Komatsu BR300J-1 BR310JG-1 Shop Manual SEBM004703 -PDF DOWNLOAD

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Komatsu BR300J-1 BR310JG-1 Engine  Shop Manual SEBM004703 -PDF DOWNLOAD

FILE DETAILS:

Komatsu BR300J-1 BR310JG-1 Engine  Shop Manual SEBM004703 -PDF DOWNLOAD

Language : English
Pages : 367
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu BR300J-1 BR310JG-1 Engine  Shop Manual SEBM004703 -PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 20
GENERAL ASSEMBLY DRAWING 21
SPECIFICATIONS 23
WEIGHT TABLE 26
LIST OF LUBRICANT AND WATER 27
10 STRUCTURE AND FUNCTION 28
POWER TRAIN 29
TRACK FRAME AND RECOIL SPRING 31
FINAL DRIVE 32
HYDRAULIC TANK 33
OLSS 34
HYDRAULIC PUMP 36
1 FRONT MAIN PUMP AND REAR MAIN PUMP(HPV090+090) 37
2 SERVO VALVE 39
3 TVC VALVE 41
4 CO・NC VALVE 46
5 CHARGING PUMP 51
CONTROL VALVE 52
CRUSHER MOTOR 59
TRAVEL MOTOR 61
PPC VALVE 65
ACCUMULATOR 73
SOLENOID VALVE (FOR CRUSHER, BELT CONVEYOR, TRAVEL) 74
TANDEM PUMP (FOR BELT CONVERYOR, PLATE FEEDER) 75
HYDRAULIC 3-TANDEM PUMP 76
PLATE FEEDER MOTOR 77
FIRST BELT CONVEYOR MOTOR 79
SOLENOID VALVE (FOR PLATE FEEDER) 81
RELIEF VALVE (FOR PLATE FEEDER) 81
SOLENOID VALVE 82
RELIEF VALVE (FOR GRIZZLY FEEDER, PRIMARY BELT CONVEYOR) 83
FLOW CONTROL VALVE 84
CRUSHER 85
PLATE FEEDER 89
GRIZZLY FEEDER 90
FIRST BELT CONVEYOR 91
PLATE FEEDER HYDRAULIC CIRCUIT 93
FIRST BELT CONVEYOR HYDRAULIC CIRCUIT 94
CRUSHER DRIVE HYDRAULIC CIRCUIT DIAGRAM 95
OPTION HYDRAULIC CIRCUIT DIAGRAM 95
MONITOR SYSTEM 96
1 MONITOR PANEL 97
2 SENSOR 99
PLATE FEEDER RETURN SYSTEM 102
1 PLATE FEEDER PRESSURE SENSOR 102
2 TIMER 102
FEEDER AUTOMATIC REVERSE SYSTEM 103
AUTOMATIC STOP SYSTEM FOR FIRST BELT CONVEYOR OVERLOAD 104
WORK EQUIPMENT SELF HOLD CIRCUIT 105
20 TESTING AND ADJUSTING 106
TABLE OF JUDGEMENT STANDARD VALUE 107
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 118
ADJUSTING VALVE CLEARANCE 119
MEASURING COMPRESSION PRESSURE 120
TESTING AND ADJUSTING FUEL INJECTION TIMING 121
ADJUSTING FUEL CONTROL LEVER 122
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CRUSHER, PLATE FEEDER (BR300J-1), GRIZZLY FEEDER (BR310JG-1), BELT CONVEYOR, TRAVEL CIRCUIT 123
TESTING AND ADJUSTING CHARGING PUMP PRESSURE 125
TESTING ADN ADJUSTING MAIN PUMP CONTROL PRESSURE 127
MEASURING STROKE OF SERVO PISTON 133
TESTING AND ADJUSTING TRAVEL DEVIATION 134
MEASURING OUTPUT PRESSURE OF PPC VALVE 136
TESTING AND ADJUSTING CRUSHER 137
TESTING AND ADJUSTING TANDEM PUMP BELT 141
AIR BLEEDING 142
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 146
TROUBLESHOOTING 147
POINTS TO REMEMBER WHEN TROUBLESHOOTING 148
SEQUENCE OF EVENTS IN TROUBLESHOOTING 149
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 150
CHECKS BEFORE TROUBLESHOOTING 158
CONNECTOR TYPES AND MOUNTING LOCATIONS 161
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 167
CONNECTION TABLE FOR CONNECTOR 173
METHOD OF PROCEEDING WITH TROUBLESHOOTING 181
METHOD OF USING JUDGEMENT TABLE 182
METHOD OF USING TROUBLESHOOTING CHARTS 183
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM 185
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 186
E-1 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 187
E-2 CRUSHER IS NOT ACTUATED EVEN WHEN CRUSHER ON SWITCH IS PRESSED 188
E-3 CRUSHER DOES NOT STOP EVEN WHEN CRUSHER OFF SWITCH IS PRESSED 190
E-4 CRUSHER DOES NOT REVERSE EVEN WHEN CRUSHER REVERSE SWITCH IS PRESSED 191
E-5 BELT CONVEYOR IS NOT ACTUATED EVEN WHEN BELT CONVEYOR ON SWITCH IS PRESSED 192
E-6 BELT CONVEYOR DOES NOT STOP EVEN WHEN BELT CONVEYOR OFF SWITCH IS PRESSED 194
E-7 FEEDER IS NOT ACTUATED EVEN WHEN FEEDER ON SWITCH IS PRESSED 195
E-8 FEEDER DOES NOT AUTOMATICALLY SWITCH TO REVERSE 197
E-9 MAGNETIC SEPARATOR IS NOT ACTUATED EVEN WHEN MAGNETIC SEPARATOR ON SWITCH IS PRESSED 199
E-10 MAGNETIC SEPARAOTR DOES NOT STOP EVEN WHEN MAGNETIC SEPARATOR OFF SWITCH IS PRESSED 201
E-11 HORN DOES NOT SOUND EVEN WHEN HORN SWITCH OR EMERGENCY STOP SWITCH ARE PRESSED 202
E-12 MACHINE DOES NOT TRAVEL (TRAVEL LOCK IS NOT RELEASED) 203
E-13 TRAVEL LOCK IS NOT ACTUATED 204
RELATED CIRCUIT DIAGRAMS 205
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 212
H-1 SPEEDS OF CRUSHER AND TRAVEL ARE ALL SLOW 213
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 214
H-3 CRUSHER AND TRAVEL DO NOT MOVE, OR SPEED IS EXTREMELY SLOW 216
H-4 CRUSHER AND TRAVEL LACK POWER 218
H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP) 218
H-6 CRUSHER TURNING SPEED IS SLOW 219
H-7 PLATE FEEDER SPEED IS SLOW 220
H-8 BELT CONVEYOR SPEED IS SLOW 220
H-9 PLATE FEEDER CAN NOT RETURN 221
H-10 DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE 222
H-11 TRAVEL LACKS POWER (OR SPEED IS SLOW) 224
H-12 EXCESSIVE DEVIATION WHEN STARTING 224
H-13 MACHINE DOES NOT MOVE (ONE SIDE ONLY) 225
H-14 TRAVEL LOCK IS NOT ACTUATED 225
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE) 226
M-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON 227
A) NO MONITOR PANEL LAMPS LIGHT UP 227
B) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP 227
M-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT 228
M-3 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP 229
M-4 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH 230
A) ALTERNATOR SYSTEM 230
B) ENGINE OIL PRESSURE SYSTEM 230
M-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH 231
M-6 WHEN STARTING SWITCH IS TURNED ON AND IS STARTED, CAUTION ITEMS FLASH 232
A) ENGINE OIL PRESSURE FLASHES 232
B) COOLANT TEMPERATURE FLASHES 233
C) CHARGE FLASHES 233
D) FUEL LEVEL FLASHES 234
M-7 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 235
M-8 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE 236
M-9 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY 236
M-10 FUEL GAUGE ALWAYS DISPLAYS FULL 237
M-11 FUEL GUAGE GIVES NO DISPLAY 237
M-12 A) LAMPS DO NOT LIGHT UP 238
B) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED 238
M-13 FUEL LEVEL SENSOR SYSTEM DEFECTIVE 240
M-14 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE 241
M-15 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE 242
30 DISASSEMBLY AND ASSEMBLY 243
METHOD OF USING MANUAL 245
PRECAUTIONS WHEN CARRYING OUT OPERATION 246
SPECIAL TOOL LIST 248
STARTING MOTOR 250
REMOVAL AND INSTALLATION 250
ALTERNATOR 251
REMOVAL AND INSTALLATION 251
ENGINE OIL COOLER 252
REMOVAL AND INSTALLATION 252
FUEL INJECTION PUMP 253
REMOVAL AND INSTALLATION 253
WATER PUMP 254
REMOVAL AND INSTALLATION 254
NOZZLE HOLDER 255
REMOVAL AND INSTALLATION 255
TURBOCHARGER 256
REMOVAL AND INSTALLATION 256
THERMOSTAT 257
REMOVAL AND INSTALLATION 257
ENGINE FRONT SEAL 258
REMOVAL AND INSTALLATION 258
ENGINE REAR SEAL 259
REMOVAL AND INSTALLATION 259
CYLINDER HEAD 260
REMOVAL AND INSTALLATION 260
REDIATOR, HYDRAULIC COOLER AND AFTER-COOLER 262
REMOVAL AND INSTALLATION 262
ENGINE, HYDRAULIC PUMP 263
REMOVAL AND INSTALLATION 263
DAMPER 265
REMOVAL AND INSTALLATION 265
TRAVEL MOTOR 266
REMOVAL AND INSTALLATION 266
TRAVEL MOTOR, FINAL DRIVE 267
REMOVAL AND INSTALLATION 267
FINAL DRIVE 268
DISASSEMBLY 268
ASSEMBLY 272
TRAVEL MOTOR 278
DISASSEMBLY 278
ASSEMBLY 281
SPROCKET 285
REMOVAL AND INSTALLATION 285
IDLER, RECOIL SPRING 286
REMOVAL AND INSTALLATION 286
DISASSEMBLY AND ASSEMBLY 287
TRACK ROLLER 289
REMOVAL AND INSTALLATION 289
CARRIER ROLLER 290
REMOVAL AND INSTALLATION 290
TRACK SHOE 291
REMOVAL AND INSTALLATION 291
CHARGING PUMP 292
REMOVAL AND INSTALLATION 292
HYDRAULIC PUMP 293
REMOVAL AND INSTALLATION 293
DISASSEMBLY 294
ASSEMBLY 299
MAIN PUMP INPUT SHAFT OIL SEAL 312
REMOVAL AND INSTALLATION 312
CONTROL VALVE 313
REMOVAL AND INSTALLATION 313
DISASSEMBLY 314
ASSEMBLY 316
MAIN RELIEF VALVE 318
REMOVAL AND INSTALLATION 318
DISASSEMBLY AND ASSEMBLY 319
TRAVEL PPC VALVE 320
REMOVAL AND INSTALLATION 320
DISASSEMBLY 321
ASSEMBLY 321
TVC VALVE 324
REMOVAL AND INSTALLATION 324
CO・NC VALVE 324
REMOVAL AND INSTALLATION 324
SERVO VALVE 325
REMOVAL AND INSTALLATION 325
PPC SHUTTLE VALVE 326
REMOVAL AND INSTALLATION 326
CHEEK PLATE 327
REMOVAL AND INSTALLATION 327
DRIVEN GEAR 328
REMOVAL AND INSTALLATION 328
TOGGLE PLATE 329
REMOVAL AND INSTALLATION 329
TOGGLE SHEET 330
REMOVAL AND INSTALLATION 330
FLYWHEEL AND V SHEAVE 330
REMOVAL AND INSTALLATION 330
SWING JAW 331
REPLACEMENT 331
THRUST RETAINER 332
REPLACEMENT 332
DRIVE GEAR 333
REMOVAL AND INSTALLATION 333
PLATE FEEDER MOTOR (BR300J-1) 334
REMOVAL AND INSTALLATION 334
40 MAINTENANCE STANDARD 335
FINAL DRIVE 336
TRACK FRAME AND RECOIL SPRING 337
IDLER 338
TRACK ROLLER 340
CARRIER ROLLER 341
TRACK SHOE 342
HYDRAULIC PUMP 344
CHARGING PUMP AND RELIEF VALVE 345
CONTROL VALVE 346
TRAVEL SHUTTLE VALVE 353
CRUSHER MOTOR 354
PLATE FEEDER MOTOR 355
TRAVEL MOTOR 356
PPC VALVE 357
TANDEM PUMP 359
CRUSHER 360
PLATE FEEDER 362
90 OTHERS 363
HYDRAULIC CIRCUIT DIAGRAM 364
ELECTRICAL CIRCUIT DIAGRAM 365

DESCRIPTION:

Komatsu BR300J-1 BR310JG-1 Engine  Shop Manual SEBM004703 -PDF DOWNLOAD

FOREWORD
This shop manual has been prepared as an aid in improving 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 availably opportunity.
Organization
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes” are also included in this section.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standards
This section gives the judgement standards when inspecting disassembled parts.

G.B  14/12/24