SEBM027804
MACHINE MODEL
SERIAL NUMBER
BR100JG-2
1301 and up
•
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.
•
BR100JG-2 mount the 4D95LE-2 engine. For details of the engine, see the 95-2 Series Engine Shop Manual.
© 2015 All Rights Reserved Printed in Japan 07-15 (01)
00-1 (04)
CONTENTS No. of page
01 GENERAL ............................................................................................................................ 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................ 10-1 20 TESTING AND ADJUSTING ........................................................................ 20-1 30 DISASSEMBLY AND ASSEMBLY ...................................................... 30-1 90 OTHERS ................................................................................................................................. 90-1
00-2
BR100JG-2
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Mark
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00-2-3 (04)
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GENERAL
01 GENERAL SPECIFICATION DRAWING........................................................................................................................ 01- 2 SPECIFICATION .......................................................................................................................................... 01- 3 WEIGHT TABLE ........................................................................................................................................... 01- 5 TABLE OF OIL AND COOLANT CAPACITIES ............................................................................................ 01- 6
BR100JG-2
01-1
GENERAL
SPECIFICATION DRAWING
SPECIFICATION DRAWING DIMENSIONS DRAWING
DIMENSIONS No. A
Item
Unit
BR100JG-2
Overall length
mm
8,070
B
Overall height
mm
2,700
C
Overall width (for transport)
mm
2,345 (2,200)
D
Track shoe width
mm
400
E
Track gauge
mm
1,700
F
Length of track on ground
mm
2,115
01-2
BR100JG-2
GENERAL
SPECIFICATION
SPECIFICATION Machine model
BR100JG-2
Serial Number
1301 and up —
Crawler type, diesel engine drive
Operating weight
kg
9,900
Performance
Type of machine Max. dimension of loaded material (concrete)
mm
600 x 500 x 300
Max. dimension of loaded material (natural rock)
mm
250 x 250 x 250
Travel speed
km/h
2.5 (both in forward and reverse)
Gradeability
°
Ground pressure (standard shoe)
kPa {kg/cm }
60 {0.59}
mm
8,070
(when operating)
mm
2,345
(when transporting)
mm
2,200
mm
2,100
mm
2,700
Overall length
Engine
Dimensions
Overall width
Overall crawler width Overall height
(including rear-view mirror)
mm
2,515
Min. ground clearance
mm
205
Length of track on ground
mm
2,115
Tread
mm
1,700
Model
—
4D95LE-2
Type
—
4-cycle, water-cooled, in-line, vertical, direct injection
No. of cylinders–bore x stroke
mm
4 – 95 x 115
Piston displacement
{cc}
3.26 {3,260}
Flywheel horsepower
kW/rpm {HP/rpm}
40.5/2,100 {54/2,100}
Max. torque
Nm/rpm {kgm/rpm}
236/1,500 {24/1,500}
Max. speed at no load
rpm
2,250
Min. speed at no load
rpm
1,050
Min. fuel consumption
Performance
(height of rear face of hopper)
g/kWh {g/HP}
224 {163}
Starting motor
—
24 V, 3.0 kW
Alternator
—
24 V, 25 A
Battery
—
12 V, 50Ah x 2
Radiator core type
—
CWX-4.5
No. of rollers Undercarriage
20 2
Track shoe
Carrier roller (each side)
—
1
Track roller (each side)
—
5
Track shoe type
—
Assembly-type triple grouser, 41 on each side
Track shoe width
mm
400
—
Grease cylinder type (with cushion spring)
—
Hydraulic type lock
Tension adjuster Travel brake type
BR100JG-2
01-3
SPECIFICATION
Machine model
BR100JG-2
Serial Number
1301 and up —
FS2514 single toggle jaw crusher
Nominal dimensions
mm
640 x 345
Speed
rpm
300
Drive type
—
Hydraulic motor V-belt drive
Type
—
Grizzly feeder with speed control
Vibrator type
—
Horizontal 2-shaft type
mm
606 x 1,730
Vibration frequency (at variable max.)
c.p.m
Approx. 1,400
Amplitude (at no load, full amplitude)
mm
Approx. 4.9
Drive type
—
Hydraulic motor directly coupled
Total capacity
m3
1.3
Capacity above trough
m3
0.8
Type x No.
—
Variable displacement piston type x 1
Discharge
l/min
155
Set pressure
MPa {kg/cm2}
26.0 {265}
Control valve
—
6-spool type x 1
Hopper
Trough dimensions (width x height)
Hydraulic pump
Name, type
Hydraulic equipment (for travel and operation)
Feeder
Crusher
GENERAL
Capacity
Type x no. Control method
—
Hydraulic type
Travel motor
—
Piston type (with brake valve): x 2
Crusher motor
—
Piston type (with safety valve): x 1
Feeder motor
—
Gear type x 1
Conveyor motor
—
Gear type x 1
Magnetic separator motor
—
Gear type x 1
Secondary muck discharge conveyor (If equipped)
—
Gear type x 1
Hydraulic tank
—
Box-shaped, open
Hydraulic filter
—
Tank return side
Hydraulic cooler
—
Air cooled (CFT-1)
Hydraulic motor
01-4
BR100JG-2
GENERAL
WEIGHT TABLE
WEIGHT TABLE k This weight table is for reference when handling or transpoeting components.
Unit: kg Machine model
BR100JG-2
Serial No.
1301 and up
Engine assembly • Engine (excluding water and oil) • Damper • Hydraulic pump
445 382 6 57
Radiator, oil cooler assembly
31
Hydraulic tank, filter assembly (excluding hydraulic oil)
58
Fuel tank assembly (excluding fuel)
50
Main frame
393
Rear cover
63
Control valve
39
Travel motor
56 x 2
Crusher motor
46
Primary conveyor motor assembly
10
Grizzly feeder motor
8
Track frame assembly • Track frame • Idler • Idler cushion • Carrier roller • Track roller • Final drive (including travel motor)
1,155 800 45 x 2 17 x 2 2.5 x 4 10 x 12 63 x 2
Track shoe assembly • Standard triple shoe (400 mm)
321 x 2
Hopper
250
Grizzly feeder assembly
254
Jaw crusher assembly
4,200
Primary belt conveyor assembly
552
BR100JG-2
01-5
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
TABLE OF OIL AND COOLANT CAPACITIES
01-6
BR100JG-2
GENERAL
TABLE OF OIL AND COOLANT CAPACITIES
FUEL, OIL • Select the fuel and oil according to the ambient temperature as shown in the table. The specified oil capacity indicates the total amount of oil including the oil in the piping for each component; the refill capacity indicates the amount of oil added when the oil is changed for normal inspection and maintenance. When starting the engine in ambient temperature of below 0°C, even if the daytime temperature rises to 10°C, always use SAE10W or SAE10W30. Note 1: For hydraulic oil HO46-HM, use the oil recommended by Komatsu. See the Operation and Maintenance Manual for details of the procedure for changing the oil.
ANTI-FREEZE Komatsu genuine Super Coolant (AF-NAC) is added at a proportion of 30% to the cooling water, so there is no need to change the density for temperatures down to –10°C. If the temperature goes below –10°C, adjust the density according to the table below. Below –10°C –15°C –20°C –25°C Proportion of anti-freeze
30%
36%
41%
46%
Proportion of water
70%
64%
59%
54%
Use tap water for the coolant.
BR100JG-2
01-7
STRUCTURE, FUNCTION AND MAINTENANCE
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STANDARD
RADIATOR, OIL COOLER .......................10- 2 PTO (COUPLING)....................................10- 3 POWER TRAIN DIAGRAM ......................10- 4 DRIVE SYSTEMS FOR EACH COMPONENT.................10- 5 TRACK FRAME .......................................10- 6 IDLER CUSHION .....................................10- 8 IDLER.......................................................10- 9 TRACK ROLLER......................................10- 10 CARRIER ROLLER..................................10- 11 SPROCKET .............................................10- 12 TRACK SHOE..........................................10- 14 SHOE .......................................................10- 16 HYDRAULIC EQUIPMENT LAYOUT DRAWING ...........................10- 18 HYDRAULIC TANK ..................................10- 20 HYDRAULIC PUMP .................................10- 21 CONTROL VALVE....................................10- 48 CLSS........................................................10- 58 SELF PRESSURE REDUCING VALVE ...10- 72 TRAVEL MOTOR .....................................10- 78 CRUSHER MOTOR .................................10- 84 MAGNETIC SEPARATOR MOTOR .........10- 87
BR100JG-2
FEEDER MOTOR .................................... 10- 88 TRAVEL PPC VALVE............................... 10- 90 ON/OFF VALVE ....................................... 10- 94 EPC VALVE ............................................. 10- 96 WORK EQUIPMENT ............................... 10- 99 CRUSHER GENERAL VIEW................... 10-100 JAW CRUSHER ASSEMBLY .................. 10-102 GRIZZLY FEEDER .................................. 10-106 VIBRATOR............................................... 10-107 PRIMARY BELT CONVEYOR ................. 10-108 PRIMARY BELT CONVEYOR ASSEMBLY ....................................... 10- 110 MAGNETIC SEPARATOR ....................... 10- 112 ENGINE CONTROL SYSTEM................. 10- 113 LX CONTROLLER................................... 10- 114 MACHINE MONITOR SYSTEM............... 10- 119 FEEDER AUTOMATIC CONTROL SYSTEM WHEN THERE IS CRUSHER OVERLOAD .................... 10-124 EMERGENCY STOP SYSTEM FOR CONVEYOR, OPTION OVERLOAD .. 10-125
10-1
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