Description

Komatsu BR100JG-2 2002 Workshop Manual

Ever pull a manual for a crusher and find it’s a generic reprint that skips the specific adjustment procedures? I’ve seen techs waste half a day because an aftermarket manual had the wrong valve clearance spec for a Komatsu BR100JG-2 2002 Workshop Manual is the real deal – OEM factory print, 400 pages, direct from Komatsu. It’s what you need when you’re in the middle of a job and can’t afford guesswork.

If you’re maintaining your own Komatsu crushing equipment, this saves you from expensive mistakes. The manual is written for technicians who know their way around a torque wrench, but the step-by-step testing procedures – like adjusting valve clearance – are clear enough for an owner with some mechanical experience. Do not trust aftermarket reprints.

This isn’t a third-party scanned copy. It’s the original Komatsu publication, printed in Japan in 2002. The diagrams are clean, the specifications are factory-verified. I never trust aftermarket documentation for hydraulic pressures – they’re often off by 50 psi. This manual gives you the exact numbers from Komatsu. For example, the standard value table for the engine is in section 20. That matters when you’re testing compression or blow-by pressure.

Valve Clearance Adjustment: Factory Procedure

Section 20 covers measuring engine speed, exhaust color, and adjusting valve clearance. The manual specifies the exact feeler gauge thickness and sequence. No guesswork. If you’ve ever rounded a valve stem because you used a generic spec, you’ll appreciate this. The procedure is straightforward: remove the cylinder head cover, rotate the engine to TDC, then check and adjust each valve according to the cold clearance values printed in the manual. Overlook this and you’ll have power loss or valve damage.

400 Pages of Verified Factory Data

From general specifications (page 01) to disassembly (section 30), this manual is thorough. The structure function section (10) details every hydraulic component: PTO, travel motor, crusher motor, magnetic separator motor, feeder motor. It includes layout drawings and maintenance standards. That’s 400 pages of actual usable data – not filler. The weight table and oil/coolant capacities are also in section 01. For the drivetrain, the manual covers track frame, idler cushion, track roller, carrier roller, sprocket, track shoe, and shoe.

For other Komatsu models, check out Komatsu WA65-5 WA70-5 WA80-5 2005 Workshop Manual or Komatsu WH609-1E0 WH613-1E0 WH713-1E0 WH714H-1E0 WH716-1E0 Workshop Manual. Also available is Komatsu PW95R-2 Workshop Manual – 520 Pages of Factory Specs.

Troubleshooting: Failure Codes and M Mode

The electrical troubleshooting section is extensive. It covers failure codes [10] through [51], including disconnection in emergency stop switch, crusher off switch, feeder off switch, and short circuits in various switch systems. The manual provides connector arrangement diagrams and T-adapter tables. If you’re chasing an electrical gremlin, this is your map. The section also includes M Mode and E Mode electrical circuit diagrams with connection tables for connector pin numbers. You’ll find specific diagnostics for each failure code – for example, failure code [21] is disconnection in the feeder speed dial system, and the manual tells you exactly which connector to check and what resistance to expect. This is not a generic list; it’s specific to the BR100JG-2.

Don’t confuse this with a generic Manual Transmission repair book – that won’t help you with the hydraulic crusher motor. The depth of this manual far exceeds what you’d find in a typical Manual Transmission manual.

What Torque Values Are Included?

Torque specifications are scattered throughout the sections. For example, the testing section includes standard value tables for engine and chassis. You’ll find tightening torques for track shoes, sprockets, and hydraulic fittings. Don’t rely on a generic torque chart – use the factory numbers from this manual. The manual also covers testing and adjusting hydraulic pressures in the work equipment circuit, measuring LS differential pressure, and adjusting LS and PC valves. Every torque value is given in Imperial units (ft-lb).

Get the Right Valve Clearance Specs

The adjusting valve clearance procedure is clearly outlined. You need the correct clearance for intake and exhaust valves. This manual tells you the cold adjustment values. Overlook this and you’ll have power loss or valve damage. The process is detailed in section 20 under “ADJUSTING VALVE CLEARANCE.” It also explains how to measure compression pressure and blow-by pressure – essential if you suspect worn rings or valves.

Does this manual cover the jaw crusher assembly?

Yes. Section 10 in the “Crusher” subsection includes a jaw crusher assembly drawing and maintenance standards.

What about the electrical system troubleshooting? I have an error code [21] on my display.

That’s failure code [21] – disconnection in feeder speed dial system. The manual devotes several pages to each failure code, providing diagnostic steps, wiring diagrams, and connector pin checks. It tells you exactly which connector to inspect and what resistance values to expect. This is not a generic list; it’s specific to the BR100JG-2. You’ll find the procedure in the troubleshooting section under “E Mode System Electrical Circuit Diagram.” If you’re not familiar with reading these diagrams, take your time and trace the circuit – the manual labels every wire.

Access the Factory Manual and get the correct specs for your Komatsu BR100JG-2. No more guessing – just straight factory data.