner, travel motor and final drive, sprocket, idler and idler cushion, track roller and carrier roller, hydraulic tank, main pump, control valve, crusher motor, lock cylinder, primary conveyor motor, grizzly feeder motor, magnetic separator motor, cheek plate, fixed jaw plate, swing jaw plate, toggle plate, fixed link, swing jaw assembly, V-sieve and balance weight, crusher assembly, belt, crusher main bearing, engine front cover, engine controller, work equipment controller, machine monitor, pump swash plate sensor, mass air flow sensor, KCCV crankcase pressure sensor, SCR temperature sensor, and KOMTRAX terminal.
• 60 Maintenance standard — engine mount, cooling system, final drive, sprocket, track frame and idler cushion, idler, track roller, carrier roller, track shoe, triple grouser shoe, hydraulic tank, main pump, LS-EPC valve, PC-EPC valve, control valve, crusher motor, solenoid valve, EPC valve, travel motor, travel PPC valve, primary conveyor, vibrator, conveyor lift cylinder, muck discharge conveyor lift cylinder, and lock cylinder.
• 90 Circuit diagrams — hydraulic circuit diagram and electrical circuit diagram, each with their own symbol legends.

Across these chapters, the manual gives a technician the complete lifecycle view of the BR380JG-3 — how each system is built and how it works, what values are correct on a new machine, how to measure and adjust those values, how to diagnose what is wrong when the machine misbehaves, how to take components apart and put them back together, and what wear limits decide whether a part can stay in service. Because the manual covers the urea SCR system, the KDPF aftertreatment system, and the full hydraulic and electrical architecture of the crusher, it supports diagnostics that simpler service books do not.

Machine Coverage

The BR380JG-3 is a Komatsu mobile jaw crusher with an operating weight of 34,800 kg. Travel speed is 0.8 km/h in the Lo range, 2.3 km/h in Mi, and 3.0 km/h in Hi; gradeability is 25 degrees. The crusher is a KCJ4222 single-toggle jaw crusher with nominal dimensions of 1065 x 550 mm and a rotation speed range of 170 to 330 rpm (150 to 290 rpm on the optional configuration). The grizzly feeder is a horizontal two-shaft unit with a 1000 x 3220 mm trough, rated at 1,000 c.p.m. Hydraulic power comes from two variable-displacement piston pumps (HPV125 x 125) discharging 245 liters per minute each at a set pressure of 37.2 MPa (380 kg/cm²). The travel motors are HMV160 x 2 variable-displacement piston units with brake valves. Hydraulic tank capacity is 227 liters total, with a 132-liter refill.

Engine Coverage — SAA6D107E-3

The engine installed in the BR380JG-3 is the SAA6D107E-3. It is a four-cycle, water-cooled, in-line, vertical, direct-injection diesel with a turbocharger and air-cooled aftercooler. The configuration is six cylinders with a bore and stroke of 107 x 124 mm, giving a total displacement of 6.69 liters. Rated horsepower is 158.6 kW (213 HP) at 2,050 rpm on the SAE J1995 gross rating, and maximum torque is 941 Nm (95.9 kgm) at 1,500 rpm. No-load maximum speed is 2,180 rpm and no-load minimum is 1,050 rpm. The engine runs a CRI common rail injection system and is paired with a variable geometry turbocharger (VGT), an EGR cooler, and a KCCV closed crankcase ventilation system. The cooling package uses a CF90-4 radiator.

Aftertreatment and Urea SCR Coverage

The BR380JG-3 is equipped with a full exhaust aftertreatment system, and the manual covers it in depth. The Komatsu Diesel Particulate Filter (KDPF) captures soot from the exhaust, and the manual explains its construction (KDOC oxidation catalyst, KCSF catalyzed soot filter), regeneration strategy (passive, active, and manual stationary regeneration), soot accumulation monitoring, and the temperature and pressure sensor architecture that supports it. The Urea SCR system is covered as a complete chapter in the Structure and Function section — component layout, system diagram, function descriptions, and every major component (AdBlue/DEF injector, mixing tube, tank, tank sensor, pump, hoses, and tank heating valve). Troubleshooting for the aftertreatment side includes the full failure code list for KDPF and SCR conditions (CA1664, CA1691, CA1883, CA1921, CA1922, CA2637, CA2639, CA2777, CA3135, CA3144, CA3148, CA3151, CA3543, and many more), plus the manual stationary regeneration and KDPF cleaning procedures.

Hydraulic and Travel Systems

The hydraulic architecture is the CLSS (Closed-center Load Sensing System) with two main pumps, PC and LS valves, and electronic control through the work equipment controller and engine controller. The manual covers pump swash plate angle control, pressure compensation, the pump-and-engine combined control system, and the pump-and-valve control system. Travel is handled by HMV160 variable-displacement piston motors with counterbalance valves, parking brakes, and final drives with a reduction ratio of -57.000. The manual documents travel speed selection (manual, automatic by conveyor position, and radio control), travel junction, travel lock, and the travel PPC valve. The crusher is driven by a KMF125B-5 piston motor through V-belts, and the grizzly feeder uses an MSF-53 gear motor. The conveyor uses an MSE02-2-123-R02-1240-YJF0 piston motor. Each of these is covered both in the structure and function section and in the testing and adjusting section, with relief pressures, flow rates, and adjustment procedures.

Electrical System and Diagnostics

The manual includes full electrical content — controller pin-outs, connector pin numbers and wiring table, fuse location table, CAN communication diagnostics, and the electrical circuit diagrams. The engine controller (Delphi 96-pin), work equipment controller (DRC-24 and DRC-40), and machine monitor (070-18P, 070-12P, 070-20P) are all documented with their input and output signals. Troubleshooting of the electrical system is organized as E-mode (E-1 through E-47), covering everything from "Engine does not start" to KOMTRAX system issues. The manual also covers the KOMTRAX system, including terminal startup, GPS and communication status checks, modem information, and service messages. The machine monitor service mode and diagnostic tests (SCR service test, KDPF memory reset, cylinder cutout, active regeneration for service) are documented in detail.

Who This Komatsu BR380JG-3 Shop Manual Is For

This manual is written for the working technician, the service manager building a repair plan, and the fleet owner who wants the actual Komatsu procedures rather than a generic overview. It fits independent repair shops, dealer technicians, and owners who service their own BR380JG-3. Because the manual is organized by system and by failure mode, it also works well as a training reference for technicians moving onto the BR380JG-3 platform, and as a reference for anyone who needs to cross-check a failure code, a torque value, a pressure reading, or a wear limit before authorizing a repair.

IMAGES PREVIEW

Get the Complete Komatsu BR380JG-3 Shop Manual — Instant PDF Delivery

With this manual you can diagnose a no-start condition on the SAA6D107E-3, trace a hydraulic fault through the CLSS circuit, test the SCR system with the machine monitor, adjust the crusher clearance, replace the KDPF or SCR assembly, set track shoe tension, interpret any failure code the machine throws, and confirm every torque value and clearance against Komatsu’s own standard. Correct procedures and correct specifications are what separate a repair that lasts from one that comes back — this manual is the reference that gives you both.

Delivery is instant. The manual is a PDF that you can download immediately after payment, open on any device, print pages for the shop floor, and keep on hand for every job on the BR380JG-3. No shipping, no waiting, no lost paper manual.