Komatsu BR100JG-2 Series Shop Manual SEBM027804

Description

• Model List:
  • BR100JG-2 Series

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. Specification drawing
• 3.2. Specification
• 3.3. Weight table
• 3.4. Table of oil and Coolant Capacities
• 4. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 4.1. RADIATOR, OIL COOLER
• 4.2. PTO (COUPLING)
• 4.3. POWER TRAIN DIAGRAM
• 4.4. DRIVE SYSTEMS FOR EACH COMPONENT
• 4.5. HYDRAULIC EQUIPMENT LAYOUT DRAWING
• 4.6. HYDRAULIC TANK
• 4.7. HYDRAULIC PUMP
• 4.8. CONTROL VALVE
• 4.9. CLSS
• 4.10. SELF PRESSURE REDUCING VALVE
• 4.11. TRAVEL MOTOR
• 4.12. CRUSHER MOTOR
• 4.13. MAGNETIC SEPARATOR MOTOR
• 4.14. FEEDER MOTOR
• 4.15. TRAVEL PPC VALVE
• 4.16. ON/OFF VALVE
• 4.17. EPC VALVE
• 4.18. WORK EQUIPMENT
• 4.19. CRUSHER GENERAL VIEW
• 4.20. JAW CRUSHER ASSEMBLY
• 4.21. GRIZZLY FEEDER
• 4.22. VIBRATOR
• 4.23. PRIMARY BELT CONVEYOR
• 4.24. PRIMARY BELT CONVEYOR ASSEMBLY
• 4.25. MAGNETIC SEPARATOR
• 4.26. ENGINE CONTROL SYSTEM
• 4.27. LX CONTROLLER
• 4.28. MACHINE MONITOR SYSTEM
• 4.29. FEEDER AUTOMATIC CONTROL SYSTEM WHEN THERE IS CRUSHER OVERLOAD
• 4.30. EMERGENCY STOP SYSTEM FOR CONVEYOR, OPTION OVERLOAD
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE
• 5.1.1. STANDARD VALUE TABLE FOR ENGINE
• 5.1.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.2. TESTING AND ADJUSTING
• 5.2.1. TOOLS FOR TESTING AND ADJUSTING
• 5.2.2. MEASURING ENGINE SPEED
• 5.2.3. MEASURING EXHAUST COLOR
• 5.2.4. ADJUSTING VALVE CLEARANCE
• 5.2.5. MEASURING COMPRESSION PRESSURE
• 5.2.6. MEASURING BLOWBY PRESSURE
• 5.2.7. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.2.8. MEASURING ENGINE OIL PRESSURE
• 5.2.9. TESTING AND ADJUSTING ALTERNATOR BELT TENSION
• 5.2.10. ADJUSTING FUEL CUT SOLENOID LINKAGE
• 5.2.11. ADJUSTING FUEL CONTROL LINKAGE
• 5.2.12. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT CIRCUIT
• 5.2.13. MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE
• 5.2.14. ADJUSTING PC VALVE
• 5.2.15. MEASURING CONTROL CIRCUIT OIL PRESSURE
• 5.2.16. MEASURING PPC, EPC VALVE OUTPUT PRESSURE
• 5.2.17. TESTING SOLENOID VALVE OUTPUT PRESSURE
• 5.2.18. TESTING TRAVEL DEVIATION
• 5.2.19. MEASURING TRAVEL MOTOR OIL LEAKAGE
• 5.2.20. TESTING AND ADJUSTING TRACK SHOE TENSION
• 5.2.21. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 5.2.22. BLEEDING AIR FROM HYDRAULIC CIRCUIT
• 5.2.23. TESTING AND ADJUSTING CRUSHER RELATED PARTS
• 5.3. TROUBLESHOOTING
• 5.3.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.3.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.3.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.3.4. CHECKS BEFORE TROUBLESHOOTING
• 5.3.5. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 5.3.6. CONNECTOR ARRANGMENT DIAGRAM (1/5)
• 5.3.7. E MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM
• 5.3.8. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.3.9. TADAPTER TABLE
• 5.3.10. CATEGORIES OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
• 5.3.11. POSSIBLE FAILURE AND TROUBLESHOOTING NO.
• 5.3.12. TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E MODE)
• 5.3.13. TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
• 5.3.14. TROUBLESHOOTING FOR MONITOR SYSTEM (M MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. REMOVAL and INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
• 6.5. REMOVAL and INSTALLATION OF CYLINDER HEAD ASSEMBLY
• 6.6. REMOVAL and INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY
• 6.7. REMOVAL and INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY
• 6.8. REMOVAL and INSTALLATION OF FUEL TANK ASSEMBLY
• 6.9. REMOVAL and INSTALLATION OF FINAL DRIVE ASSEMBLY
• 6.10. DISASSEMBLY and ASSEMBLY OF RECOIL SPRING ASSEMBLY
• 6.11. ASSEMBLY OF IDLER ASSEMBLY
• 6.12. ASSEMBLY OF TRACK ROLLER ASSEMBLY
• 6.13. REMOVAL and INSTALLATION OF TRACK SHOE ASSEMBLY
• 6.14. REMOVAL OF MAIN PUMP
• 6.15. REMOVAL and INSTALLATION OF CONTROL VALVE ASSEMBLY
• 6.16. DISASSEMBLY and ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
• 6.17. REMOVAL and INSTALLATION OF CONVEYOR MOTOR ASSEMBLY
• 6.18. REMOVAL and INSTALLATION OF MAGNETIC SEPARATOR MOTOR ASSEMBLY
• 6.19. REMOVAL and INSTALLATION OF FEEDER MOTOR ASSEMBLY
• 6.20. REMOVAL and INSTALLATION OF CRUSHER MOTOR ASSEMBLY
• 6.21. REMOVAL and INSTALLATION OF CONVEYOR ASSEMBLY
• 6.22. REMOVAL and INSTALLATION OF FEEDER ASSEMBLY
• 6.23. REMOVAL AND INSTALLATION OF CRUSHER ASSEMBLY
• 6.24. DISASSEMBLY AND ASSEMBLY OF CRUSHER ASSEMBLY
• 6.25. REMOVAL and INSTALLATION OF COUNTERWEIGHT
• 7. OTHERS
• 7.1. HYDRAULIC CIRCUIT DIAGRAM
• 7.2. ELECTRICAL CIRCUIT DIAGRAM (1/2)
• 7.3. ELECTRICAL CIRCUIT DIAGRAM (2/2)