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KOMATSU BR500JG-1 SERVICE REPAIR MANUAL (SN:1006 & UP) KOMATSU BR500JG 1 – PDF DOWNLOAD
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- KOMATSU BR500JG-1 SERVICE REPAIR MANUAL
- SERIAL NUMBER:1006 & UP
- PUBLICATION NUMBER:SEBM012103
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Description
KOMATSU BR500JG-1 SERVICE REPAIR MANUAL (SN:1006 & UP) KOMATSU BR500JG 1
KOMATSU BR500JG-1 SERVICE REPAIR MANUAL (SN:1006 & UP) KOMATSU BR500JG 1 – PDF DOWNLOAD:
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DESCRIPTION:
- KOMATSU BR500JG-1 SERVICE REPAIR MANUAL (SN:1006 & UP) KOMATSU BR500JG 1
- This shop manual has been prepared as an aid to improve 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 opportunity.
- 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 the following chapters; these chapters are further divided into the each main group of components.
- 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 eXpiains 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 “Problems” 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 STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU BR500JG-1 SERVICE REPAIR MANUAL (SN:1006 & UP) KOMATSU BR500JG 1
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
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