Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 PDF
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Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
BR500JG-1 1006 and up
Description
Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 – PDF DOWNLOAD
FILE DETAILS:
Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 – PDF DOWNLOAD
Language : English
Pages : 391
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
BR500JG-1 1006 and up
COVER 1
CONTENTS 2
01 GENERAL 26
DIMENSION 27
SPECIFICATIONS 29
TABLE OF OIL AND COOLANT CAPACITIES 37
10 STRUCTURE AND FUNCTION 40
PARTS RELATED TO ENGINE 41
RADIATOR, OIL COOLER 43
DRIVE SYSTEMS FOR EACH COMPONENT 44
FINAL DRIVE 46
TRACK FRAME, RECOIL SPRING 47
TRACK SHOE 48
HYDRAULIC TANK, HYDRAULIC FILTER 49
HYDRAULIC PUMP 50
CONTROL VALVE 71
SUCTION SAFETY VALVE 77
SELF-REDUCING PRESSURE VALVE 78
CLSS 83
CRUSHER MOTOR 100
TRAVEL MOTOR 103
TRAVEL PPC VALVE 110
HYDRAULIC CYLINDER 114
ELECTRIC CIRCUIT DIAGRAM 115
ENGINE CONTROL SYSTEM 117
MACHINE MONITOR SYSTEM 118
BELT CONVEYOR MACHINERY 124
BELT CONVEYOR MOTOR 125
SOLENOID VALVE (6-SPOOL) 126
SOLENOID VALVE (FOR CRUSHER MOTOR) 127
PPC VALVE 128
FIRST BELT CONVEYOR 130
GRIZZLY FEEDER 131
VIBRATOR 132
FLOW CONTROL VALVE 133
CRUSHER 134
20 TESTING AND ADJUSTING 138
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 139
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 140
TOOLS FOR TASTING, ADJUSTING, AND TROUBLESHOOTING 143
MEASURING ENGINE SPEED 144
MEASURING EXHAUST COLOR 145
ADJUSTING VALVE CLEARANCE 146
MEASURING COMPRESSION PRESSURE 147
MEASURING BLOW-BY PRESSURE 147
TESTING AND ADJUSTING FUEL INJECTION TIMING 148
MEASURING ENGINE OIL PRESSURE 149
TESTING AND ADJUSTING FAN BELT TENSION 150
ADJUSTING ENGINE SPEED SENSOR 151
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 152
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUIT 153
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 155
TESTING SOLENOID VALVE OUTPUT PRESSURE 156
MEASURING PPC VALVE OUTPUT PRESSURE 156
TESTING TRAVEL DEVIATION 157
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 158
TESTING AND ADJUSTING TRACK SHOE TENSION 159
BLEEDING AIR FROM HYDRAULIC CIRCUIT 160
ADJUSTING FUEL CONTROL LEVER 164
TESTING AND ADJUSTING CRUSHER 165
TROUBLESHOOTING 182
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 183
CHECKS BEFORE TROUBLESHOOTING 191
1 FOR CHASSIS 191
2 FOR CRUSHER 192
3 FOR BELT CONVEYOR 194
CONNECTOR TYPES AND MOUNTING LOCATIONS 195
CONNECTOR ARRANGEMENT DIAGRAM 199
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 217
METHOD OF PROCEEDING WITH TROUBLESHOOTING 221
METHOD OF USING TROUBLESHOOTING CHARTS 222
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 223
E-1 TRAVEL LOCK DOES NOT WORK NORMALLY 224
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 225
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN 226
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT 226
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS 227
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 227
b) TRAVEL LOCK, PREHEATING LAMPS DO NOT LIGHT UP 227
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP 227
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 227
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP 228
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 228
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP 229
M-7 WHEN SWITCH IS OPERATED, TRAVEL LOCK LAMP DOES NOT LIGHT UP 229
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 230
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING 230
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 231
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE 231
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE 231
c) ENGINE WATER TEMPERATURE GAUGE GOES OUT 231
M-11 ABNORMALITY IN FUEL GAUGE 232
a) ALL FUEL GAUGE SEGMENTS GO OUT 232
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL 232
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL 232
M-12 DEFECTIVE OPERATION OF ALARM BUZZER 234
a) BUZZER DOES NOT SOUND (WHEN ABNORMAL) 234
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP (WHEN NORMAL) 234
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE 235
a) CHARGE CAUTION LAMP LIGHTS UP 235
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP 235
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 236
a) GAUGE LIGHTING DOES NOT LIGHT UP 236
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY) 236
30 DISASSEMBLY AND ASSEMBLY 237
METHOD OF USING MANUAL 239
PRECAUTIONS WHEN CARRYING OUT OPERATION 241
SPECIAL TOOL LIST 243
SKETCHES OF SPECIAL TOOLS 245
STARTING MOTOR ASSEMBLY 247
REMOVAL AND INSTALLATION 247
ALTERNATOR ASSEMBLY 248
REMOVAL AND INSTALLATION 248
ENGINE OIL COOLER ASSEMBLY 249
REMOVAL AND INSTALLATION 249
FUEL INJECTION PUMP ASSEMBLY 250
REMOVAL 250
INSTALLATION 252
WATER PUMP ASSEMBLY 253
REMOVAL AND INSTALLATION 253
NOZZLE HOLDER ASSEMBLY 254
REMOVAL AND INSTALLATION 254
TURBOCHARGER ASSEMBLY 255
REMOVAL AND INSTALLATION 255
THERMOSTAT ASSEMBLY 256
REMOVAL AND INSTALLATION 256
ENGINE FRONT SEAL 257
REMOVAL AND INSTALLATION 257
ENGINE REAR SEAL 258
REMOVAL 258
INSTALLATION 259
CYLINDER HEAD ASSEMBLY 262
REMOVAL 262
INSTALLATION 266
AFTERCOOLER CORE ASSEMBLY 269
REMOVAL AND INSTALLATION 269
HYDRAULIC COOLER ASSEMBLY 270
REMOVAL 270
INSTALLATION 271
RADIATOR, HYDRAULIC COOLER ASSEMBLY 272
REMOVAL 272
INSTALLATION 274
ENGINE, MAIN PUMP ASSEMBLY 275
REMOVAL 275
INSTALLATION 278
DAMPER ASSEMBLY 279
REMOVAL AND INSTALLATION 279
FUEL TANK ASSEMBLY 280
REMOVAL AND INSTALLATION 280
FINAL DRIVE ASSEMBLY 281
REMOVAL AND INSTALLATION 281
DISASSEMBLY 282
ASSEMBLY 286
SPROCKET 292
REMOVAL AND INSTALLATION 292
IDLER, RECOIL SPRING ASSEMBLY 293
REMOVAL AND INSTALLATION 293
IDLER ASSEMBLY 294
DISASSEMBLY 294
ASSEMBLY 295
RECOIL SPRING ASSEMBLY 297
DISASSEMBLY 297
ASSEMBLY 298
TRACK ROLLER ASSEMBLY 299
REMOVAL AND INSTALLATION 299
DISASSEMBLY 300
ASSEMBLY 301
CARRIER ROLLER ASSEMBLY 303
REMOVAL AND INSTALLATION 303
DISASSEMBLY 304
ASSEMBLY 306
TRACK SHOE ASSEMBLY 308
REMOVAL AND INSTALLATION 308
HYDRAULIC TANK ASSEMBLY 309
REMOVAL 309
INSTALLATION 310
CONTROL PUMP ASSEMBLY 311
REMOVAL AND INSTALLATION 311
MAIN PUMP ASSEMBLY 312
REMOVAL 312
INSTALLATION 313
MAIN PUMP INPUT SHAFT OIL SEAL 314
REMOVAL AND INSTALLATION 314
SERVO VALVE ASSEMBLY FOR FRONT PUMP 315
REMOVAL AND INSTALLATION 315
SERVO VALVE ASSEMBLY FOR REAR PUMP 316
REMOVAL AND INSTALLATION 316
TRAVEL PPC VALVE ASSEMBLY 317
DISASSEMBLY 317
ASSEMBLY 318
CONVEYOR MACHINERY, MOTOR ASSEMBLY 319
REMOVAL AND INSTALLATION 319
CONVEYOR MACHINERY ASSEMBLY 320
DISASSEMBLY 320
ASSEMBLY 323
CHEEK PLATE 326
REMOVAL 326
INSTALLATION 327
FIXED JAW PLATE 328
REMOVAL AND INSTALLATION 328
SWING JAW PLATE 330
REMOVAL 330
INSTALLATION 331
TOGGLE PLATE 332
REMOVAL 332
INSTALLATION 333
TOGGLE SEAT 334
REMOVAL AND INSTALLATION 334
FLYWHEEL AND V SHEAVE 335
REMOVAL AND INSTALLATION 335
SWING JAW 336
REPLACEMENT 336
BEARING 337
REPLACEMENT 337
THRUST SEAT 338
REPLACEMENT 338
CHEEK PLATE 339
REPLACEMENT 339
FIXED JAW TEETH 341
TURNING AND REPLACEMENT 341
SWING JAW TEETH 343
TURNING AND REPLACEMENT 343
TOGGLE PLATE 344
REPLACEMENT 344
TOGGLE SEAT 347
REPLACEMENT 347
HYDRAULIC RAM 348
HANDLING 348
FLYWHEEL AND V-PULLEY 350
REPLACEMENT 350
SWING JAW 352
REPLACEMENT 352
BEARING 354
REPLACEMENT 354
40 MAINTENANCE STANDARD 355
ENGINE MOUNT 356
FINAL DRIVE 357
TRACK FRAME AND RECOIL SPRING 359
IDLER 360
CARRIER ROLLER 362
TRACK ROLLER 363
TRACK 364
HYDRAULIC PUMP 366
CONTROL PUMP AND RELIEF VALVE 367
SUCTION-SAFETY VALVE 368
SELF-REDUCING PRESSURE VALVE 369
CRUSHER MOTOR 370
TRAVEL MOTOR 371
TRAVEL PPC VALVE 372
BELT CONVEYOR MACHINERY 373
BELT CONVEYOR MOTOR 375
CRUSHER 376
WEAR MEASUREMENT OF MAJOR CONSUMABLE PARTS 379
90 OTHERS 381
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO : 1006-1103) 382
HYDRAULIC CIRCUIT DIAGRAM (SERIAL NO : 1201 AND UP) 383
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO : 1002-1006) 384
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO : 1007-1103) 385
ELECTRIC CIRCUIT DIAGRAM (SERIAL NO : 1201 AND UP) 386
DESCRIPTION:
Komatsu BR500JG-1 Mobile Crusher Shop Manual SEBM012103 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
BR500JG-1 1006 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
S.V 24/12/24
