Komatsu BR300J-1, BR300JG-1 Series Shop Manual SEBM004703

Description

• Model List:
  • BR300J-1 Series
  • BR300JG-1 Series

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND WATER
• 4. STRUCTURE AND FUNCTION
• 4.1. POWER TRAIN
• 4.2. TRACK FRAME AND RECOIL SPRING
• 4.3. FINAL DRIVE
• 4.4. HYDRAULIC TANK
• 4.5. OLSS
• 4.6. HYDRAULIC PUMP
• 4.6.1. FRONT MAIN PUMP AND REAR MAIN PUMP(HPV090090)
• 4.6.2. SERVO VALVE
• 4.6.3. TVC VALVE
• 4.6.4. CONC VALVE
• 4.6.5. CHARGING PUMP
• 4.7. SOLENOID VALVE (FOR CRUSHER, BELT CONVEYOR, TRAVEL)
• 4.8. TANDEM PUMP (FOR BELT CONVERYOR, PLATE FEEDER)
• 4.9. HYDRAULIC 3TANDEM PUMP
• 4.10. PLATE FEEDER MOTOR
• 4.11. FIRST BELT CONVEYOR MOTOR
• 4.12. SOLENOID VALVE (FOR PLATE FEEDER)
• 4.13. RELIEF VALVE (FOR PLATE FEEDER)
• 4.14. SOLENOID VALVE
• 4.15. RELIEF VALVE (FOR GRIZZLY FEEDER, PRIMARY BELT CONVEYOR)
• 4.16. FLOW CONTROL VALVE
• 4.17. CRUSHER
• 4.18. PLATE FEEDER
• 4.19. GRIZZLY FEEDER
• 4.20. FIRST BELT CONVEYOR
• 4.21. PLATE FEEDER HYDRAULIC CIRCUIT
• 4.22. FIRST BELT CONVEYOR HYDRAULIC CIRCUIT
• 4.23. CRUSHER DRIVE HYDRAULIC CIRCUIT DIAGRAM
• 4.24. OPTION HYDRAULIC CIRCUIT DIAGRAM
• 4.25. MONITOR SYSTEM
• 4.25.1. MONITOR PANEL
• 4.25.2. SENSOR
• 4.26. PLATE FEEDER RETURN SYSTEM
• 4.26.1. PLATE FEEDER PRESSURE SENSOR
• 4.26.2. TIMER
• 4.27. FEEDER AUTOMATIC REVERSE SYSTEM
• 4.28. AUTOMATIC STOP SYSTEM FOR FIRST BELT CONVEYOR OVERLOAD
• 4.29. WORK EQUIPMENT SELF HOLD CIRCUIT
• 5. TESTING AND ADJUSTING
• 5.1. TABLE OF JUDGEMENT STANDARD VALUE
• 5.2. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.3. ADJUSTING VALVE CLEARANCE
• 5.4. MEASURING COMPRESSION PRESSURE
• 5.5. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.6. ADJUSTING FUEL CONTROL LEVER
• 5.7. TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CRUSHER, PLATE FEEDER (BR300J1), GRIZZLY FEEDER (BR310JG1), BELT CONVEYOR, TRAVEL CIRCUIT
• 5.8. TESTING AND ADJUSTING CHARGING PUMP PRESSURE
• 5.9. TESTING ADN ADJUSTING MAIN PUMP CONTROL PRESSURE
• 5.10. MEASURING STROKE OF SERVO PISTON
• 5.11. TESTING AND ADJUSTING TRAVEL DEVIATION
• 5.12. MEASURING OUTPUT PRESSURE OF PPC VALVE
• 5.13. TESTING AND ADJUSTING CRUSHER
• 5.14. TESTING AND ADJUSTING TANDEM PUMP BELT
• 5.15. AIR BLEEDING
• 5.16. RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
• 5.17. TROUBLESHOOTING
• 5.17.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.17.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.17.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.17.4. CHECKS BEFORE TROUBLESHOOTING
• 5.17.5. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 5.17.6. TYPE OF CONNECTOR AND POSITION OF INSTALLATION
• 5.17.7. CONNECTION TABLE FOR CONNECTOR
• 5.17.8. METHOD OF PROCEEDING WITH TROUBLESHOOTING
• 5.17.9. METHOD OF USING JUDGEMENT TABLE
• 5.17.10. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.17.11. JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM
• 5.17.12. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.17.13. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
• 5.17.14. TROUBLESHOOTING OF 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. STARTING MOTOR
• 6.4.1. REMOVAL AND INSTALLATION
• 6.5. ALTERNATOR
• 6.5.1. REMOVAL AND INSTALLATION
• 6.6. ENGINE OIL COOLER
• 6.6.1. REMOVAL AND INSTALLATION
• 6.7. FUEL INJECTION PUMP
• 6.7.1. REMOVAL AND INSTALLATION
• 6.8. WATER PUMP
• 6.8.1. REMOVAL AND INSTALLATION
• 6.9. NOZZLE HOLDER
• 6.9.1. REMOVAL AND INSTALLATION
• 6.10. TURBOCHARGER
• 6.10.1. REMOVAL AND INSTALLATION
• 6.11. THERMOSTAT
• 6.11.1. REMOVAL AND INSTALLATION
• 6.12. ENGINE FRONT SEAL
• 6.12.1. REMOVAL AND INSTALLATION
• 6.13. ENGINE REAR SEAL
• 6.13.1. REMOVAL AND INSTALLATION
• 6.14. CYLINDER HEAD
• 6.14.1. REMOVAL AND INSTALLATION
• 6.15. REDIATOR, HYDRAULIC COOLER AND AFTERCOOLER
• 6.15.1. REMOVAL AND INSTALLATION
• 6.16. ENGINE, HYDRAULIC PUMP
• 6.16.1. REMOVAL AND INSTALLATION
• 6.17. DAMPER
• 6.17.1. REMOVAL AND INSTALLATION
• 6.18. TRAVEL MOTOR
• 6.18.1. REMOVAL AND INSTALLATION
• 6.19. TRAVEL MOTOR, FINAL DRIVE
• 6.19.1. REMOVAL AND INSTALLATION
• 6.19.2. REMOVAL AND INSTALLATION
• 6.20. IDLER, RECOIL SPRING
• 6.20.1. REMOVAL AND INSTALLATION
• 6.20.2. DISASSEMBLY AND ASSEMBLY
• 6.21. TRACK ROLLER
• 6.21.1. REMOVAL AND INSTALLATION
• 6.22. CARRIER ROLLER
• 6.22.1. REMOVAL AND INSTALLATION
• 6.23. TRACK SHOE
• 6.23.1. REMOVAL AND INSTALLATION
• 6.24. CHARGING PUMP
• 6.24.1. REMOVAL AND INSTALLATION
• 6.25. HYDRAULIC PUMP
• 6.25.1. REMOVAL AND INSTALLATION
• 6.25.2. DISASSEMBLY
• 6.25.3. ASSEMBLY
• 6.26. MAIN PUMP INPUT SHAFT OIL SEAL
• 6.26.1. REMOVAL AND INSTALLATION
• 6.27. CONTROL VALVE
• 6.27.1. REMOVAL AND INSTALLATION
• 6.27.2. DISASSEMBLY
• 6.27.3. ASSEMBLY
• 6.28. MAIN RELIEF VALVE
• 6.28.1. REMOVAL AND INSTALLATION
• 6.28.2. DISASSEMBLY AND ASSEMBLY
• 6.29. TRAVEL PPC VALVE
• 6.29.1. REMOVAL AND INSTALLATION
• 6.29.2. DISASSEMBLY
• 6.29.3. ASSEMBLY
• 6.30. TVC VALVE
• 6.30.1. REMOVAL AND INSTALLATION
• 6.31. CONC VALVE
• 6.31.1. REMOVAL AND INSTALLATION
• 6.32. SERVO VALVE
• 6.32.1. REMOVAL AND INSTALLATION
• 6.33. PPC SHUTTLE VALVE
• 6.33.1. REMOVAL AND INSTALLATION
• 6.34. CHEEK PLATE
• 6.34.1. REMOVAL AND INSTALLATION
• 6.35. DRIVEN GEAR
• 6.35.1. REMOVAL AND INSTALLATION
• 6.36. TOGGLE PLATE
• 6.36.1. REMOVAL AND INSTALLATION
• 6.37. TOGGLE SHEET
• 6.37.1. REMOVAL AND INSTALLATION
• 6.38. FLYWHEEL AND V SHEAVE
• 6.38.1. REMOVAL AND INSTALLATION
• 6.39. SWING JAW
• 6.39.1. REPLACEMENT
• 6.40. THRUST RETAINER
• 6.40.1. REPLACEMENT
• 6.41. DRIVE GEAR
• 6.41.1. REMOVAL AND INSTALLATION
• 6.42. PLATE FEEDER MOTOR (BR300J1)
• 6.42.1. REMOVAL AND INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. FINAL DRIVE
• 7.2. TRACK FRAME AND RECOIL SPRING
• 7.3. CHARGING PUMP AND RELIEF VALVE
• 7.4. CONTROL VALVE
• 7.5. TRAVEL SHUTTLE VALVE
• 7.6. CRUSHER MOTOR
• 7.7. PLATE FEEDER MOTOR
• 7.8. HYDRAULIC CIRCUIT DIAGRAM
• 7.9. ELECTRICAL CIRCUIT DIAGRAM