Komatsu BR350JG-1 Shop Manual SEBM013803 -PDF DOWNLOAD

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Komatsu BR350JG-1 Shop Manual SEBM013803 -PDF DOWNLOAD

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Komatsu BR350JG-1 Shop Manual SEBM013803 -PDF DOWNLOAD

Language : English
Pages : 454
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu BR350JG-1 Shop Manual SEBM013803 -PDF DOWNLOAD

SERIAL NUMBER
1005 and up

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
FOREWORD 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE 16
ELECTRIC WIRE CODE 19
CONVERSION TABLE 20
UNITS 26
01 GENERAL 27
DIMENSION 28
SPECIFICATIONS 29
WEIGHT TABLE 37
TABLE OF OIL AND COOLANT CAPACITIES 38
10 STRUCTURE AND FUNCTION 40
PARTS RELATED TO ENGINE 41
RADIATOR, OIL COOLER 42
POWER TRAIN DIAGRAM 43
DRIVE SYSTEMS FOR EACH COMPONENT 44
FINAL DRIVE 45
TRACK FRAME, RECOIL SPRING 46
HYDRAULIC PIPING DIAGRAM 47
HYDRAULIC CIRCUIT DIAGRAM 48
HYDRAULIC TANK, HYDRAULIC FILTER 50
HYDRAULIC PUMP 51
CONTROL VALVE 68
SELF-REDUCING PRESSURE VALVE 74
CLSS 79
CRUSHER MOTOR 96
TRAVEL MOTOR 99
TRAVEL PPC VALVE105
ON/OFF VALVE 109
EPC VALVE 111
ELECTRIC CIRCUIT DIAGRAM 114
ENGINE CONTROL SYSTEM 116
ENGINE THROTTLE • PUMP CONTROLLER120
MACHINE MONITOR SYSTEM132
INPUT/OUTPUT SYSTEM STRUCTURE DIAGRAM 138
FEEDER AUTOMATIC CONTROL SYSTEM WHEN THERE IS CRUSHER OVERLOAD 139
EMERGENCY STOP SYSTEM FOR CONVEYOR, OPTION OVERLOAD 141
BELT CONVEYOR MACHINERY 142
BELT CONVEYOR MOTOR 143
PRIMARY BELT CONVEYOR 144
GRIZZLY FEEDER 145
CRUSHER 146
VIBRATOR 153
20 TESTING AND ADJUSTING154
STANDARD VALUE TABLE155
STANDARD VALUE TABLE FOR ENGINE 155
STANDARD VALUE TABLE FOR CHASSIS 156
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 160
TESTING AND ADJUSTING163
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 164
MEASURING ENGINE SPEED 165
MEASURING EXHAUST GAS COLOR 166
ADJUSTING VALVE CLEARANCE 167
MEASURING COMPRESSION PRESSURE 168
MEASURING BLOW-BY PRESSURE 168
TESTING AND ADJUSTING FUEL INJECTION TIMING 169
MEASURING ENGINE OIL PRESSURE 170
TESTING AND ADJUSTING FAN BELT TENSION 171
MEASURING ENGINE SPEED SENSOR172
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE 173
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, TRAVEL CIRCUIT174
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 177
MEASURING CONTROL CIRCUIT OIL PRESSURE (PRESSURE WHEN SELF PRESSURE IS REDUCED) 179
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 180
MEASURING SOLENOID VALVE OUTPUT PRESSURE 182
TESTING AND ADJUSTING JAW CRUSHER 183
TESTING AND ADJUSTING OUTLET184
METHOD OF ADJUSTING OUTLET CLEARANCE (MACHINES EQUIPPED WITH DOUBLE-ACTING CYLINDER)188
CHECKING WEAR OF MAIN WEAR PARTS191
TESTING AND ADJUSTING TRAVEL DEVIATION 193
MEASURING OIL LEAKAGE 194
TESTING AND ADJUSTING TRACK SHOE TENSION 195
BLEEDING AIR FROM HYDRAULIC CIRCUIT 196
TROUBLESHOOTING200
POINTS TO REMEMBER WHEN TROUBLESHOOTING 201
SEQUENCE OF EVENTS IN TROUBLESHOOTING 202
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 203
CHECKS BEFORE TROUBLESHOOTING 211
CONNECTOR TYPES AND MOUNTING LOCATIONS214
CONNECTOR ARRANGEMENT DIAGRAM (1/4) 218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS226
METHOD OF USING TROUBLESHOOTING CHARTS 235
TROUBLESHOOTING OF ENGINE (S MODE)237
METHOD OF USING TROUBLESHOOTING CHARTS 238
S-1 Starting performance is poor (starting always takes time)242
S-2 Engine does not start243
(1) Engine does not turn243
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)244
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)245
S-3 Engine does not pick up smoothly (follow-up is poor)246
S-4 Engine stops during operations247
S-5 Engine does not rotate smoothly (hunting)248
S-6 Engine lacks output (no power)249
S-7 Exhaust smoke is black (incomplete combustion)250
S-8 Oil consumption is excessive (or exhaust smoke is blue)251
S-9 Oil becomes contaminated quickly252
S-10 Fuel consumption is excessive253
S-11 Oil is in cooling water, or water spurts back, or water level goes down254
S-12 Oil pressure caution lamp lights up (drop in oil pressure)255
S-13 Oil level rises (water, fuel in oil)256
S-14 Water temperature becomes too high (overheating)257
S-15 Abnormal noise is made258
S-16 Vibration is excessive259
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)260
CONTROLLER DISPLAY AND SELF-DIAGNOSTIC FUNCTION265
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEM ON MACHINE 267
JUDGEMENT TABLE FOR CHASSIS CONTROL RELATED PARTS283
E-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM285
E-2 ERROR CODE [11] (DISCONNECTION IN OPTION 1 OFF SWITCH) IS DISPLAYED287
E-3 ERROR CODE [12] (DISCONNECTION IN OPTION 2 OFF SWITCH) IS DISPLAYED288
E-4 ERROR CODE [14] (DISCONNECITON ON oPTION 3 OFF SWITCH) IS DISPLAYED289
E-5 ERROR CODE [18] (DISCONNECTION ON OPTION 4 OFF SWITCH) IS DISPLAYED290
E-6 ERROR CODE [21] (DISCONNECTION IN CRUSHER OFF SWITCH) IS DISPLAYED291
E-7 ERROR CODE [22] (DISCONNECTION IN CONVEYOR OFF SWITCH) IS DISPLAYED292
E-8 ERROR CODE [24] (DISCONNECTION IN FEEDER OFF SWITCH) IS DISPLAYED (MACHINES NOT EQUIPPED WITH RADIO CONTROL)293
E-8 ERROR CODE [24] (DISCONNECTION IN FEEDER OFF SWITCH) IS DISPLAYED (MACHINES EQUIPPED WITH RADIO CONTROL)294
E-9 ERROR CODE [31] (ABNORMALITY IN FEEDER SPEED DIAL) IS DISPLAYED295
E-10 ERROR CODE [32] (ABNORMALITY IN CRUSHER SPEED DIAL) IS DISPLAYED296
E-11 ERROR CODE [41] (SHORT CIRCUIT IN CRUSHER MANUAL NORMAL ROTATION SWITCH) IS DISPLAYED297
E-12 ERROR CODE [42] (SHORT CIRCUIT IN CRUSHER MANUAL REVERSE ROTATION SWITCH) IS DISPLAYED298
E-13 ERROR CODE [51] (SHORT CIRCUIT IN OPTION 1 ON SWITCH) IS DISPLAYED299
E-14 ERROR CODE [52] (SHORT CIRCUIT IN OPTION 2 ON SWITCH) IS DISPLAYED300
E-15 ERROR CODE [54] (SHORT CIRCUIT IN OPTION 3 ON SWITCH 301
E-16 ERROR CODE [58] (SHORT CIRCUIT IN OPTION 4 ON SWITCH) IS DISPLAYED302
E-17 ERROR CODE [61] (SHORT CIRCUIT IN CRUSHER ON SWITCH) IS DISPLAYED303
E-18 ERROR CODE [62] (SHORT CIRCUIT IN CONVEYOR ON SWITCH) IS DISPLAYED 304
E-19 ERROR CODE [64] (SHORT CIRCUIT IN FEEDER ON SWITCH) IS DISPLAYED305
E-20 ERROR CODE [71] (DISCONNECTION IN ENGINE SPEED SENSOR) IS DISPLAYED308
E-21 ERROR CODE [81] (ABNORMALITY IN MACHINE MODEL SELECTION) IS DISPLAYED309
E-22 ERROR CODE [91] (SHORT CIRCUIT IN OPTION 1 SOLENOID) IS DISPLAYED310
E-22 ERROR CODE [92] (SHORT CIRCUIT IN OPTION 2 SOLENOID) IS DISPLAYED310
E-22 ERROR CODE [94] (SHORT CIRCUIT IN OPTION 3 SOLENOID) IS DISPLAYED310
E-22 ERROR CODE [91] (SHORT CIRCUIT IN OPTION 4 SOLENOID) IS DISPLAYED310
E-23 ERROR CODE [A1] (SHORT CIRCUIT IN FEEDER (ROTATION) LAMP) IS DISPLAYED312
E-24 ERROR CODE [A2] (SHORT CIRCUIT IN HORN) IS DISPLAYED313
E-25 ERROR CODE [A4] (SHORT CIRCUIT IN BELT CONVEYOR ON/OFF VALVE) IS DISPLAYED314
E-26 ERROR CODE [B1] (SHORT CIRCUIT IN CRUSHER EPC VALVE) IS DISPLAYED315
E-27 ERROR CODE [B2] (SHORT CIRCUIT IN FEEDER EPC VALVE) IS DISPLAYED317
E-28 ERROR CODE [C1] (DISCONNECTION IN LS SOLENOID) IS DISPLAYED319
E-29 ERROR CODE [C2] (DISCONNECTION IN TVC SOLENOID) IS DISPLAYED320
E-30 ERROR CODE [C4] (SHORT CIRCUIT IN LS SOLENOID) IS DISPLAYED321
E-31 ERROR CODE [C8] (SHORT CIRCUIT IN TVC SOLENOID) IS DISPLAYED322
E-32 ERROR CODE [D1] (STEP OUT IN GOVERNOR MOTOR) IS DISPLAYED323
E-33 ERROR CODE [D2] (SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM) IS DISPLAYED324
E-34 ERROR CODE [D4] (ABNORMALITY IN FEED BACK POTENTIOMETER SYSTEM) IS DISPLAYED325
E-35 ERROR CODE [D8] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE) IS DISPLAYED326
E-36 ERROR CODE [E1] (DISCONNECTION IN GOVERNOR MOTOR) IS DISPLAYED327
E-37 ERROR CODE [E2] (SHORT CIRCUIT IN GOVERNOR MOTOR) IS DISPLAYED328
E-38 ERROR CODE (-E) (DISCONNECITON IN EMERGENCY STOP SWITCH) IS DISPLAYED329
E-39 ENGINE DOES NOT START333
E-40 ENGINE SPEED STAYS AT LOW IDLING (ACCORDING TO MONITOR WARNING LAMP)336
E-41 ENGINE DOES NOT STOP337
A) WHEN GOVERNOR MOTOR DRIVE SYSTEM IS DEFECTIVE337
B) WHEN ACTUATION OF BATTERY RELAY SYSTEM IS DEFECTIVE339
E-42 ENGINE SPEED IS IRREGULAR341
A) IDLING SPEED IS IRREGULAR341
B) THERE IS HUNTING343
E-43 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)345
E-44 WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMLITY IN ENGINE OIL PRESSURE, ENGINE WATER TEMPERATURE OR BATTERY CHARGE347
E-45 CONVEYER DOES NOT WORK EVEN WHEN CONVEYOR ON SWITCH IS PRESSED348
A) ABNORMALITY IN INPUT SYSTEM348
B) ABNORMALITY IN OUTPUT SYSTEM348
E-46 CONVEYOR DOES NOT STOP EVEN WHEN CONVEYOR OFF SWITCH IS PRESSED349
E-47 CRUSHER DOES NOT WORK EVEN WHEN CRUSHER START SWITCH IS PRESSED350
A) ABNORMALITY IN INPUT SYSTEM350
B) ABNORMALITY IN OUTPUT SYSTEM350
E-48 CRUSHER DOES NOT STOP EVEN WHEN CRUSHER STOP SWITCH IS PRESSED352
E-49 CRUSHER DOES NOT WORK EVEN WHEN CRUSHER MANUAL NORMAL ROTATION SWITCH IS PRESSED353
A) ABNORMALITY IN INPUT SYSTEM353
B) ABNORMALITY IN OUTPUT SYSTEM353
E-50 CRUSHER DOES NOT WORK EVEN WHEN CRUSHER MANUAL REVERSE ROTATION SWITCH IS PRESSED355
A) ABNORMALITY IN INPUT SYSTEM355
B) ABNORMALITY IN OUTPUT SYSTEM355
E-51 FEEDER DOES NOT WORK EVEN WHE FEEDER ON SWITCH IS PRESSED357
A) ABNORMALITY IN INPUT SYSTEM357
B) ABNORMALITY IN OUTPUT SYSTEM357
E-52 FEEDER DOES NOT STOP EVEN WHEN FEEDER OFF SWITCH IS PRESSED359
E-53 OPTION 1 DOES NOT WORK EVEN WHEN OPTION 1 ON SWITCH IS PRESSED362
E-53 OPTION 2 DOES NOT WORK EVEN WHEN OPTION 2 ON SWITCH IS PRESSED362
E-53 OPTION 3 DOES NOT WORK EVEN WHEN OPTION 3 ON SWITCH IS PRESSED362
E-53 OPTION 4 DOES NOT WORK EVEN WHEN OPTION 4 ON SWITCH IS PRESSED362
A) ABNORMALITY IN INPUT SYSTEM362
B) ABNORMALITY IN OUTPUT SYSTEM363
E-54 OPTION 1 DOES NOT STOP EVEN WHEN OPTION 1 OFF SWITCH IS PRESSED365
E-54 OPTION 2 DOES NOT STOP EVEN WHEN OPTION 2 OFF SWITCH IS PRESSED365
E-54 OPTION 3 DOES NOT STOP EVEN WHEN OPTION 3 OFF SWITCH IS PRESSED365
E-54 OPTION 4 DOES NOT STOP EVEN WHEN OPTION 4 OFF SWITCH IS PRESSED365
E-55 FEEDER ROTATING SPEED DOES NOT CHANGE (REMAINS AT LOWEST SPEED)367
E-56 FEEDER DOES NOT AUTOMATICALLY STOP WHEN CRUSHER IS OVERLOADED368
E-57 ALL WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMAL LOAD ON CONVEYOR369
E-58 ALL WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMAL LOAD ON OPTION 1370
E-59 ALL WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMAL LOAD ON OPTION 2371
E-60 ALL WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMAL LOAD ON OPTION 3372
E-61 ALL WORK EQUIPMENT DOES NOT STOP WHEN THERE IS ABNORMAL LOAD ON OPTION 4373
E-62 ROTATING LAMP DOES NOT LIGHT UP375
E-63 HORN DOES NOT SOUND377
A) HORN DOES NOT SOUND EVEN WHEN HORN SWITCH OR EMERGENCY STOP SWITCH ARE PRESSED377
B) HORN DOES NOT SOUND WHEN THERE IS ABNORMAL LOAD ON CONVEYOR OR OPTION379
E-64 MACHINE DOES NOT TRAEL WHE TRAVE/WORK SWITCH IS SET TO TRAVEL381
E-65 WORK EQUIPMENT DOES NOT MOVE WHEN TRAVEL/WORK SWITCH IS SET TO WORK382
E-66 ERROR CODE [A8] (SHORT CIRCUIT IN CRUSHER NORMAL/REVERSE SELECTOR RELAY) IS DISPLAYED383
E-67 ERROR CODE [01] (ABNORMALITY IN CRUSHER OVERLOADE DIAL) IS DISPLAYED384
E-68 ERROR CODE [02] (ABNORMALITY IN CRUSHER NORMAL ROTATION PRESSURE SENSOR) IS DISPLAYED385
E-69 ERROR CODE [04] (ABNORMALITY IN CRUSHER REVERSE RETATION PRESSURE SENSOR) IS DISPLAYED386
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)387
H-1 Speeds of all work equipment, travel are slow or lack power388
H-2 There is excessive drop in engine speed, or engine stalls389
H-3 Neither work equipment nor travel move390
H-4 Abnormal noise generated (around pump)390
H-5 Crusher feeder is slow or lacks power391
H-6 Conveyor, option is slow or lacks power391
H-7 In compound operations, work equipment extremely slow392
H-8 Machine deviates to one side when traveling393
a) Deviates in same direction when traveling in FORWARD and REVERSE393
b) Deviates in opposite direction when traveling in FORWARD and REVERSE393
H-9 Excessive deviation when starting394
H-10 Travel speed is slow or lacks power394
H-11 Steering is difficult or lacks power395
H-12 Machine does not move397
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)398
M-1 When starting switch is turned ON, no display is given (3-second self check is also not carried out)399
M-2 When starting switch is turned ON, even when self check is completed (all lamps light up for 3 seconds), lamps do not go out399
M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds400
a) No gauge lamps light up (caution lamps light up)400
b) Travel lock monitor lamp, and preheating lamp do not light up (gauge lamps light up)400
c) Battery charge caution lamp does not light up400
d) Engine oil pressure caution lamp does not light up400
M-4 When starting switch is turned ON, battery charge caution lamp does not light up401
M-5 When starting switch is turned ON, engine oil pressure caution lamp does not light up401
M-6 During preheating, preheating pilot lamp does not light up402
M-7 When travel/work selector switch is operated, travel lock monitor lamp does not change403
a) Does not light up403
b) Does not go out404
M-8 When engine is running, engine oil pressure caution lamp lights up (engine oil pressure-is normal)405
M-9 When starting switch is turned ON, battery charge caution lamp does not light up405
M-10 Abnormality in engine water temperature gauge406
a) After engine is started, only lowest level lamp (white range) lights up and level does not rise406
b) After engine is started, level immediately rises and b) After engine is started, level immediately rises and406
c) Water temperature gauge goes out406
M-11 Abnormality in fuel gauge407
a) All segments of fuel gauge go out407
b) Fuel level has gone down, but fuel gauge always displays FULL407
c) Even when fuel tank is filled, fuel gauge does not display FULL407
M-12 Defective operation of revolving warning lamp409
a) Does not light up409
b) Does not go out410
M-13 Night lighting does not light up411
a) Gauge lighting does not light up411
b) Service meter lighting does not light up411
40 MAINTENANCE STANDARD412
FINAL DRIVE 413
IDLER 415
CARRIER ROLLER 417
TRACK ROLLER 418
TRACK SHOE 419
TRACK FRAME • RECOIL SPRING 423
HYDRAULIC PUMP 424
SELF-REDUCING PRESSURE VALVE 425
CONTROL VALVE 426
EPC • SOLENOID VALVE 431
TRAVEL PPC VALVE 432
TRAVEL MOTOR 433
CRUSHER MOTOR434
CRUSHER 435
90 OTHERS440
HYDRAULIC CIRCUIT DIAGRAM (1/2)442
HYDRAULIC CIRCUIT DIAGRAM (2/2)444
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO: 1005-1499)446
ELECTRICAL CIRUIT DIAGRAM (2/2) (SERIAL NO 1005-1499)448
ELECTRICAL CIRCUIT DIAGRAM (1/2) (SERIAL NO 1501 AND UP)450
ELECTRICAL CIRCUIT DIAGRAM (2/2) (SERIAL NO: 1501 AND UP)452
INPUT/OUTPUT SYSTEM STRUCTURE DIAGRAM454

DESCRIPTION:

Komatsu BR350JG-1 Shop Manual SEBM013803 -PDF DOWNLOAD

SERIAL NUMBER
1005 and up

G.B 13/12/24